Volkswagen Amarok 2017 Maintenance Manual
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Volkswagen Amarok 2017 Maintenance Manual

Volkswagen Amarok 2017 Maintenance Manual

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Service
Maintenance
Amarok 2017 ➤
Edition 02.2021
Service Department. Technical Information

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Summary of Contents for Volkswagen Amarok 2017

  • Page 1 Service Maintenance Amarok 2017 ➤ Edition 02.2021 Service Department. Technical Information...
  • Page 2 Service Maintenance H e a d i n g 1. Engine list 2. Service work 3. General information 4. Descriptions of work 5. Exhaust emissions test 6. Periodic Technical Inspection (PTI) 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.

  • Page 3: Table Of Contents

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Contents Engine list ............. .
  • Page 4 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.36 Tyre Pressure Loss Indicator: calibrating ........

  • Page 5: Engine List

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Engine list (VIGG001512; Edition 02.2021) ⇒ o1.1 f engines - diesel engines”, page 1 ⇒ o1.2 f engines - petrol engines”, page 2 Overview of engines - diesel engines Note To ease the search for an engine, the engine codes are listed in alphabetical order.

  • Page 6: Overview Of Engines - Petrol Engines

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Engines ⇒ Diesel Diesel Diesel Diesel Diesel Displacement 09.2016 ▶ 09.2016 ▶ 09.2016 ▶ 09.2016 05.2018 Engine code DDXA DDXB DDXC DDXD DDXE Compression ratio 16:1 16:1 17:1 17:1 17:1 Injection/ignition TDI common...

  • Page 7: Service Work

    For vehicles with a fixed service, fixed services are calculated. This means that the indicated mileage or time intervals have al‐ ready been determined and specified by Volkswagen Commer‐ cial Vehicles. For normal operating conditions achieving these service intervals is technically assured.
  • Page 8 Calculation of service intervals: ♦ The service interval for vehicles with a fixed service is calcu‐ lated in fixed service intervals. This means that the mileage or time values have been previously determined and speci‐ fied by Volkswagen Commercial Vehicles. 2. Service work...

  • Page 9: Service Tables

    100 km or the remaining time rounded to full days. Service tables The following chapter contains the well-known service tables with the service specifications of the Volkswagen Commercial Vehicles brand. Since, in the past, individual service specifications were set up...

  • Page 10: Scopes Of Service

    2 years. Scopes of service The following chapter contains the well-known service tables of the Volkswagen Commercial Vehicles brand. Since, in the past, individual service specifications were set up in various markets, mostly through severe operating conditions, these are listed in the scopes of service tables with market specific deviations.
  • Page 11 Amarok 2017 ➤ Maintenance - Edition 02.2021 Delivery inspection ⇒ page 7 Scopes of service 2017 ► ⇒ page 9 Note Under certain circumstances, different types of service can ♦ be performed at the same time. Doubly listed activities are charged only once.
  • Page 12 Amarok 2017 ➤ Maintenance - Edition 02.2021 Scope of work Page ♦ All equipment that has been packed inside the vehicle (floor mats, wiper arms, spoil‐ ers, roof aerial, wheel trims/hub caps, covers): Install (if included) ♦ Edge protection on doors (plastic film): Remove ♦...
  • Page 13 Amarok 2017 ➤ Maintenance - Edition 02.2021 Scope of work Page ♦ Digital Service Schedule – Enter pre-delivery inspection – Complete vehicle data in Digital Service Schedule, see “Vehicle delivery documenta‐ tion” • For markets where the Digital Service Schedule does not apply, the respective data is entered in the service history book ♦...
  • Page 14 Amarok 2017 ➤ Maintenance - Edition 02.2021 Insp Ext. Measure insp. ♦ Doors: greasing door arrester ⇒ page 121 ♦ AdBlue: Replenish if necessary (on the customer's request only) ⇒ page 23 Underside of vehicle ♦ Engine oil: Change / Engine oil filter: Renew •...
  • Page 15 Amarok 2017 ➤ Maintenance - Edition 02.2021 Insp Ext. Measure insp. ♦ Cooling system: check frost protection and coolant level and correct as necessary. Frost-protection specification: -25°C (in countries with an arctic climate: -35°C) ⇒ page 78 ♦ Window wash/wipe system, wiper blade and headlight washer system: Check func‐...
  • Page 16 Amarok 2017 ➤ Maintenance - Edition 02.2021 Scopes of service Additional work Interval Description of work ♦ Multi-purpose additive for petrol fuels: add At every service ⇒ page 94 Indian market model year 2017 ► Additional work Interval Description of work ♦...
  • Page 17 Amarok 2017 ➤ Maintenance - Edition 02.2021 Measure Interval ♦ Renew fuel filter; if vehicle runs on diesel fuel: ♦ Diesel fuel conform with standard “DIN EN 590” • Engine codes DDXA, DDXB, DDXC, DDXD, DDXE • With water separation ⇒...
  • Page 18 Amarok 2017 ➤ Maintenance - Edition 02.2021 Measure Interval ♦ Cleaning roll cover Every 40,000 km or 2 years • Only applies for diesel engines ⇒ page 102 ♦ Poly V-belt: renewing Every 60,000 km • Valid in “dusty” regions ⇒...

  • Page 19: General Information

    Amarok 2017 ➤ Maintenance - Edition 02.2021 General information ⇒ 3.7 , page 19 ⇒ i3.8 n the Digital Service Schedule”, page 20 ⇒ o3.3 perating conditions”, page 17 ⇒ i3.1 dentification number”, page 15 ⇒ d3.2 ata sticker”, page 15 ⇒...
  • Page 20 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Attach the upper of the two vehicle data stickers -arrow- in the vehicle wallet. The sticker contains the following data of the vehicle 1 - Vehicle identification number 2 - Vehicle type, motor output, gearbox 3 - Motor and gearbox codes, paint number, interior equipment 3.

  • Page 21: Severe Operating Conditions

    Amarok 2017 ➤ Maintenance - Edition 02.2021 4 - Optional equipment, PR numbers Severe operating conditions If the vehicle is used under severe operating conditions some work will have to be performed before the next service is due or at shorter service intervals.

  • Page 22: Engine Code And Engine Number

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Bhutan Cambodia Dutch Overseas Territo‐ Chad ries Bolivia Cameroon Niger Tunisia Botswana Canada Nigeria Turkey Brazil Cape Verde North Korea Turkmenistan Brunei Caribbean driving on the Oman Uganda left Burkina Faso Kazakhstan Pakistan...

  • Page 23: Stickers

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Australia India Mozambique Thailand Bahrain Indonesia Myanmar (Burma) Togo Bangladesh Iraq Namibia Chad Belize Israel Nepal (Indian subconti‐ Tunisia nent) Benin (Dahomey) Yemen Nicaragua Turkey Bhutan Jordan Niger Turkmenistan Bolivia Cambodia Nigeria Uganda...

  • Page 24: Entries In The Digital Service Schedule

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Entries in the Digital Service Schedule If a component is changed which has a change interval prescri‐ bed by the manufacturer, e.g. the toothed belt, the new change interval begins at the time the component is changed.
  • Page 25 Amarok 2017 ➤ Maintenance - Edition 02.2021 4. Descriptions of work...

  • Page 26: Descriptions Of Work

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Descriptions of work ⇒ (4.1 reducing agent)”, page 23 ⇒ j4.3 oints and suspension link mountings: visual check”, page ⇒ t4.2 he vehicle”, page 30 ⇒ a4.4 sh mass (saturation level) of diesel particulate filter”, page 38 ⇒...

  • Page 27: Adblue® (Reducing Agent)

    Amarok 2017 ➤ Maintenance - Edition 02.2021 ⇒ o4.26 il: capacities and specifications ”, page 84 ⇒ o4.34 ut a road test”, page 98 ⇒ s4.33 et: checking”, page 97 ⇒ s4.35 ecuring bolts: tightening to specified torque”, page 99 ⇒...
  • Page 28 ♦ The reducing agent (AdBlue ® /DEF) is filled in a separate tank in the vehicle. It is NOT therefore mixed with diesel fuel. ♦ A refill container approved by Volkswagen must be used for ® replenishing the reducing agent (AdBlue /DEF).
  • Page 29 Amarok 2017 ➤ Maintenance - Edition 02.2021 System malfunction or incorrect filling Caution The vehicle is damaged by filling with reducing agent (AdBl‐ ® ) that does NOT comply with the standard or by filling with other fluids. In case of system malfunction or incorrect filling, one of the following messages appears on the dash panel insert: ♦...
  • Page 30 Amarok 2017 ➤ Maintenance - Edition 02.2021 Caution ® Never allow reducing agent (AdBlue /DEF) to come into con‐ tact with trim or body parts. ® If this happens, wash off the reducing agent (AdBlue /DEF) with clear water and wipe area with a lint-free cotton cloth.
  • Page 31 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Clean reducing agent tank filler neck with a water-soaked, lint-free cotton cloth. – Insert nozzle of AdBlue filling system -VAS 6960- in tank filler neck for reducing agent. Start filling procedure. Note...
  • Page 32 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.1.5 Filling the reducing agent tank from containers Procedure Note Ensure that the vehicle is on a hard, level standing and that ♦ the ignition is switched off. Use only demineralised water for cleaning any components ♦...
  • Page 33 Amarok 2017 ➤ Maintenance - Edition 02.2021 Note After filling the reducing agent tank, switch on the ignition and leave it switched on for at least 30 seconds so that the system can detect the replenishment. 4.1.6 Filling the reducing agent tank from re‐...

  • Page 34: Lifting The Vehicle

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Note Refer to the product information and handling instructions ♦ from the manufacturer. Do not overfill AdBlue® tank. ♦ – Screw in tank cap -1- of tank filler neck until it engages. – Close tank flap.
  • Page 35 Amarok 2017 ➤ Maintenance - Edition 02.2021 WARNING ♦ Before driving onto a lifting platform, ensure that there is sufficient clearance between low-lying components and lifting platform. ♦ Before driving a vehicle onto a lifting platform, ensure that the vehicle weight does not exceed the permissible lifting capacity of the platform.
  • Page 36 Amarok 2017 ➤ Maintenance - Edition 02.2021 Procedure – Re-equip lifting platform so that existing 4 mounting plates are replaced by 4 wheel lift supports -1-. – Adjust distances of lifting platform so that all 4 wheels sit exactly in the wheel lift supports -2-.
  • Page 37 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ 4 x tensioning straps -T10038- ♦ 4 x securing devices -VAS 5244/2- Observe safety precautions for raising the vehicle ⇒ page 30 Note Vehicle must under no circumstances be raised on sills, oth‐...
  • Page 38 Amarok 2017 ➤ Maintenance - Edition 02.2021 Note To avoid damage to the fuel lines, the tensioning strap - T10038- must be routed behind the fuel lines. – If fitted, remove heat shield ⇒ 6-cyl. diesel engine (3.0 l en‐...

  • Page 39: Swivel Joints And Suspension Link Mountings: Visual Check

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – Alternatively, height-adjustable stands -2- can be positioned under rear leaf spring brackets -1- on rear axle tube. Swivel joints and suspension link mountings: visual check ⇒ j4.3.1 oints and suspension link mountings, front”, page 35 ⇒...
  • Page 40 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Check boots -arrow- of upper swivel joints for leaks and damage. – Check upper axial bearings for large cracks, perforating cracks or cuts in rubber material -arrows-. – Check front lower axial bearings for large cracks, perforating cracks or cuts in rubber material -arrow-.
  • Page 41 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Check rear lower axial mountings for large cracks, perforat‐ ing cracks or cuts in rubber material -arrows-. – In addition, check axial bearings also for following damage: ♦ Complete separation of rubber and metal parts.

  • Page 42: Reading Ash Mass (Saturation Level) Of Diesel Particulate Filter

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – Check rubber bushes also for following damage: ♦ Complete separation of rubber and metal parts. ♦ Large play between mounting and suspension link, which has a considerably negative effect on the function of the mounting.

  • Page 43: Battery: Checking With Battery Tester (Always Refer To Workshop Manual)

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Note If the display is not as shown in the procedure: ⇒ Operating instructions for vehicle diagnostic tester ODIS Service – Connect vehicle diagnostic tester ⇒ page 59 – Switch on ignition. – Carry out identification of vehicle.

  • Page 44: Battery: Checking Battery Terminal Clamps For Secure Seating

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Battery: checking battery terminal clamps for secure seating ⇒ c4.6.1 hecking battery terminal clamps for secure seating”, page 40 ⇒ t4.6.2 erminal connections”, page 42 4.6.1 Battery: checking battery terminal clamps for secure seating Special tools and workshop equipment required ♦...
  • Page 45 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Loosen nut on POSITIVE battery clamp -1-. – Tighten nut on POSITIVE battery clamp -1- to specified tor‐ que using torque wrench -V.A.G 1331- and ratchet -V.A.G. 1331/1-. – Reconnect NEGATIVE battery clamp -1-, and tighten it to specified torque using torque wrench -V.A.G 1331- and...

  • Page 46: Charge Battery (Establish Backup Power Supply)

    Amarok 2017 ➤ Maintenance - Edition 02.2021 4.6.2 Battery terminal connections Caution To prevent damage to the battery terminal clamps and the battery terminals, observe the following: ♦ The battery terminal clamps must only be connected by hand (without using force).

  • Page 47: Front Passenger Front Airbag: Checking Key Switch And "On/Off Function

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Front passenger front airbag: checking key switch and “ON/OFF function” Note If the airbag is deactivated, the front airbag, side airbag and curtain airbag are deactivated on the front passenger side. All other airbags in the vehicle remain functional.

  • Page 48: Checking Tyres: Condition, Wear Pattern, Tyre Pressure, Tread Depth

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – Switch off ignition. Checking tyres: condition, wear pat‐ tern, tyre pressure, tread depth ⇒ i4.9.1 nformation”, page 44 ⇒ t4.9.2 yre age”, page 45 ⇒ p4.9.4 attern: checking”, page 46 ⇒ p4.9.6 ressure (including spare wheel): Checking using tyre inflatorVAS 5216, correcting tyre pressure if necessary”, page...
  • Page 49 Amarok 2017 ➤ Maintenance - Edition 02.2021 Winter tyres Note Important information on recommended winter tyres can be ♦ found in ⇒ Wheels and tyres guide; Rep. gr. 44; Wheels, tyres, vehicle geometry; Wheel and tyre combinations. If winter tyres are fitted, a sticker indicating the speed limit ♦...
  • Page 50 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.9.3 Tyres: checking condition WARNING If damage is determined, always check to see if a new tyre should be fitted. Tests at delivery inspection: – Check tyre side walls and treads for damage and foreign bodies such as, for example, nails or glass splinters.
  • Page 51 Amarok 2017 ➤ Maintenance - Edition 02.2021 Note This figure may vary according to legislation in individual ♦ countries. Your importer will inform you about this. 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.
  • Page 52 Amarok 2017 ➤ Maintenance - Edition 02.2021 Note During delivery inspection, check that tyre inflation pressure ♦ sticker is fitted. If the sticker is missing, order a new sticker through ETKA. “Checking tyre pressure” also applies to the spare wheel, if a ♦...

  • Page 53: Brake System And Shock Absorbers: Inspecting For Leaks And Damage

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Applies to all factory-fitted tyre sizes Spare wheel with standard tyres The spare wheel should have the highest tyre pressure deter‐ mined for the vehicle. 4.10 Brake system and shock absorbers: in‐ specting for leaks and damage –...
  • Page 54 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Fluorescent lamp, 13 watts -VAS 6485- The adapter to loosen and tighten the anti-theft wheel bolts can be found in the vehicle tool kit ⇒ page 99 Note A suitable adapter for loosening and tightening anti-theft wheel bolts is provided in the vehicle tool kit.

  • Page 55: Brake And Clutch Mechanism: Change Brake Fluid

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Wear limit: ⇒ Brake system; Rep. gr. 46; Rear brake; Assembly overview - rear brake 4.11.3 Checking condition of brake discs Procedure – Check all brake discs for the following damage patterns: ♦ Cracks ♦...
  • Page 56 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Tool set for brake bleeding -VAS 6564- ♦ Upgrade kit and extraction unit -V.A.G 1869/4- WARNING ♦ Never allow brake fluid to come into contact with flu‐ ids that contain mineral oils (e.g. oil, petrol, cleaning agents).
  • Page 57 Amarok 2017 ➤ Maintenance - Edition 02.2021 Note The strainer in brake fluid reservoir must remain in place. – Extract as much brake fluid as possible out of the brake fluid reservoir using suction hose from brake filling and bleeding unit -VAS 6860-.
  • Page 58 Amarok 2017 ➤ Maintenance - Edition 02.2021 – 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 cm flow out.
  • Page 59 Amarok 2017 ➤ Maintenance - Edition 02.2021 Repeat procedure on rear left of vehicle. Changing brake fluid at front – Push collector bottle bleed hose -1- onto front right bleed valve. Open bleeder valve and let appropriate quantity of brake fluid run out (see table).

  • Page 60: Brake Fluid Level: Check

    ⇒ Electronic parts catalogue “ETKA”. Permissible brake fluid specifications ♦ Volkswagen recommends using new brake fluid acc. to VW Standard 501 14 for optimum function of brake system. ♦ Alternatively, a brake fluid acc. to requirements of US stand‐...
  • Page 61 Amarok 2017 ➤ Maintenance - Edition 02.2021 WARNING ♦ Never allow brake fluid to come into contact with flu‐ ids that contain mineral oils (e.g. oil, petrol, cleaning agents). Mineral oils damage the seals and boots in the brake system and clutch mechanism.

  • Page 62: Electric Windows: Initialising (Activation)

    Amarok 2017 ➤ Maintenance - Edition 02.2021 4.13.2 Checking brake fluid level at inspection service Caution When replenishing, make sure to not spill any liquids in the engine compartment. Spilled liquids may cause damage to the paintwork and to components in the engine compartment.

  • Page 63: Vehicle Diagnostic Tester

    Amarok 2017 ➤ Maintenance - Edition 02.2021 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 ♦...

  • Page 64: Fault Memory Of All Systems: Reading With Vehicle Diagnostic Tester, Correcting Possible

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Perform the following procedure: – Connect diagnostic line connector to diagnostic connection. – Switch on vehicle diagnostic tester. – Switch on ignition. Now follow information given on screen to start desired func‐ tions.

  • Page 65: Dust And Pollen Filter: Cleaning Housing And Renewing Filter Element

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Static faults If one or more static faults are found in the event memory, we recommend seeking agreement from the customer to rectify these faults using Guided Fault Finding. Sporadic faults If only sporadic faults or messages are stored in the event memory and the customer has no complaints in conjunction with the electronic vehicle system, clear event memory.
  • Page 66 Amarok 2017 ➤ Maintenance - Edition 02.2021 Procedure – If fitted, remove noise insulation ⇒ General body repairs, ex‐ terior; Rep. gr. 66; Noise insulation; Removing and installing noise insulation. Note As wear of the poly V-belt progresses, the poly V-belt be‐...
  • Page 67 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Layer separation (top layer, cord strands) ♦ Base disruption ♦ Frayed cord strands ♦ Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks-, surface cracks) ♦ Traces of oil and grease ♦...
  • Page 68 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.18.2 Poly V-belt: checking condition, 6-cylin‐ der diesel engines – Crank engine at vibration damper on pulley using a socket. Check poly V-belt -1- for: ♦ Sub-surface cracks (cracks, core ruptures, cross-sectional breaks) ♦...
  • Page 69 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Battery lamp -VAS 6901- ♦ Fluorescent lamp, 13 watts -VAS 6485- ♦ Mirror Procedure – If fitted, remove noise insulation ⇒ General body repairs, ex‐ terior; Rep. gr. 66; Noise insulation; Removing and installing noise insulation.

  • Page 70: Poly V-Belt: Renewing

    Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Examine the poly V-belt for the effect of foreign bodies. ♦ Bearing damage (turn by hand and examine for noises and smooth running). ♦ Functional check of alternator pulley with freewheel ⇒ Elec‐...
  • Page 71 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.21.1 Diesel fuel system: flushing, 4-cylinder diesel engine (2.0 l engine) Carry out the following work: Note Ensure that no components come into contact with diesel ♦ fuel. Clean immediately, if necessary. Wear suitable protective gloves when carrying out the follow‐...
  • Page 72 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ A – fuel supply line (from fuel filter to high-pressure pump) ♦ B – fuel supply line (from fuel tank to fuel filter) ♦ C – fuel return line (from high-pressure pump to fuel tank) ♦...
  • Page 73 Amarok 2017 ➤ Maintenance - Edition 02.2021 Continued for both flushing systems: – Connect flushing unit lines as shown in diagram. – Inspect connections for leaks. Flushing equipment for Amarok (Ezatta) – EZA.000.001 – Place flushing equipment next to vehicle (see diagram).
  • Page 74 Amarok 2017 ➤ Maintenance - Edition 02.2021 Continued for both flushing systems: – Connect electrical cables of flushing unit to positive and neg‐ ative battery terminals, and switch on the flushing unit. – Observe pressure displayed on pressure gauge (it must be between 3.5 and 4.0 bar).
  • Page 75 Amarok 2017 ➤ Maintenance - Edition 02.2021 Note Dispose of the excessive flushing mixture according to valid regulations for disposal, and clean the flushing unit. – Start engine. 4.21.2 Diesel fuel system: flushing, 6-cylinder diesel engine (3.0 l engine) Carry out the following work:...
  • Page 76 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ A – fuel supply line (from fuel filter to high-pressure pump) ♦ B – fuel supply line (from fuel tank to fuel filter) ♦ C – fuel supply line (from fuel tank to fuel filter) ♦...
  • Page 77 Amarok 2017 ➤ Maintenance - Edition 02.2021 Flushing equipment for Amarok (Snapon) – FEM.000.073 – Secure flushing unit to underside of vehicle so that pressure gauge faces towards outer side of vehicle. Continued for both flushing systems: – Connect flushing unit lines as shown in diagram.
  • Page 78 Amarok 2017 ➤ Maintenance - Edition 02.2021 Continued for both flushing systems: – Connect electrical cables of flushing unit to positive and neg‐ ative battery terminals, and switch on the flushing unit. – Observe pressure displayed on pressure gauge (it must be between 3.5 and 4.0 bar).

  • Page 79: Diesel Fuel Filter: Draining

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Note Dispose of the excessive flushing mixture according to valid regulations for disposal, and clean the flushing unit. – Start engine. 4.22 Diesel fuel filter: draining ⇒ f4.22.1 uel filter: draining”, page 75 ⇒...
  • Page 80 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Fit quick-release coupling of fuel line -2- back on (line must engage audibly). – Screw water drain plug -1- back in, if necessary replace it with a new seal if the old one was damaged.
  • Page 81 Amarok 2017 ➤ Maintenance - Edition 02.2021 Caution Ensure that no components come into contact with diesel fuel. Clean immediately, if necessary. – Fit a suitable hose -2- onto water drain plug -1-. – Insert the end of the hose in a suitable container -3-.

  • Page 82: Cooling System: Checking Frost Protection And Coolant Level

    Volkswagen. Distilled water fulfils all requirements. Therefore, only ever use distilled water when mixing coolant for topping up or renewing coolant.
  • Page 83 Amarok 2017 ➤ Maintenance - Edition 02.2021 Do not reduce the coolant concentration by adding water ♦ even in the warm season or in hot countries. Frost protection must be guaranteed down to at least -25°C. The temperature reading on the refractometer corresponds ♦...
  • Page 84 Amarok 2017 ➤ Maintenance - Edition 02.2021 – If frost protection is insufficient, drain some coolant and top up with coolant additive ⇒ page 80 Note If the currently used coolant additive cannot be determined ♦ precisely, use the scale -2- for coolant additive G13.

  • Page 85: Air Filter: Cleaning Housing And Renewing Filter Element

    Amarok 2017 ➤ Maintenance - Edition 02.2021 4.23.3 Mixing ratio Caution Use only distilled water for mixing coolant additives. The use of distilled water ensures optimum protection against corro‐ sion. Anti-freeze protection Coolant additive portion Water -25°C approx. 40% approx. 60% -36°C...
  • Page 86 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Torque screwdriver -VAS 6494- Removing Note When changing the fir filter ensure that no debris enters into the intake hose, air mass meter -G70- and air filter upper part. – Before changing air filter, clean outside of air filter housing.

  • Page 87: Engine Oil Level: Checking

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Installing Install in reverse order of removal, observing the following: – Clean air filter housing. – Remove all caps or hood covers from sealed components. – Ensure air filter insert is seated correctly in the housing.

  • Page 88: Engine Oil: Capacities And Specifications

    On vehicles set up for flexible service (PR number QI6/QI8) ♦ but serviced according to fixed service intervals, the service interval display must be recoded accordingly. Only engine oils approved by Volkswagen Commercial Ve‐ ♦ hicles may be used. Up-to-date information ⇒ Volkswagen Commercial Vehicles ServiceNet, Technical information, In‐...

  • Page 89: Engine Oil: Draining, Renewing Oil Filter And Filling Engine Oil

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Amarok Diesel engines Oil quantity with VW engine oil standards filter (I) Engine code Capacity / out‐ With flexible With fixed serv‐ Without DPF service with DPF with DPF CNFB 2.0 l / 103 kW...
  • Page 90 Amarok 2017 ➤ Maintenance - Edition 02.2021 Carry out the following work: – Removing and installing skid plate ⇒ General body repairs, exterior; Rep. gr. 66; Noise insulation; Removing and instal‐ ling skid plate for engine/gearbox. – Remove oil drain plug.
  • Page 91 Amarok 2017 ➤ Maintenance - Edition 02.2021 Removing Carry out the following work: Removing fuel line retainer, engine codes “CDCA” and “CDBA” Note To ensure proper removal and installation of the oil filter on vehicles with engine codes “CDCA” and “CDBA”, it is necessary to remove the retainer for fuel lines.
  • Page 92 Amarok 2017 ➤ Maintenance - Edition 02.2021 Continuation for all engine codes: Note Before draining, loosen screw cap so that engine oil can flow ♦ out of filter housing. Prevent engine oil from dripping onto components in engine ♦ compartment.
  • Page 93 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Tighten nut -1- on transportation shackle -2- of engine. – Fit rubber damper -3- to fuel lines. – Fit retainer -1- to rubber damper -3-, and secure it with nuts -2-. – Ensure that all parts have been installed without tension, and tighten bolts and nuts to specified torque.
  • Page 94 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.27.4 Renewing oil filter, 4-cylinder petrol en‐ gines Note Observe relevant disposal regulations. Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Oil filter tool -VAS 3417- ♦ Oil filter with tensioning strap Hazet - 2171-1 ♦...
  • Page 95 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Clean sealing surface for example with universal cloth -VAS 6385-. Installing Carry out the following work: – Oil rubber seal lightly on new oil filter. – Screw on new filter and tighten.
  • Page 96 Amarok 2017 ➤ Maintenance - Edition 02.2021 This will open a valve. – Wait briefly, so that the engine oil can flow out of filter hous‐ ing. – Remove threaded cap -1- from the oil filter housing -4-. – Ensure that no engine oil drips onto engine.
  • Page 97 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.27.6 Engine oil: replenishing Note On the engines, it is absolutely essential to perform an oil ♦ level check while the engine is warm (coolant temperature 90°C or engine oil temperature 85°C) to ensure correct ap‐...

  • Page 98: Multi-Purpose Additive For Diesel Fuel: Adding

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – If oil level is below marking -C- replenish a sufficient amount of oil (at least 0.7 l). 4.28 Multi-purpose additive for diesel fuel: adding Note In the market mentioned below there is a particularly high ♦...

  • Page 99: Engine And Components In Engine Compartment: Inspecting For Leaks And Damage (From Above And Below)

    Amarok 2017 ➤ Maintenance - Edition 02.2021 China Russia India – Observe dosing instructions on – Observe dosing instructions on – Observe dosing instructions on additive tank. additive tank. additive tank. 4.30 Engine and components in engine compartment: inspecting for leaks and...

  • Page 100: Bringing Era Glonass Into Operation

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Carry out the following work: – Clean bonnet lock -arrow- using cleaning solution -D 009 401 04- and, for example, a lint-free cloth. Also use “com‐ pressed air” to clean if necessary. – Lubricate bonnet lock -arrow- with lubricating paste -G 000 150-.

  • Page 101: Breakdown Set: Checking

    Amarok 2017 ➤ Maintenance - Edition 02.2021 If the status LED in the emergency assistance call button -E276- lights up red, proceed as follows: – Connect ⇒ Vehicle diagnostic tester ⇒ page 59 • Data for “Guided Fault Finding” is current –...

  • Page 102: Carry Out A Road Test

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Carry out the following work: – Check the expiry date and renew the tyre filler bottle with sealant, if the expiry date is reached. In this example, the expiry date is 05/2003. The tyre inflation bottle with sealant must be renewed.

  • Page 103: Wheel Securing Bolts: Tightening To Specified Torque

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – Tilting roof: function – Radio/radio navigation system: function, reception, GALA, interference noise – Multi-function indicator (MFI): functions – Air conditioning system: check function (At low temperatures the function of air conditioner must be checked in a work‐...
  • Page 104 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Adapter set for tamper-proof wheel bolts -T10313- Pulling off wheel hub trim • Only applies to steel wheel The puller hooks to remove the cover caps are located with the vehicle tool kit.

  • Page 105: Tyre Pressure Loss Indicator: Calibrating

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – 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. Screw in wheel bolts hand-tight first, then tighten them to speci‐...

  • Page 106: Cleaning Roll Cover

    Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ A “PERMANENT LIGHTING-UP” in conjunction with a warn‐ ing tone, means “WARNING”, pressure loss has been detec‐ ted, check tyre pressure and carry out calibration. Calibration, vehicles as of 06.2018 – Switch on ignition.

  • Page 107: Timing Chain: Renewing

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – Clean roll cover on both sides in area of guide rail -1- with water, and wipe it dry afterwards using a clean cloth. – Then grease sliding surface -2- of guide rail -1- with lubricat‐...
  • Page 108 Amarok 2017 ➤ Maintenance - Edition 02.2021 Read precise value for the following tests at light/dark boun‐ dary. Using a pipette, place a drop of water on the glass to improve the readability of the light/dark boundary. The light-dark border can be clearly recognised on the “WATERLINE”.
  • Page 109 Amarok 2017 ➤ Maintenance - Edition 02.2021 Note Genuine washer fluid ⇒ ETKA prevents the spray jets, wash‐ ♦ er fluid reservoirs and connecting hoses from freezing. In vehicles with fan jets, the reservoir must be filled with ♦ Genuine washer fluid, as this fluid has a low viscosity at tem‐...
  • Page 110 Amarok 2017 ➤ Maintenance - Edition 02.2021 Spray jet settings on preset washer jets Carry out the following work: The spray jets are preset. However, small differences in height may be corrected. – If spray field is not at correct height, adjust spray direction upwards or downwards as follows: –...

  • Page 111: Headlight Adjustment: Checking And Adjusting As Necessary

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Spray jet adjustment on 3-jet spray nozzle: Carry out the following work: – Actuate window washer system and check spray pattern. The spray pattern must meet the following standard: ♦ Equally distributed, symmetrical spray pattern ♦...
  • Page 112 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ The vehicle must be rolled forward and backward several metres or front and rear springs must be bounced fully sev‐ eral times so that springs settle. ♦ Vehicle and headlight adjuster must be on a level surface.
  • Page 113 Amarok 2017 ➤ Maintenance - Edition 02.2021 4.40.2 Checking headlight adjustment Special tools and workshop equipment required ♦ Headlight adjustment unit -VAS 5046 A- ♦ Headlight adjustment unit -VAS 5047 A- ♦ Headlight adjustment unit -VAS 621 001- Halogen headlights Carry out the following work: –...
  • Page 114 Amarok 2017 ➤ Maintenance - Edition 02.2021 – The breaking point -2- between the horizontal part of the light-dark border on the left and the slope on the right should be on the vertical line passing through the centre mark.
  • Page 115 Amarok 2017 ➤ Maintenance - Edition 02.2021 Left headlight Carry out the following work: – Observe conditions for testing ⇒ page 107 – Check headlight adjustment ⇒ page 109 ♦ Height adjustment screw -1- ♦ Height/lateral adjustment screw -2- Location of adjuster screws on right halogen headlight is a mir‐...
  • Page 116 Amarok 2017 ➤ Maintenance - Edition 02.2021 Location of adjuster screws on right gas discharge headlight is a mirror image. – For height adjustment, turn adjuster screws -1- and -2- by same number of turns until correct setting is reached.

  • Page 117: Service Interval Display: Reset

    Amarok 2017 ➤ Maintenance - Edition 02.2021 4.41 Service interval display: Reset ⇒ s4.41.1 ervice interval display using vehicle diagnostic tester program Offboard Diagnostic Information System”, page 113 ⇒ s4.41.2 ervice interval display without vehicle diagnostic test‐ er”, page 113 4.41.1...
  • Page 118 Amarok 2017 ➤ Maintenance - Edition 02.2021 Resetting oil change service for dash panel insert with text mes‐ sage – With ignition switched off, press and hold button -3-. – Switch on ignition. Wait until “Reset oil change service?” appears on the display -2-.
  • Page 119 Amarok 2017 ➤ Maintenance - Edition 02.2021 Resetting inspection service for dash panel insert with text mes‐ sage – With ignition switched off, press and hold button -3-. – Switch on ignition. Wait until “Reset inspection service?” appears on the display -2-.

  • Page 120: Service Interval Display: Recoding

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Note If the oil change service was manually reset, the service in‐ ♦ terval display will then also change to a fixed service interval on vehicles with flexible oil change service. If the vehicle battery was disconnected for a long period on ♦...

  • Page 121: Transportation Mode: Switching Off

    Amarok 2017 ➤ Maintenance - Edition 02.2021 ODIS Service – Select “Oil change service (fixed)”. – Follow instructions in “Guided functions” mode. – Reset “-1- Oil change service (fixed)”. – Follow instructions in “Guided functions” mode. The current values for maximum distance to be driven (km) until next oil change service are shown in the display of the vehicle diagnostic tester.

  • Page 122: Power Assisted Steering: Checking Fluid Level

    Amarok 2017 ➤ Maintenance - Edition 02.2021 – Switch transport mode off again. – Switch on ignition again for 10 seconds. After this procedure has been carried out, the event entry “Loading mode active” is no longer stored. Note The vehicle diagnosis tester may need to remain connected for further procedures or tests.

  • Page 123: Track Rod Ends: Checking Clearance, Firm Seating And Boots

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Note The cap must be fully screwed on in order to obtain an accurate fluid level reading. • The fluid level must be in area -A-. Fluid at operating temperature (approx. 80°C) – Unscrew filler cap.
  • Page 124 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Battery lamp -VAS 6901- ♦ Fluorescent lamp, 13 watts -VAS 6485- ♦ Mirror Carry out the following work: – Check play by moving track rods and wheels with the vehicle raised (wheels hanging free).

  • Page 125: Doors: Greasing Door Arrester

    Amarok 2017 ➤ Maintenance - Edition 02.2021 4.46 Doors: greasing door arrester Carry out the following work: – Lubricate door arrester at positions marked -arrows-. – Use lubricating paste -G 000 150- or lock cylinder lubricating spray -G 052 778 A2-.

  • Page 126: Protective Foil: Remove (If Fitted)

    Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Sliding sunroof frame ♦ Inner and outer door frame ♦ Area around trim strips ♦ Windscreen roof edge ♦ Outer and inner A-pillar ♦ Bonnet ♦ Wheel arches ♦ Inner and outer tailgate 4.48...

  • Page 127: Underbody: Visual Check For Damage To Underbody Protection And Underbody Covers

    Amarok 2017 ➤ Maintenance - Edition 02.2021 4.49 Underbody: Visual check for damage to underbody protection and under‐ body covers During visual check, also check underbody, underbody clad‐ ding, wheel housings and sills. Always ensure that all lines are secured in their mountings, that all plugs are available and that there is no visible damage on the underbody.

  • Page 128: Spark Plugs: Renew

    Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Layer separation (toothed belt body, tensile cords) ♦ Toothed belt body breakup ♦ Frayed cord strands ♦ Surface cracks (synthetic coating) ♦ Traces of oil and grease Note If faults are found, always renew toothed belt. This can avoid breakdowns and malfunctions.
  • Page 129 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Spark plug socket -VAS 3122B- ♦ Puller -T40039- Removing Carry out the following work: – Pull out all ignition coils with final output stage from cylinder head approx. 30 mm using puller -T40039-.
  • Page 130 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Remove ignition coil with output stage. – Unscrew spark plugs with spark plug spanner -VAS 3122B-. Installing Carry out the following work: – Fit new spark plugs with spark plug spanner -VAS 3122B-.

  • Page 131: Exhaust Emissions Test

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Exhaust emissions test ⇒ e5.1 missions test for petrol engines”, page 127 ⇒ e5.2 missions test for diesel engines”, page 129 Exhaust emissions test for petrol en‐ gines Note Please observe the country-specific laws and regulations.
  • Page 132 Amarok 2017 ➤ Maintenance - Edition 02.2021 ♦ Key numbers ♦ Vehicle identification number ♦ Fuel type ♦ Mileage The following vehicle data can be found in the vehicle registra‐ tion certificate part 1: ♦ Registration number: “e.g. WOB-HH 1234”...

  • Page 133: Exhaust Emissions Test For Diesel Engines

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Lambda probe value Specified data input for EET as bar code: – If EET nominal data is present in bar code format then read in bar code of EET data sheet using reader pen.
  • Page 134 Amarok 2017 ➤ Maintenance - Edition 02.2021 • Manual gearbox: gear lever in neutral • Parking brake applied – Perform exhaust emission test according to instructions on display. Vehicle data input – Enter the following data: ♦ Registration number ♦ Key numbers ♦...
  • Page 135 Amarok 2017 ➤ Maintenance - Edition 02.2021 – Perform manual data input according to instructions on dis‐ play. – Enter displayed values on EET data sheet under “Test val‐ ues for exhaust emissions test” on display in following se‐ quence:...
  • Page 136 Amarok 2017 ➤ Maintenance - Edition 02.2021 Inspection – Perform visual check of any components which are relevant for exhaust emissions. – Check if exhaust system is fitted and complete and check for leaks and damage. Procedure – Follow instructions of emissions testing station.

  • Page 137: Periodic Technical Inspection (Pti)

    Amarok 2017 ➤ Maintenance - Edition 02.2021 Periodic Technical Inspection (PTI) Note The following information is provided on the basis of the ♦ Commission Implementing Regulation (EU) 2019/621 and is intended solely as information for the regular roadworthiness testing of motor vehicles.
  • Page 138 Amarok 2017 ➤ Maintenance - Edition 02.2021 Description Method Necessary information Vehicle- Location of vehicle inter‐ specific de‐ face ⇒ page 59 scription of the location of and ac‐ cess to the vehicle in‐ terface Information individual systems are in...

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