Amarok 2.0 Biturbo Corpo Carro PDF

Service
Workshop Manual
Amarok 2011 ➤
General body repairs, exterior
Edition 10.2012
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
61 - Convertible roof, hardtop, canopy
63 - Bumpers
64 - Glazing
66 - Exterior equipment
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2012 Volkswagen AG, Wolfsburg D4B8026F790

Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Assembly overview - lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Assembly overview - support for lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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Assembly overview - air ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.4 Assembly overview - bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.5 Removing and installing front lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1.6 Removing and installing support for lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Assembly overview - wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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2.2 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3 Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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3.1 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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3.2 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.1 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.2 Assembly overview - bonnet lock and release components . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.3 Assembly overview - release lever and mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.4 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.5 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.6 Bonnet lock and Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.7 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.8 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.9 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.10 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.11 Separating Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.12 Removing and installing adjustable buffer film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.13 Removing and installing support rod with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.1 Assembly overview - add-on parts on tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Assembly overview - tailgate with torsion bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Assembly overview - hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Assembly overview - tailgate lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5 Assembly overview - tailgate handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.6 Assembly overview - tailgate handle with lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.7 Assembly overview - arrester cable, tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8 Assembly overview - tailgate spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.9 Assembly overview - tailgate seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.10 Removing and installing tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.11 Adjusting tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.12 Removing and installing hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.13 Removing and installing tailgate lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.14 Removing and installing tailgate handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.15 Removing and installing tailgate handle with lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.16 Removing and installing striker plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.17 Removing and installing torsion bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3 Load bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Assembly overview - load bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2 Assembly overview - load bed add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3 Assembly overview - lashing eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Contents i
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AG. Volkswagen AG d
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3.4 Removing and installing load bed . . . . . b.y .V. . . . . . . . . . . . . . . . . . . . . . . o.t g. u.a. . . . . . . . . .
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3.5 Removing and installing cross-member horis buffer . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . .
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4 Cab . . . . . . . . . . . . . . . . . . . . . .ss.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . .
. 65
4.1 Assembly overview - cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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4.2 Assembly overview - front mounting for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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4.3 Assembly overview - centre mounting for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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4.4 Assembly overview - rear mounting for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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4.5 Assembly overview - retaining strap for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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4.6 Removing and installing cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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4.7 Removing and installing retaining strap for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.8 Removing and installing pressure hoses and hose connections with screw-type clamps . . 74
5 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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5.1 Removing and installing tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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5.3 Removing and installing actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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1.1 Assembly overview - door hinge on A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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1.2 Assembly overview - door hinge on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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1.3 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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1.4 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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1.5 Adjusting striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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1.6 Removing and installing door hinge on A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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1.7 Removing and installing door hinge on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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1.8 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.3 Assembly overview - door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.4 Assembly overview - door lock cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.5 Assembly overview - cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.6 Assembly overview - window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.7 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.8 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.11 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.12 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.13 Removing and installing housing (without lock cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.14 Removing and installing inner door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.15 Removing and installing door handle bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.16 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.17 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.18 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.19 Removing and installing top door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.20 Removing and installing bottom door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.21 Assembly overview - impact rail of front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.22 Removing and installing loudspeaker in front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Assembly overview - door hinges on B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Assembly overview - door hinge on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.3 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
ii Contents
AG. Volkswagen AG d
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1.4 Adjusting striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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1.5 Removing and installing door hinge on B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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1.6 Removing and installing door hinge on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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1.7 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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1.8 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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1.9 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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2.3 Assembly overview - door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2.4 Assembly overview - door lock cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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2.5 Assembly overview - cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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2.6 Assembly overview - window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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2.7 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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2.8 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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2.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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2.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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2.11 Removing and installing housing (without lock cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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2.12 Removing and installing inner door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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2.13 Removing and installing door handle bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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by lksw
2.14 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
153
agen
Prote AG.
2.15 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.16 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1 Tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
61 - Convertible roof, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

1 Hardtop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Assembly overview - hardtop, aluminium rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.2 Assembly overview - seals and protective films, hardtop . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.3 Assembly overview - protective films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.4 Removing and installing hardtop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.5 Preassembly of aluminium rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2 Lid for hardtop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.1 Assembly overview - hardtop lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.2 Assembly overview - hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.3 Assembly overview - lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.4 Assembly overview - lid handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.5 Assembly overview - gas strut bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.6 Assembly overview - striker for lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.7 Removing and installing hardtop lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.8 Removing and installing hardtop lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.9 Removing and installing hardtop lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.10 Removing and installing hardtop lid handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.11 Removing and installing gas strut bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.12 Removing and installing hardtop lid striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.13 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.14 Removing and installing lock cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.15 Removing and installing high-level brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.16 Hardtop lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.1 Assembly overview - anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.2 Assembly overview - tailgate seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.3 Removing and installing anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Contents iii
Amarok 2011 ➤
4 Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.1 Assembly overview - glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.2 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.4 Removing and installing sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.5 Removing and installing front sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5 Trims, foam components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.1 Assembly overview - hardtop foam components, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.2 Assembly overview - foam components, n AG. Volkswagen AG
lkswage top and side . .d.oe.s.n . . . . . . . . . . . . . . . . . . . . . . . 210
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5.3 Removing and installing topedpanel by . . . . . . . . . . . . . . . . . . . . . t. g.ua. r.a . . . . . . . . . . . . . . . . . . . 211
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5.4 Removing and installingthright o D-pillar trim . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . 213
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5.5 Removing and installing ss left D-pillar trim . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . .
a 215
5.6 Removing and installing hardtop middle trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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5.7 Removing and installing hardtop securing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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5.8 Removing and installing front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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ility
5.9 Removing and installing edge protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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5.10 Installing speed nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
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hole
5.11 Removing and installing rear seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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t to the co
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1 Front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
rrectness of i
1.1 Assembly overview - front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.2 Assembly overview - front bumper cover, add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
l purpos
1.3 Assembly overview - wheel arch trim, bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

1.4 Assembly overview - parking aid retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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ercia
1.5 Assembly overview - substructure components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

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1.6 Removing and installing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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tion in
1.7 Removing and installing wheel arch trim, front bumper cover . . . . . . . . . . . . . . . . . . . . . . 239
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te o
1.8 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi 242

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iva
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1.9 Installing brackets for parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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2 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

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2.1 Assembly overview - rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
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2.2 Assembly overview - bottom step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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2.3 Assembly overview - rear bumper cover step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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Prote AG.
2.4 Assembly overview - closing plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.5 Assembly overview - rear bumper carrier to 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.6 Assembly overview - rear bumper carrier from 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.7 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.1 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.2 Window repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.4 Preparing old undamaged windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.5 Preparing new window without precoating for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.6 Preparing body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.7 Cleaning off excess adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.1 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3 Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.1 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.2 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4 Door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
iv Contents
Amarok 2011 ➤
4.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

4.2 Assembly overview - rear door window n AG. Vo. lk. s.w.a.ge. n. A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
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4.3 Removing and installing bfronty V door window . . . . . . . . . . t. g.ua. . . . . . . . . . . . . . . . . . . . . . . .
olk o 275
d
4.4 Removing and installing
ir se guide rail . . . . . . . . . . . . . . . . . . . . .an. te. . . . . . . . . . . . . . . . . . . . . .
r
276
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4.5 Removing and installing
au
t
rear door window . . . . . . . . . . . . . . . . . .or.ac. . . . . . . . . . . . . . . . . . . 277
ss
4.6 Removing and installing fixed door-window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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an
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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ab
1 Radiator grille and front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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1.1 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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1.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
hole
spec
2 Mouldings, trims, extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
es, in part or in w
t to the co
2.1 Assembly overview - heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3 Engine/gearbox guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
rrectness of i
3.1 Assembly overview - engine/gearbox guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.2 Removing and installing engine/gearbox guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
l purpos
4 Roof moulding and roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

4.1 Renewing roof strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
nf
ercia
or
5 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
m
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atio
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5.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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c
5.2 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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thi
te
5.3 Removing and installing housing frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
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5.4 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
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ng
5.5 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

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6 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
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6.1 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
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6.2 Assembly overview - fasteners for rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . 303
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Prote AG.
6.3 Assembly overview - rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
6.4 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
6.5 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
7 Lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
7.1 Dimensions - lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
7.2 Removing and installing radiator grille emblem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
7.3 Removing and installing emblem on tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8 Wheel arch trim (PR No. “0FA”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
8.1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
8.2 Removing and installing wheel arch trim, wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
8.3 Removing and installing wheel arch trim - left load bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
8.4 Removing and installing wheel arch trim - right load bed . . . . . . . . . . . . . . . . . . . . . . . . . . 325
9 Wheel arch trim (PR No. “0FX”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
9.1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
9.2 Removing and installing wheel arch trim, wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
9.3 Removing and installing wheel arch trim - left load bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
9.4 Removing and installing wheel arch trim - right load bed . . . . . . . . . . . . . . . . . . . . . . . . . . 342
10 Protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
10.1 Fitting notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
10.2 Renewing window frame films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
10.3 Removing and installing inner film of front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
10.4 Removing and installing inner door film of rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
10.5 Scuff protection film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
10.6 Protective film, B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
10.7 Anti-abrasion film, tailgate and D-pillar, load bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
11 Buffer - rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
11.1 Assembly overview - buffer, rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Contents v
Amarok 2011 ➤
12 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

12.1 Assembly overview - towing bracket with ball head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
13 Spare wheel winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
13.1 Assembly overview - spare wheel winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
14 Mudflaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
14.1 Assembly overview - front mudflap, without wheel arch trim . . . . . . . . . . . . . . . . . . . . . . . . 359
14.2 Assembly overview - front mudflap,
gen AG
. Volkswagwithen AGwheel arch trim . . . . . . . . . . . . . . . . . . . . . . . . . .
does
360
swa
14.3 Assembly overview yV
olk - rear mudflap, without wheel not arch trim . . . . . . . . . . . . . . . . . . . . . . . .
gu 361
b a
14.4 Assembly roverview
ised
- rear mudflap, with wheel archratrim nte .......................... 362
o e
14.5 Assemblyaut overview - rear mudflap bracket . . . . . . . . o. r .a . . . . . . . . . . . . . . . . . . . . . . . . . .
h
363
ss c
14.6 Removing and installing front mud flaps, without wheel arch trim . . . . . . . . . . . . . . . . . . . . 363
ce
e
nl
pt
14.7 Removing and installing front mud flaps, with wheel arch trim . . . . . . . . . . . . . . . . . . . . . . 365
du
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14.8 Removing and installing rear mud flaps, without wheel arch trim . . . . . . . . . . . . . . . . . . . . 366
erm
ab
14.9 Removing and installing rear mud flaps, with wheel arch trim . . . . . . . . . . . . . . . . . . . . . . 368
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vi Contents
Amarok 2011 ➤
50 – Body - front
1 Lock carrier
(VRL005195; Edition 10.2012)
⇒ “1.1 Assembly overview - lock carrier”, page 1
⇒ “1.2 Assembly overview - support for lock carrier”, page 2
⇒ “1.3 Assembly overview - air ducting”, page 3
⇒ “1.4 Assembly overview - bumper”, page 3
⇒ “1.5 Removing and installing front lock carrier”, page 4
⇒ “1.6 Removing and installing support for lock carrier”,
page 6
1.1 Assembly overview - lock carrier
1 - Front lock carrier

❑ Removing and installing
⇒ page 4
2 - Bolt
❑ Qty. 2 on each side
❑ Specified torque: 12 Nm wage
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1. Lock carrier 1
Amarok 2011 ➤
1.2 Assembly overview - support for lock carrier
1 - Support for left lock carrier

⇒ page 6
2 - Bolt
❑ Qty. 2
❑ Left and right.
❑ Specified torque: 20 Nm
+ 90°
3 - Support for left lock carrier
⇒ page 6
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2 Rep. gr.50 - Body - front

Amarok 2011 ➤
General body
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1.3 Assembly overview - air ducting by ara
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1 - Right air duct
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❑ Removing:
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– Remove front bumper
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cover ⇒ page 236 .
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❑ Remove hose to air vent
hole
spec
housing from rear ⇒
Heater and air condi‐ es, in part or in w
t to the co
tioning system; Rep. gr.
80 ; Air vent housing
❑ Unclip clip -5-, remove
rrectness of i
right air deflector ele‐
l purpos
ment forwards.
❑ Installing:
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❑ Install in reverse order

of removal.
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2 - Lock carrier
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❑ Unclip upwards out of
lock carrier -2-.
❑ Installing:
❑ Install in reverse order
of removal.
5 - Clip
❑ Left only
1.4 Assembly overview - bumper

Special tools and workshop equipment required
♦ Front end hook -3370-
1. Lock carrier 3
Amarok 2011 ➤
1 - Air duct
❑ Removing:
❑ Remove front bumper
❑ Removing foam ele‐
ment - pedestrian pro‐
tection ⇒ page 236 .
❑ Unclip clip -2- on left and
right cross members.
❑ Carefully lever off air
duct upwards using
front end hook -3370- .
❑ Installing: agen
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1.5 Removing and installing front lock carri‐

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♦ Torque wrench -V.A.G 1331-

Amarok 2011 ➤
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– Remove front bumper cover ⇒ page 236 .

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– Remove lid lock -1- unclip ⇒ page 25 . h re

hole
spec
es, in part or in w
– Unclip Bowden cable from front lock carrier -1- and disconnect
t to the co
⇒ page 33 .
– Unfasten air deflector elements ⇒ page 3 .
rrectness of i
– Unfasten radiator at front lock carrier -1- ⇒ Engine cooling

system; Rep. gr. 19 ; Removing and installing parts of the
l purpos
cooling system; Draining and filling coolant .

nform
– Remove bolts -2- on left and right.

mercia
– Remove front lock carrier -1- forwards.

a
com
tion in
Installing
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Install in reverse order of removal. When doing this, observe the

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– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
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pairs; Rep. gr. 00 ; Technical data; Body gaps; Body, front . t. C rig
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♦ ⇒ “1.1 Assembly overview - lock carrier”, page 1
1. Lock carrier 5
Amarok 2011 ➤
1.6 Removing and installing support for lock

carrier
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Removing
– Remove front bumper cover closing piece ⇒ page 236 .

Amarok 2011 ➤
– Remove bolts on lid lock ⇒ page 25 .

– Remove bolts -2- on left and right.
– Remove support for lock carrier -1- and -2- forwards.
Installing
following:
Specified torques
♦ Bolts -2-
⇒ “1.2 Assembly overview - support for lock carrier”, page 2 .
♦ Bolts -4- ⇒ “1.6 Bonnet lock and Bowden cable”, page 25 .
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1. Lock carrier 7
Amarok 2011 ➤
2 Wing
⇒ “2.1 Assembly overview - wing”, page 8
⇒ “2.2 Removing and installing wing”, page 8
2.1 Assembly overview - wing
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Only the left side is shown. The rise right side is similar.
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1 - Wing
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⇒ page 8
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❑ Qty. 1, A-pillar top
hole
spec
❑ Specified torque: 8 Nm.
es, in part or in w
t to the co
3 - Bolt
❑ Qty. 1, A-pillar bottom
rrectness of i
❑ Qty. 1, side member
l purpos
❑ Qty. 1, front wing

❑ Qty. 3, wing connection
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4 - Pop rivet nut

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❑ Qty. 1, A-pillar top

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❑ Insert using pop rivet nut

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❑ Qty. 1, side member
agen
Prote AG.
❑ Qty. 1, front wing

❑ Qty. 3, wing connection
piece
6 - Wing support
2.2 Removing and installing wing


Amarok 2011 ➤
♦ Pop rivet nut pliers -V.A.G 1765B-
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Removal and installation are described only for the left wing. Re‐
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Removing
es, in part or in w
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WARNING
rrectness of i
Clean all surrounding parts before beginning work and mask

them with tape.
l purpos
When removing wing, cutting wire should not be used due to

the risk of damage to the painted areas.
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2. Wing 9
Amarok 2011 ➤
AG. Volkswagen AG d
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– Remove front wheel housing liner ⇒ page 304 . Prote AG.

– Remove side turn signal light ⇒ Electrical system; Rep. gr.
94 ; Side turn signal lights .
– Remove bolts -2- and -3-
– Thread cutting cord -357 853 999 A- between wing -1- and A-
pillar.
– Separate bonding on wing support -4- with “sawing” motions
of both pull handles -V.A.G 1351/1- .
– Remove wing -1- carefully.
Installing
Note
Install wing -1- without subjecting it to tensile stress.

Amarok 2011 ➤
AG. Volkswagen AG d
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– Restore bonding -4- between A-pillar and wing -1- using seal‐
om
ion
ing cord -AKD 497 010 04 R10- .
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riv
pairs; Rep. gr. 00 ; Technical data; Body gaps; Body, front .

p
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Fitting is carried out with wing strut -3- removed.

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Carry out corrosion protection measures on wing and securing bolts after assembly and adjustment work.
Specified torques
♦ ⇒ “2.1 Assembly overview - wing”, page 8 .
2. Wing 11
Amarok 2011 ➤
3 Bulkhead
⇒ “3.1 Assembly overview - plenum chamber cover”, page 12
⇒ “3.2 Removing and installing plenum chamber cover”,
page 12
3.1 Assembly overview - plenum chamber cover
1 - Plenum chamber cover

⇒ page 12 .
2 - Filler piece
❑ Left and right.
❑ Between seal - bonnet,
plenum chamber and
wing
3 - Seal - bonnet, plenum
chamber
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3.2 Removing and installing plenum cham‐

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Removing
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Amarok 2011 ➤
AG. Volkswagen AG d
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Removing
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– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.

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92 ; Removing and installing windscreen wiper system .

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– Pull off entire length of plenum chamber seal -3-.

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The glass could be destroyed.
Prote AG.
The plenum chamber cover must not be levered off with a tool
(screwdriver, wedge). The windscreen will be damaged and
may subsequently crack.
– Remove filler piece -2- on side of plenum chamber covers

-1- on left and right.
– Starting from bonnet hinge, pull plenum chamber cover -1-
upwards and out of windscreen seal on bottom edge of wind‐
screen.
– Remove plenum chamber cover -1- from vehicle.
3. Bulkhead 13
Amarok 2011 ➤
Installing
WARNING
The glass could be destroyed.

Striking the plenum chamber cover can cause cracks in the
windscreen.
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Prote AG.
Note
♦ An insert is fitted in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.
♦ The plenum chamber cover may only be pushed into the windscreen seal by hand using light pressure.
Never fit with blows or with the use of tools.
– Spray windscreen seal with a soapy solution so that plenum

chamber covers -1- are easier to press on.
– Note positioning of plenum chamber cover -1- on sheet metal
flange, left and right -arrow b-.

Amarok 2011 ➤
– Starting from bonnet gen Ahinge,

G. Volkspush plenum
wagen AG
does chamber covers
swa
-1- into window
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not
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– Position
au both outer ends of bonnet seal on plenum chamber
ra
c
ss
-3- -arrow a- and push in working towards middle.
ce
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un
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– Install windscreen wiper arms ⇒ Electrical system; Rep. gr.
an
d
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92 ; Removing and installing windscreen wiper system .
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3. Bulkhead 15
Amarok 2011 ➤
55 – Bonnet, rear lid
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Rep. gr.55 - Bonnet, rear lid
agen
Prote AG.
Amarok 2011 ➤
1 Bonnet
⇒ “1.1 Assembly overview - bonnet”, page 17
⇒ “1.2 Assembly overview - bonnet lock and release compo‐
nents”, page 18
⇒ “1.3 Assembly overview - release lever and mounting bracket”,
page 19
⇒ “1.4 Removing and installing bonnet”, page 19
⇒ “1.5 Adjusting bonnet”, page 22
⇒ “1.6 Bonnet lock and Bowden cable”, page 25
⇒ “1.7 Removing and installing striker”, page 27
⇒ “1.8 Removing and installing release lever”, page 28
⇒ “1.9 Removing and installing hinges”, page 28
⇒ “1.10 Removing and installing insulation”, page 30
⇒ “1.11 Separating Bowden wcable”,
agen
AGpage
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⇒ “1.12 Removing and ed installing adjustable buffer film”,
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⇒ “1.13 Removing
ss and installing support rod with bracket”, c
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page 35
nl
pt
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1.1 Assembly overview - bonnet y li

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1 - Bonnet wit
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hole
⇒ page 19
spec
es, in part or in w
❑ Adjusting ⇒ page 22
t to the co
2 - Adjustment buffer
❑ Left and right.
rrectness of i

l purpos
3 - Insulation
nf
ercia
⇒ page 30
rm
m
atio
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4 - Hinge
o
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or c

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⇒ page 28
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5 - Plenum chamber seal
Co
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Prote AG.
6 - Lid lock
⇒ page 25
7 - Support rod
⇒ page 35
8 - Striker
⇒ page 27
1. Bonnet 17
Amarok 2011 ➤
1.2 Assembly overview - bonnet lock and release components
1 - Lid lock
⇒ page 25
2 - Bowden cable coupling
❑ Bowden cable coupling
is located above head‐
light on driver side.
❑ Separating
⇒ page 33 .
3 - Bowden cable olkswagen AG
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⇒ page 28
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⇒ page 27
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18 Rep. gr.55 - Bonnet, rear lid

Amarok 2011 ➤
1.3 Assembly overview - release lever and mounting bracket
1 - Mounting bracket
To work on mounting bracket,
it is necessary to remove A-pil‐
lar trim at bottom ⇒ General
body repairs, interior; Rep. gr.
70 ; A-pillar trim at bottom .
2 - Captive nut
❑ Qty. 2
3 - Bowden cable
❑ Installing:
– Insert ball of Bowden
cable into mounting
bracket and lock Bow‐
den cable in mounting
bracket.
4 - Bolt
❑ Specified torque: 3.0
Nm
❑ Qty. 2
5 - Release lever
⇒ page 28
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1. Bonnet 19
Amarok 2011 ➤
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– Removing washer jets ⇒ Electrical system; Rep. gr. 92 ; Win‐

ole,
dow washer system; Removing and installing washer jets for

spec
window washer system .

t to the co
– Pull line out of opening in bonnet -3-.

– Loosen bolts -3- on left and right hinges -2- (do not remove).
rrectne
Further dismantling requires the help of a second mechanic.

ss
– Remove support rod -2- from bonnet -3-.

o
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– Only now remove bolts -4- and remove bonnet -3- from hinges
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-1-.
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Installation is carried out in reverse order. When doing this, ob‐

serve the following:
– Adjusting bonnet -3- ⇒ page 22 .
Specified torques
Component Specified torques
Hinge bolts 30 Nm
1. Bonnet 21
Amarok 2011 ➤
1.5 Adjusting bonnet
Note
♦ Vehicle must be on the ground when adjusting bonnet -1-.

♦ Adjustment via outer adjustment buffer and inner centring buffer -2-, striker -4- and bonnet lock -3-.
♦ The bonnet -1- is correctly adjusted when all shut lines are even when closed. When the door does not
project in or out too far and the contours align.
♦ The bonnet -1- must engage into the bonnet lock without excessive force.
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Adjusting bonnet cted agen
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– Adjust alignment of bonnet -2- and wings at front corners by

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bonnet slightly raised.

es, in part or in w
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– Open bonnet -2-.

– Screw in adjustment buffer -3- into bonnet -2- by 180°.
rrectness of i
– Bolt on striker -1- in a centred position (note marking -5-).

l purpos
– Loosen bolts on bonnet lock until bonnet lock can be moved

freely on bolts ⇒ page 25 .
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– Close bonnet -2- so that striker engages in bonnet lock.

m
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– Tighten bonnet lock bolts to specified torque (with bonnet -2-

ion
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ate
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1. Bonnet 23
Amarok 2011 ➤
Note
Make sure bonnet and wings are correctly aligned at front corners. If necessary, repeat the work procedure.
Adjusting striker
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– Loosen bolts -2-.

Amarok 2011 ➤
– Striker -1- can be adjusted in its slots in -direction of arrow- to

left and right on bonnet -3-.
– Bolt on striker -1- in a centred position.
Note
♦ Note markings -arrow- on striker -1- and bonnet.

Volkswa
♦ The bolts -2- may only
swbe
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AG. retightened
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Striker bolts 10 Nm
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1.6 Bonnet lock and Bowden cable
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⇒ “1.6.1 Removing and installing bonnet lock and Bowden cable”,
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page 25
spec
⇒ “1.6.2 Bonnet lock, from model year 2013”, page 27
t to the co
1.6.1 Removing and installing bonnet lock
and Bowden cable
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Removing
1. Bonnet 25
Amarok 2011 ➤ n AG. Volkswagen AG do
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– Open bonnet.
– Detach Bowden cable at Bowden cable coupling
⇒ page 33 .
– Unclip Bowden cable -4- from lock carrier.
– Separate connector -5- for bonnet contact switch.
– Remove bolts -2- from lock carrier.
Bonnet lock bolts, from 2013 ⇒ page 27
– Withdraw lid lock -1- with attachment plate -3- (if fitted) up‐
wards.
– Unclip Bowden cable -4- from lid lock -1-.
Installing
– Insert lid lock -1- with attachment plate -3- (if fitted) into lock
carrier.
Note
Attachment plate -3- sits between lock support and lock carrier.
– Connect connector -5- for bonnet contact switch.

Amarok 2011 ➤
– Attach Bowden cable to Bowden cable coupling

⇒ page 33 .
– Clip in Bowden cable -4- on lock carrier.
• Before closing bonnet, check function of release lever and
Bowden cable.
Specified torques
♦ ⇒ “1.6.2 Bonnet lock, from model year 2013”, page 27
1.6.2 Bonnet lock, from model year 2013
1 - Lock carrier
⇒ page 4 .
2 - Bonnet lock
⇒ page 25 .
3 - Securing plate
4 - Bolt
❑ Qty. 2
WARNING
Bolts must always be re‐
placed by new ones after
being removed.
❑ Specified torques: 20
Nm + 180°
5 - Bolt
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❑ Specified torques:
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1.7 Removing and installing striker

nform
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Removing
m
– Remove bolts -2-.

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1. Bonnet 27
Amarok 2011 ➤
– Remove striker -1- from bonnet.

Installing
– Install striker -1- on bonnet. agen
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Specified torques
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♦ Adjusting striker pin ⇒ page 24 .
wit
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1.8 Removing and installing release lever
s o
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Removing
mer
atio
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– Tighten release lever -1- and unlock bonnet.

o
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c
i
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– Insert a small screwdriver in gap between release lever -1- and
thi
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retaining clip -2-.
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– Lever retaining clip -2- out of release lever -1- and remove
fo
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– Push retaining clip -2- completely into release lever -1-. Prote
cted AG.
agen
– Press release lever -1- onto mounting in mounting bracket and

lock release lever.
Bowden cable.
1.9 Removing and installing hinges


Amarok 2011 ➤
Note
Removal and installation are described for the right hinge only.
Removal and installation of the left hinge are similar.
Removing
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– Remove wing ⇒ page 8 .

form
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– Removing bonnet -2- ⇒ page 19

atio
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– Pull off hinge -1-.

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– Adjust bonnet if hinge -1- has been renewed cted agen
Prote AG.
1. Bonnet 29
Amarok 2011 ➤
Note
Carry out corrosion protection measures aon

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Hinge bolts 30 Nm
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1.10 Removing and installing insulation
ot p
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♦ Removal lever -80 - 200-
es, in part or in w
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AG. Volkswagen AG d
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autho
General body repairs,
eo
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ss c
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– Lever retaining clips -3- (qty. 7) out of bonnet -2- using removal
lever -80-200- .
– Pull insulation -1- out of longitudinal holes.
Installing
1. Bonnet 31
Amarok 2011 ➤
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• When installing insulation -1-, ensure that retaining clips -3-

are fitted with wider side outwards.
– Push insulation -1- with mounting tabs into slots -arrows a- and
then slots -arrows b-.
– Insert retaining clips -3- into bonnet -2-.

Amarok 2011 ➤
1.11 Separating Bowden cable
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Removing
– Open bonnet.
– Unclip Bowden cable mounting -3- above headlight on driver
side at lock carrier.
– Remove Bowden cables -1- and -2- from Bowden cable
mounting -3- and disconnect.
Installing
Note
When installing, ensure that Bowden cables -1- and -2- are correctly connected in Bowden cable mounting
-3-.

Bowden cable.
1. Bonnet 33
Amarok 2011 ➤
1.12 Removing and installing adjustable buf‐

fer film
Note
♦ Renewing anti-abrasion film is described only for the left side.

The right side is similar.
♦ Anti-abrasion film for adjustment buffer cannot be removed
without causing damage.
– Pull backing off anti-abrasion film -1-.

– Position anti-abrasion film -1- on front lock carrier and press
on firmly.
Installation instructions
Before removing anti-abrasion film, heat film with hot air blower -
V.A.G 1416- .
If the anti-abrasion film is installed for the first time on a new ve‐
hicle or on newly painted surfaces, follow the procedure in ⇒
Workshop manual "Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒
Mouldings and film .
If anti-abrasion film is removed and reinstalled, only use adhesive
remover -D 002 000 10- to remove the adhesive remains.
AG. Volkswagen
Ensure that the adhesive surfaces
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Position and apply anti-abrasion film immediately after cleaning. ran
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Remove backing from aut anti-abrasion film only immediately before or
ac
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installation.
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Working temperature is approx. 21 °C.

an
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Amarok 2011 ➤
1.13 Removing and installing support rod with bracket
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– Brace the bonnet open.

hole
spec
– Unclip mounting bracket -2- with support rod -1- from front lock
es, in part or in w
t to the co
carrier.
Installing
rrectness of i
l purpos
Note
Check mounting bracket -2- for damage, renew if necessary.

nform
mercia
at
– Guide end with hook into lock carrier.

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c
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– Position bracket -2- with support rod -1- and clip into front of
o
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lock carrier.
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1. Bonnet 35
Amarok 2011 ➤
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Amarok 2011 ➤
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⇒ “2.1 Assembly
ss overview - add-on parts on tailgate”, page 37c
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⇒ “2.2 Assembly overview - tailgate with torsion bar”, page 38
pt
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⇒ “2.3 Assembly overview - hinge”, page 39
rm
ab
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⇒ “2.4 Assembly overview - tailgate lock”, page 40
ot
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⇒ “2.5 Assembly overview - tailgate handle”, page 41
hole
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⇒ “2.6 Assembly overview - tailgate handle with lock cylinder”,
t to the co
page 42
⇒ “2.7 Assembly overview - arrester cable, tailgate”, page 42
rrectness of i
⇒ “2.8 Assembly overview - tailgate spacer”, page 45
l purpos
⇒ “2.9 Assembly overview - tailgate seals”, page 45

⇒ “2.10 Removing and installing tailgate”, page 45
nform
ercia
⇒ “2.11 Adjusting tailgate”, page 47

m
a
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⇒ “2.12 Removing and installing hinge”, page 47
n in
r
te o
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⇒ “2.13 Removing and installing tailgate lock”, page 49
s
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⇒ “2.14 Removing and installing tailgate handle”, page 51
fo
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t.
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⇒ “2.15 Removing and installing tailgate handle with lock cylin‐
Cop py
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⇒ “2.16 Removing and installing striker plate”, page 54
c by lksw
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⇒ “2.17 Removing and installing torsion bar”, page 56
2.1 Assembly overview - add-on parts on tailgate

1 - Tailgate
⇒ page 45
2 - Handle
⇒ page 51
3 - Lock
⇒ page 49
4 - Hinges
⇒ page 47
5 - Locking wedge
⇒ page 54
2. Tailgate 37
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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2.2 Assembly overview - tailgate with torsion bar
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1 - Tailgate s
ce
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un
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⇒ page 45 .
y li
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2 - Middle bracket
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3 - Washer
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spec
4 - Bolt
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Nm
5 - Rear panel
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6 - Torsion bar
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7 - Bolt
o
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❑ Specified torques: 8.0
atio
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Prote AG.

Amarok 2011 ➤
2.3 Assembly overview - hinge
1 - Tailgate
⇒ page 45
2 - Bolt
Nm
3 - Hinge
❑ Left and right.
⇒ page 47
4 - Base
❑ Left and right. AG. Volkswagen AG d
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2. Tailgate 39
Amarok 2011 ➤
2.4 Assembly overview - tailgate lock
Note
Only the left side is shown. The right side is similar.
1 - Lock
⇒ page 49
2 - Bolt
❑ Qty. 2
Nm.
3 - Arrester cable
4 - Pull rod
❑ To handle
5 - Tailgate
⇒ page 45
AG. Volkswagen AG d
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Prote
40
AG.
Amarok 2011 ➤
2.5 Assembly overview - tailgate handle
1 - Tailgate handle
⇒ page 51
2 - Bolt
❑ Qty. 2
❑ Specified torques: 2.3
Nm
3 - Tailgate
⇒ page 45
4 - Pull rod
❑ Left and right.
❑ To lock ⇒ page 40
AG. Volkswagen AG d
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Prote AG.
2. Tailgate 41
Amarok 2011 ➤
2.6 Assembly overview - tailgate handle with lock cylinder
1 - Tailgate handle
❑ With lock cylinder
⇒ page 52 .
2 - Lock cylinder
Note
3 - Bolt
❑ Qty. 2
❑ Specified torques: 2.3 lkswage es n
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2.7 Assembly overview - arrester cable, tail‐
t rig
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gate
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Prote AG.
⇒ “2.7.1 Arrester cable, tailgate ▶ 2010”, page 43

⇒ “2.7.2 Arrester cable, tailgate 2011 ▶”, page 44

Amarok 2011 ➤
2.7.1 Arrester cable, tailgate ▶ 2010
Note
♦ Only the left side is shown. The right side is similar.

♦ Bolt -1- must be screwed in completely in one operation. Subsequent tightening
G. Volkswage
is not permitted.
nA n AG d
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Volks not
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1 - Bolt oris eo
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WARNING
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❑ Qty. 2
spec
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Nm
2 - Arrester cable, tailgate
rrectness of i
❑ Press tailgate arrester
l purpos
cable in
-direction of arrow a-
against bolt -1- and pull
nform
ercia
in -direction of arrow b-
m
at
3 - Washer
om
ion
c
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ate
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rig ht
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co Vo
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Prote AG.
2. Tailgate 43
Amarok 2011 ➤
2.7.2 Arrester cable, tailgate 2011 ▶
Note

♦ Bolt -1- must be screwed in completely in one operation. Subsequent tightening is not permitted.
1 - Bolt
WARNING
being removed.
❑ Qty. 2
Nm
2 - Arrester cable, tailgate
❑ Press tailgate arrester
cable in
-direction of arrow a-
against bolt -1- and pull
in -direction of arrow b- AG. Volkswagen AG d
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3 - Washer d byV
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c
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rig ht
py by
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Prote AG.

Amarok 2011 ➤
2.8 Assembly overview - tailgate spacer

– Spacers -2- on right and left are stuck onto inside between
tailgate -1- and pull rods -3-.
– Bond top edge of spacer -2- flush with top edge of tailgate
opening.
Note
Ensure that the adhesive surfaces are free of dust and grease.
2.9 Assembly overview - tailgate seals
1 - Left seal
❑ Pushed onto edge of
load bed
2 - Right seal
load bed
3 - Tailgate seal
❑ Bonded on lower edge
of tailgate olkswage es n
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2.10 Removing and installing tailgate
Prote AG.
2. Tailgate 45
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
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ility
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es, in part or in w
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c
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Vo
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Prote AG.
Removing
– Loosen bolts -2- on left and right hinges (do not remove).
– Only now remove bolts -2- and remove tailgate -1-.
Installing

AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Amarok 2011 ➤
e nte
horis General body repairs, exterior
eo - Edition 10.2012
aut ra
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Specified torques
ce
le
un
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an
d
itte
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Tailgate bolts 40 Nm
ility
ot p
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2.11 Adjusting tailgate is n
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spec
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mer
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♦ Vehicle must be on the ground when adjusting tailgate.
♦ Tailgate must engage in striker plate -1- and fixture -3- without
excessive force.
– Loosen bolts -2-.

– The striker plate -1- with fixture -3- can be adjusted in
-direction of arrows- using a plastic head hammer to ensure
the tailgate closes flush.
Specified torques
Striker plate bolts 20 Nm
2.12 Removing and installing hinge

2. Tailgate 47
Amarok 2011 ➤ AG. Volkswagen AG d
agen oes
V olksw - Edition 10.2012 not
g y ua
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♦ Torque wrench -V.A.G u1331-
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Note
nf
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or
Removal and installation are described only for the left hinge. Removal and installation of the right hinge are
m
m
atio
similar.
om
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Removing
– Removing tailgate -1- ⇒ page 45 .

Amarok 2011 ➤
– Remove bolts -2- on hinge -3-.

– Remove hinge -3- and base plate -4-.
Installing
Note
Ensure base plate -4- is seated correctly.
Specified torques
♦ ⇒ “2.3 Assembly overview - hinge”, page 39 .
2.13 Removing and installing tailgate lock

G. Volkswage
nA n AG d
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Special tools and workshop
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b ara
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♦ Torque wrench
ho
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Note
nform
ercia
Removal and installation are described only for the left lock. The removal and installation of the right lock are
m
similar.
a
com
tion in
r
te o
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Prote AG.
2. Tailgate 49
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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spec
es, in part or in w
t to the co
Removing
– Removing tailgate trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing tailgate trim .
rrectness of i
– Unclip pull rod -4- from handle ⇒ page 51 .

l purpos
– Remove bolts -2- from tailgate -5-.

nform
mercia
Note
com
tion in
r
te o
Arrester cable -3- for tailgate -5- is bolted under lower bolt -2- ⇒ page 42 .
thi
s
iva
do
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rp
cum
– Remove lock -1- from tailgate -5-.

fo
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t.
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– Unclip pull rod -4- from lock. Cop py
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Installation is carried out in reverse order. When doing this, ob‐ Prote AG.
Specified torques
♦ ⇒ “2.4 Assembly overview - tailgate lock”, page 40 .

AG. Volkswagen AG d
agen oes
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gu Amarok 2011 ➤
Vol
by ara
d
orise General body repairs, exterior - nEdition
tee 10.2012
th or
au a
ss c
2.14 Removing and installing tailgate handle
ce
e
nl
pt
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nf
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Removing
n in
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Prote AG.

– Unclip pull rods -4- on left and right from tailgate handle -1-.
2. Tailgate 51
Amarok 2011 ➤
– Remove bolts -2- from tailgate -3-.

– Swivel outside tailgate handle -1- in -direction of arrow- out of
tailgate.
Installing
lkswage es n
o ot g
byV ua
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un
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an
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is n
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cial p
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mer
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Vo
co lksw
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cted agen
Prote AG.
– Pull on tailgate handle -1-, insert at bottom and swing into po‐
sition.
– Clip pull rods -3- on left and right onto tailgate handle -1-.
Specified torques
♦ ⇒ “2.5 Assembly overview - tailgate handle”, page 41 .
2.15 Removing and installing tailgate handle

with lock cylinder

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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ce
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un
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mer
atio
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Removing
n
c
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t
sd
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pr
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– Unclip pull rods on left and right from tailgate handle -1-.
t.
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– Unscrew bolts -3- from tailgate -2-.
t. rig
gh ht
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o
– Swivel tailgate handle -1- out of tailgate -2-. by c lksw
cted agen
Prote AG.
2. Tailgate 53
Amarok 2011 ➤
Installing
• Lock cylinder is installed ⇒ page 42 .
– Installation in unlocked state (lock cylinder slot vertical).
– Pull on tailgate handle -1-, insert at bottom and swing into po‐
sition.
– Clip pull rods on left and right onto tailgate handle -1-.
Specified torques
Component Specified
agentorques
AG. Volkswagen AG d
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Tailgate handle bolts 2.3
d bNm
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2.16 Removing and installing striker plate
t or
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⇒ “2.16.1 Removing and installing striker plate ▶ 2010”,

un
pt
an
d
page 54
itte
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⇒ “2.16.2 Removing and installing striker plate 2011 ▶”,
pe
ility
page 55
ot
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spec
Note
es, in part or in w
t to the co
Removal and installation are described only for the left side. The
removal and installation of the right side are similar.
rrectness of i
2.16.1 Removing and installing striker plate ▶
l purpos
2010
nform
ercia
Removing
m
a
com
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– Remove bolts -2- and remove locking wedge -1-.
on in
r
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Installing
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um
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– Adjusting tailgate ⇒ page 47 .
C py
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rig ht
py by
Specified torques
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
2.16.2 Removing and installing striker plate

2011 ▶
Removing
– Remove striker plate -1- with fixture -3-.
Installing
– Adjusting tailgate ⇒ page 47 . wage
es n
olks ot g
Specified torques byV ua
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Component Specified
aut
torques or
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Cop py
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cted agen
Prote AG.
2. Tailgate 55
Amarok 2011 ➤
2.17 Removing and installing torsion bar
Note
Torsion bar may be installed or removed only when tailgate is closed.
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
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, is n
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hole
spec
es, in part or in w
Removing
t to the co
– Unscrew bolts -7- of brackets -2- and -9-.

– Unscrew bolt -4- together with washer -3-.
rrectness of i
– Pull torsion bar -6- out of clip -8-.

l purpos
Installing
nf
ercia
– Insert torsion bar -6- through clip -8-.

rm
m
atio
m
– Secure washer -3- and bolt -4- to hinge through eyelet of tor‐
o
n in
c
sion bar -6-.

or
thi
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sd
a
– Secure brackets -2- and -9- with bolts -7-.

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56
by lksw
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Rep. gr.55 - Bonnet, rear lid Prote AG.
Amarok 2011 ➤
Specified torques
♦ ⇒ “2.2 Assembly overview - tailgate with torsion bar”,
page 38
AG. Volkswagen AG d
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tion in
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Prote AG.
2. Tailgate 57
Amarok 2011 ➤
3 Load bed agen

AG. Volkswagen AG d
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⇒ “3.1 Assembly overview - load bed”, d bypage
V 58 gu
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⇒ “3.2 Assembly overview - load ut bed add-on parts”, page 59
ho eo
ra
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s
⇒ “3.3 Assembly overview - lashing eyes”, page 59
ce
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nl
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an
⇒ “3.4 Removing and installing load bed”, page 61
itte
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⇒ “3.5 Removing and installing cross-member buffer”,
ility
ot p
page 63
wit
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3.1 Assembly overview - load bed
hole
spec
es, in part or in w
t to the co
1 - Fastening ring
❑ Assembly overview
rrectness of i
⇒ page 59 .
l purpos
2 - Load bed
⇒ page 61
nf
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orm
m
3 - Support
atio
om
❑ Outer side part
n in
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⇒ page 59
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⇒ page 63 . Cop py
rig
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rig
5 - Tank filler neck py by
co Vo
by lksw
❑ Unscrew ⇒ page 78 . cted agen
Prote AG.
6 - Ladder frame

Amarok 2011 ➤
3.2 Assembly overview - load bed add-on parts
Note
wage es n
Only the left side is shown. The right side is similar. byV
olks ot g
ua
d ran
ir se tee
tho
u or
a ac
1 - Load bed ss
ce
e
nl
pt
du
an
itte
⇒ page 61
y li
erm
ab
ility
2 - Pop rivet nut
ot p
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❑ Insert using pop rivet nut , is n
h re
pliers -V.A.G 1765B- .
hole
spec
es, in part or in w
3 - Bolt
t to the co
4 - Left support
rrectness of i
5 - Bolt
l purpos
6 - Bolt
nform
ercia
❑ Qty. 4
m
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Prote AG.
3.3 Assembly overview - lashing eyes

⇒ “3.3.1 Lashing eyes, double cab”, page 60
⇒ “3.3.2 Lashing eyes, single cab”, page 61
3. Load bed 59
Amarok 2011 ➤
3.3.1 Lashing eyes, double cab
Note
Only the left side is shown. The right side is analogous.
1 - Rear lashing eye

❑ Secured with bolts -2-
2 - Middle lashing eye
3 - Front lashing eye
4 - Bolt
Volkswagen AG
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Amarok 2011 ➤
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3.3.2 Lashing eyes, single cab
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1 - Rear lashing eye
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2 - Middle lashing eye

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3 - Front lashing eye

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3.4 Removing and installing load bed

3. Load bed 61
Amarok 2011 ➤
Note
Removal and installation are described only for the double cab load bed. The removal and installation of the
single cab load bed are similar.
AG. Volkswagen AG d
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Amarok 2011 ➤
– Remove tail lights ⇒ Electrical system; Rep. gr. 94 ; Tail

lights .
– Unfasten handbrake cable from underneath ⇒ Brake system;
Rep. gr. 46 ; Rear brake .
– Unscrew tank filler neck ⇒ page 78 .
– Guide electrical cables out of load bed.
– Remove bolts -2- on left and right (-6- bolting points).
Note
Note: single cab load bed has -8- bolting points.
– 4 mechanics are required to lift load bed off ladder frame.

Installing
WARNING
Bolts must always be renewed after being loosened.
Specified torques
Component Specified
swa
torques
gen AG. Volkswagen AG d
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Load bed bolts 90
ed Nm + 90°
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3.5 Removing and installing cross-member ss
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buffer
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Installation is described only for the left side. The right side is
hole
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Removing
• Load bed removed
rrectness of i
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3. Load bed 63
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Amarok 2011 ➤ byV
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General body repairs, exterior - Edition
horis 10.2012 tee
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– Unclip outer side of buffer -2- -arrow A-.
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– Swivel buffer -2- out of cross member -arrow B-.
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Installing
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Install in reverse order of removal.
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Amarok 2011 ➤
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⇒ “4.1 Assembly
tho
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au ra
⇒ “4.2
ss Assembly overview - front mounting for cab”, page 67 c
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nl
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⇒ “4.3 Assembly overview - centre mounting for cab”, page 68
du
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⇒ “4.4 Assembly overview - rear mounting for cab”, page 68
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⇒ “4.5 Assembly overview - retaining strap for cab”, page 71
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⇒ “4.6 Removing and installing cab”, page 71
hole
spec
es, in part or in w
⇒ “4.7 Removing and installing retaining strap for cab”,
t to the co
page 73
⇒ “4.8 Removing and installing pressure hoses and hose con‐
rrectness of i
nections with screw-type clamps”, page 74
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4.1 Assembly overview - cab

⇒ “4.1.1 Double cab”, page 65
nform
ercia
⇒ “4.1.2 Single cab”, page 66

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4.1.1 Double cab
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1 - Cab
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⇒ page 71 . t. C rig
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2 - Front mounting
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AG.
⇒ page 67 .
3 - Bolt
❑ Specified torque 90 Nm
+ turn 180° further.
❑ Bolts must always be re‐
newed after being loos‐
ened.
4 - Rear mounting
⇒ page 69 .
5 - Bolt
ened.
6 - Middle mounting
⇒ page 68 .
7 - Bolt
ened.
4. Cab 65
Amarok 2011 ➤
4.1.2 Single cab
1 - Cab
⇒ page 71 .
2 - Front mounting
⇒ page 67 .
3 - Bolt AG. Volkswagen AG d
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❑ Specified torque 90 Nm Volksw not
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+ turn 180° further. d b ara
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❑ Bolts must always be re‐ autho eo
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newed after being loos‐ ss c
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4 - Rear mounting itte
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5 - Bolt
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ened.
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6 - Middle mounting
nform
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⇒ page 68 .
m
7 - Bolt
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Amarok 2011 ➤
4.2 Assembly overview - front mounting for cab
Note
1 - Top mounting
2 - Bottom mounting
3 - Ladder frame
4 - Front mounting support
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4. Cab 67
Amarok 2011 ➤
4.3 Assembly overview - centre mounting for cab
Note
1 - Top mounting
2 - Bottom mounting
3 - Ladder frame
4 - Middle mounting support
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4.4 Assembly overview - rear mounting for

cab
rrectness of i
⇒ “4.4.1 Rear mounting for double cab”, page 69

l purpos
⇒ “4.4.2 Rear mounting for single cab”, page 70

nform
mercia
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Prote AG.

Amarok 2011 ➤
4.4.1 Rear mounting for double cab
Note
1 - Rear mounting
❑ Removing:
– Lift cab and remove
bolts -2-.
2 - Bolt
❑ Qty. 2
3 - Ladder frame
4 - Rear mounting support
AG. Volkswagen AG d
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4. Cab 69
Amarok 2011 ➤
4.4.2 Rear mounting for single cab
1 - Rear mounting
❑ Removing:
– Lift cab and remove
bolts -2-.
2 - Bolt
❑ Qty. 2
3 - Ladder frame
4 - Rear mounting support
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Amarok 2011 ➤
4.5 Assembly overview - retaining strap for cab
Note
olksw
For single cab and double cab vehicles the retaining strap is installed
swa
gen Aon driveraside.
G. V gen AG
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1 - Retaining strap au ra
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⇒ page 73
an
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2 - Protective hose
ab
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❑ For retaining strap -1-.
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❑ Installation only on left-
ole,
hand drive vehicles as
spec
of 2012
t to the co
3 - Bolt
❑ For holding together
rrectne
structure/for dust pro‐
tection
s
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4 - Hexagon nut
nform
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5 - Bolt
n
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Prote AG.
4.6 Removing and installing cab

4. Cab 71
Amarok 2011 ➤
AG. Volkswagen AG d
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Note
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hole
spec
es, in part or in w
Removal and installation are described only for the double cab. The removal and installation of the single cab
t to the co
load bed are analogous.
rrectness of i
l purpos
nform
mercia
a
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tion in
r
te o
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Removing
– Remove load bed ⇒ page 61

Amarok 2011 ➤

– Remove wheel housing liners ⇒ page 304 .
– Unplug electrical connectors in engine compartment.
– Disconnect electrical coupling point for cab on underbody.
– Disconnect steering column ⇒ Chassis, axles, steering; Rep.
gr. 48 ; Steering wheel, steering column
– Unhook handbrake cable from underneath ⇒ Brake system;
Rep. gr. 46 ; Rear brake
– Disconnect gear selector cable from underneath ⇒ Manual
gearbox; Rep. gr. 34 ; Repairing selector mechanism .
– Completely separate brake pressure lines at brake servo ⇒
Brake system; Rep. gr. 47 ; Assembly overview: Brake servo/
main brake cylinder .
– Drain coolant and disconnect coolant lines ⇒ Engine cooling
system; Rep. gr. 19 ; Removing and installing parts of the
cooling system; Draining and filling coolant .
– Disconnect lines to condenser ⇒ Heating and air conditioning
system; Rep. gr. 87 ; Air conditioning system; Removing and
installing condenser .
– Disconnect pressure hoses for charge-air cooler
⇒ page 74 .
– Remove bolts -3-, -7- and -5-nfrom body
AG. Vo mountings
lkswagen AG -2-, -6- and
-4-. olkswage does
no V t gu
by ara
– Carefully lift body
ris -1- off upwards.
ed nte
ho eo
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Installing ss
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nl
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Note
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spec
During assembly, it is helpful to guide cab -1- onto body mountings using commercially available threaded rods.
es, in part or in w
t to the co
Specified torques
♦ ⇒ “4.1 Assembly overview - cab”, page 65 .
rrectness of i
4.7 Removing and installing retaining strap

l purpos
for cab
nf
ercia
Removing
orm
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Note
or
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Retaining strap with protective hose is installed on models as of

rp
cu
o
2012 ⇒ Item 2 (page 71) .

f
en
ng
t.
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Cop py
t. rig
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Prote AG.
4. Cab 73
Amarok 2011 ➤
– Unscrew hexagon nut -2- from ladder frame -5-.

– Unscrew bolt -3- from cab -4- and remove retaining strap -1-.
Installing
Specified torques
♦ ⇒ “4.5 Assembly overview - retaining strap for cab”, page 71 .
AG. Volkswagen AG d
agen oes
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4.8 Removing and installing pressure hoses
h re
ole,
and hose connections with screw-type
spec
clamps
t to the co
⇒ “4.8.1 Hose connections with push-on couplings”, page 74
rrectne
⇒ “4.8.2 Pressure hose with ribbed union and hose clamp”, page
75
ss
⇒ “4.8.3 Notes on hose connections with screw-type clamps”,
o
cial p
f
page 76
inform
mer
4.8.1 Hose connections with push-on cou‐

atio
om
plings n
c
i
or
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te
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Caution
cum
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The sealing ring for the push-on coupling can be damaged if Cop py
.
the retaining clip is in the locked position during installation.
ht rig
rig ht
py by
co Vo
This would result in leaking.
by lksw
cted agen
Prote AG.
Do not use any fluid containing oil, silicone or grease. Only use
clean water.

Amarok 2011 ➤
Releasing pressure hose.

– Release push-on coupling -3- by pulling the retaining clip -1-
in -direction of arrow a-.
– Pull charge air hose -2- out of push-on coupling -3- in
AG. Volkswagen AG d
agen
-direction of arrow b- without using any tools.
V olksw
oes
not
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Fitting pressure hose so that it latches into
or place.
ise tee
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Note
un
pt
an
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♦ When replacing the sealing ring, place the sealing ring in the
ab
pe
ility
groove of the charge air hose.
ot
wit
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♦ Make sure that the sealing ring is completely resting in the
h re
hole
groove all around the hose. Make sure that the sealing ring is
spec
not twisted.
es, in part or in w
t to the co
♦ Apply clean water to sealing surfaces and sealing ring.
rrectness of i
– Move retaining clip -2- to release position.
l purpos
– Push charge air hose -3- in -direction of arrow- into plug-in

coupling -1- as far as it will go.
nform
ercia
– Move retaining clip -2- to locking position and then give the
m
charge air hose another push.
a
com
tion in
– Check that the plug-in coupling is correctly engaged and seat‐
r
te o
thi
ed by pulling on the charge air hose.
s
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♦ If the retaining clip cannot be pushed down fully, the pressure pyri by
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hose is not inserted sufficiently in the coupling.
lksw
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Prote AG.
♦ Press pressure hose again and lock retaining clip.
• Check push-on coupling by pulling on it.
4.8.2 Pressure hose with ribbed union and

hose clamp
Removing pressure hose.
– Loosen screw of hose clamp -A-.
– Pull pressure hose together with hose clamp -A- off the ribbed
union.
Fitting pressure hose.
4. Cab 75
Amarok 2011 ➤
. Volkswagen AG
gen AG does
– Push pressure hose together with hose clamp -A- onto ribbed
Vol
ksw
a
not
union as far as it will go. ed
by gu
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– Tighten screw of hose clamp -A-. utho eo
ra
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pt
Caution
du
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The hose clamp screw -A- must be tightened as prescribed. If
ility
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the tightening torque is too low or too high, the pressure hose
wit
, is n
may slip off the ribbed union when the vehicle is being driven.
h re
hole
spec
es, in part or in w
t to the co
Notes on hose connections with screw-type clamps
⇒ page 76 .
rrectness of i
Specified torque for hose clamps:
l purpos
1- Hose clamp -a- = 13 mm wide: 5.5 Nm

2- Hose clamp -b- = 9 mm wide: 3 Nm
nf
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4.8.3 Notes on hose connections with screw- cted agen
Prote AG.
type clamps
Caution
It is essential that the screw-type clamps on the charge air lines

are tightened to 5.5 Nm. If the tightening torque is too low or
too high, the charge air hose may slip off the charge air pipe
when the vehicle is being driven.
There are conventional screw-type clamps at the hose connec‐

tions on the “intake side”.
There are screw-type clamps with “barbs” -arrows- at the hose
connections on the “discharge side”.
Caution
• Do not loosen these hose clamps and pull them back over
the hose.
• Risk of damage to hose!
• If a clamp has been removed, it must be renewed together
with the hose.

Amarok 2011 ➤
– It is permissible only to loosen the screw-type clamps with

“barbs” -arrows-. Loosen the screw of the screw-type clamps
just enough to remove the hoses.
Screw-type clamps that have only been loosened can be re-used.
Hose and clamp are supplied together as one spare part.
– When installing, does not use any fluid containing oil, silicone
or grease. Only use clean water.
AG. Volkswagen AG d
agen oes
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pt
du
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es, in part or in w
t to the co
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ion
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Cop py
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rig ht
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Prote AG.
4. Cab 77
Amarok 2011 ➤
5 Tank flap unit

⇒ “5.1 Removing and installing tank flap”, page 78
⇒ “5.2 Removing and installing tank flap unit”, page 78
⇒ “5.3 Removing and installing actuator”, page 80
5.1 Removing and installing tank flap
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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nl
pt
du
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ab
ility
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es, in part or in w
t to the co
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ion
c
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Removing
ate
do
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– Use a screwdriver -3- to unlock clip -arrow- on tank flap unit

um
for
-2-.
en
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t.
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– Pull tank flap -1- in -direction of arrow- off tank flap unit -2-. t. C rig
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Installing
co Vo
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Prote AG.
– Push tank flap -1- onto tank flap unit -2- until it clips in securely.
5.2 Removing and installing tank flap unit


AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b ara
nte Amarok 2011 ➤
autho
General
eo
ra body repairs, exterior - Edition 10.2012
ss c
ce
le
♦ Torque screwdriver -V.A.G 1624-
un
pt
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tion in
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Prote AG.
Removing
– Remove tank flap ⇒ page 78 .
– Remove bolt -2-.
– Peel rubber grommet off fuel filler neck.
– Pull tank flap unit -1- forwards -arrow A-.
– Swivel tank flap unit -1- out of side part -arrow B-.
5. Tank flap unit 79

Amarok 2011 ➤
Note
♦ Bolts -3- are used for securing tank filler neck to load bed. AG. Volkswagen AG d
agen oes
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Specified torques
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Tank flap unit bolts 1.5 Nm
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es, in part or in w
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5.3 Removing and installing actuator
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Removing
– Remove fuel tank flap unit ⇒ page 78
– Remove rear wheel housing liner ⇒ page 306

Amarok 2011 ➤
– Separate connectors -4-.

– Detach cable -2- from clips -3-.
– Swivel actuator -1- in -direction of arrow-.
Installing
AG. Volkswagen AG d
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5. Tank flap unit 81

Amarok 2011 ➤
57 – Front doors, door components, central locking

1 Door
⇒ “1.1 Assembly overview - door hinge on A-pillar”, page 82
⇒ “1.2 Assembly overview - door hinge on door”, page 84
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⇒ “1.7 Removing and installing door hinge on door”, page 90
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⇒ “1.8 Removing and installing door arrester”, page 92
h re
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spec
1.1 Assembly overview - door hinge on A-
es, in part or in w
t to the co
pillar
rrectness of i
Note
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♦ Installation overview only shows left side. The right side is

similar.
nform
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♦ Removal and installation are described for the upper door

m
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82 Rep. gr.57 - Front doors, door components, central locking

Amarok 2011 ➤
1 - Door
⇒ page 86
2 - Door hinge
❑ The hinge is split and wage
es n
s
bolted to the A-pillar. yV
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3 - Bolt ir se tee
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❑ Specified torques: 30 ss
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1. Door 83
Amarok 2011 ➤
1.2 Assembly overview - door hinge on door
Note
The assembly overview is for the right side. The left side is similar.
1 - Front door
⇒ page 86
2 - Door hinge
❑ Hinge is split and bolted
to door.
3 - Bolt
Nm
❑ Always renew after
loosening.
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1.3 Removing and installing door inner seal

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During production, a sealant is applied to the door inner seals,

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Amarok 2011 ➤
Note
♦ When removing the seal, the sealant is distributed across the

inside of the seal.
♦ The edges are bent up slightly.
♦ If the seal is then refitted, sealing and firm seating are no lon‐
ger guaranteed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.
♦ The removal and installation sequence is only for the left door
inner seal. The removal and installation of the right door inner
seal is similar.
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Removing
– Loosen sill panel strip up to B-pillar ⇒ General body repairs,
interior; Rep. gr. 68 ; Interior equipment; Sill panel strips .
1. Door 85
Amarok 2011 ➤
– Pull door inner seal -1- off body flange.

Installing
– Align door inner seal -1- with mark -2- on fixing point -arrow-.
– Start installing inner door seal -1- in upper radius of door aper‐
ture.
1.4 Removing and installing door

AG. Volkswagen AG d
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Note Volksw
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not
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Removal and installation are described for the
ut
hor
left door. The removal and installation of theteeright
or door are similar.
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oes Amarok 2011 ➤
AG. Volkswagen AG d
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yGeneral
Vol body repairs, exterior - Edition
not
gu 10.2012
edb ara
ris nte
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s au ra
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s
ce
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un
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es, in part or in w
t to the co
rrectness of i
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nform
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Removing
– Release boot -5- by pressing fastener -arrow a- and pull off A-
pillar.
– Swing locking lever -6- downwards -arrow b- and disconnect
electrical connector from coupling station.
– Unscrew bolts -2- on top and bottom hinges.
– Unscrew bolts -3- for door arrester -4-.
– Lift door -1- upwards out of hinges.
Installing
– Observe front door gaps ⇒ Body Repairs; Rep. gr. 00 ; Tech‐
nical data; Body panel gaps/shut lines; Body - front .
Note
Specified torque for bolt -3- differs according to strength rating:
1. Door 87
Amarok 2011 ➤
Specified torques
Bolt -3- on door arrester at 8.8 20 Nm
Hinge bolt 23 Nm
1.5 Adjusting striker

AG. Volkswagen AG d
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Note ss a c
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♦ Threaded plate of striker pin is secured in pillar using a method
an
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♦ Bow outside of threaded plate is welded firmly to pillar. Webs
wit
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to threaded plate are plastically deformable.

h re
ole,
♦ Increased forces must be applied so that striker pin can be spec

adjusted with bolts loosened. t to the co
♦ The door must lock fully when closing without any additional
force being required and must not have any play.
rrectne
♦ The door must not be pushed up or down due to striker pin

adjustment.
ss o
cial p
The following can be adjusted at the striker pin:

inform
mer
• When the front door does not align with the rear door or the D-
atio
m
pillar.
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Amarok 2011 ➤
– Loosen striker -1- by loosening bolts -2- in B-pillar.

– Adjust striker -1- with light taps (plastic hammer) so that front
door is flush with rear door or the B-pillar when shut (wind
noise).
– Tighten bolts -2-.
Specified torques
Striker bolts 20 Nm
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1.6 Removing andy Vinstalling door hingeoeon
wa s no d
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Note
atio
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Removal and installation are described for the left door. The removal and installation of the right door are similar.
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1. Door 89
Amarok 2011 ➤
AG. Volkswagen AG d
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Removing opyri
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– Remove upper door hinge on dash panel cover ⇒ General
by lksw
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Prote
body repairs, interior; Rep. gr. 70 ; Dash panel cover .
AG.
– Remove door hinge on A-pillar trim at bottom ⇒ General body

repairs, interior; Rep. gr. 70 ; Trims, insulation; Pillars and side
trims .
– Remove front door ⇒ page 86 .
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - door hinge on A-pillar”, page 82 .
1.7 Removing and installing door hinge on

door

AG. Volkswagen AG d
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ra
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ss General body repairs, exterior - Edition 10.2012 c
ce
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nl
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ility
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es, in part or in w
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nform
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at
om
Note
ion
c
in t
or
his
e
Removal and installation are described for the upper door hinge. The lower door hinge is similar.
at
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Removing
– Remove front door ⇒ page 86 .
1. Door 91
Amarok 2011 ➤
– Pull door hinge -2- off front door.

Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - door hinge on A-pillar”, page 82 .
1.8 Removing and installing door arrester

AG. Volkswagen AG d
♦ Torque wrench -V.A.G 1331- lksw
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es, in part or in w
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Note
l purpos
The removal and installation sequence is only for the right door
arrester. Removal and installation of the left door arrester is sim‐
nform
ercia
ilar.
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Amarok 2011 ➤
AG. Volkswagen AG d
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Prote
Removing
AG.
– Removing front door trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Door trim .
– Remove inside door film of front door ⇒ page 348 .
– Unscrew bolt -4- in A-pillar.
– Remove bolts -3- and remove door arrester -1- through open‐
ing in door.
Installing
Specified torques
Bolts -3- 9.0 Nm
Bolt -4- 33 Nm
1. Door 93
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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Amarok 2011 ➤
2 Door components
⇒ “2.1 Assembly overview - door components”, page 95
⇒ “2.2 Assembly overview - window regulator”, page 97
⇒ “2.3 Assembly overview - door lock”, page 98
⇒ “2.4 Assembly overview - door lock cover”, page 99
⇒ “2.5 Assembly overview - cap”, page 100
⇒ “2.6 Assembly overview - window regulator motor”, page 101
⇒ “2.7 Removing and installing window regulator motor”,
page 101
⇒ “2.8 Removing and installing window regulator”, page 103
⇒ “2.9 Removing and installing door handle”, page 105
⇒ “2.10 Removing and installing door lock”, page 105
⇒ “2.11 Removing and installing window channel”, page 108
⇒ “2.12 Removing and installing lock cylinder”, page 109
⇒ “2.13 Removing and installing housing (without lock cylinder)”,
page 111
⇒ “2.14 Removing and installing inner door handle”, page 113
⇒ “2.15 Removing and installing door handle bracket”,
page 115
⇒ “2.17 Removing and installing window slot outer seal”,
page 117
AG . Volkswagen AG
⇒ “2.18 Removing and installing window slot inner seal”,ksw
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page 119 by
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⇒ “2.19 Removing and installing top door seal”,
ut
ho page 121
r eo
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sa c
⇒ “2.20 Removing and installing bottom door
s seal”, page 122 ce
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nl
pt
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⇒ “2.21 Assembly overview - impact rail of front door”,

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page 123
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⇒ “2.22 Removing and installing loudspeaker in front door”, page

wit
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123
h re
hole
spec
2.1 Assembly overview - door components

es, in part or in w
t to the co
Note
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1 - Locking rod
nform
ercia
❑ Right and left

m
at
❑ Clipped into door lock

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2 - Door lock
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❑ Emergency locking
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Prote AG.
2. Door components 95
Amarok 2011 ➤
4 - Bolt
❑ Right and left
❑ Qty. 2
5 - Cable
❑ Right and left
❑ From inner door handle -6- to door lock -2-
6 - Door lock cover
❑ Right and left
❑ Assembly sequence ⇒ page 99
7 - Interior door handle
❑ Right and left
❑ Removing and installing ⇒ page .113
Volkswage n AG n AG d
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8 - Cover Vol
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❑ Right and left orise nte
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❑ For the bolts a-8- ra
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9 - Bolt
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❑ Right and left
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❑ For lock cylinder.
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❑ Specified torque: 2.5 Nm. wit

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hole
10 - Cover spec
es, in part or in w
❑ Removing and installing with lock cylinder ⇒ page 109 .

t to the co
11 - Lock cylinder
❑ Removing and installing ⇒ page 109
rrectness of i
❑ A lock cylinder can only be found in the driver door.

l purpos
12 - Base
❑ Clipped into door
nf
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or
13 - Cable
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❑ From door lock to door handle bracket.

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14 - Door handle bracket

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15 - Bolt
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❑ Specified torque: 1.5 Nm.
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❑ Bearing plate is loosened from door when this bolt is loosened
agen
Prote AG.
16 - Right door handle

❑ Right and left
17 - Cover
❑ Right door
18 - Housing
❑ Right door

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th or
au General body repairs, exterior - aEdition
c 10.2012
ss
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2.2 Assembly overview - window regulator
an
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1 - Front door
wit
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2 - Window regulator
ole,
spec
t to the co
⇒ page 103
3 - Bolt
rrectne
❑ Qty. 2
ss o
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Prote AG.
Amarok 2011 ➤
2.3 Assembly overview - door lock
1 - Door lock
❑ Removing ⇒ page 105
2 - Bowden cable
❑ To inner door handle
⇒ page 113
3 - Bowden cable
❑ To door handle bracket
⇒ page 115
4 - Locking rod
❑ For mechanical door
lock
❑ The end of the rod must
always point away from
the B-pillar.
AG. Volkswagen AG d
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Amarok 2011 ➤
2.4 Assembly overview - door lock cover
AG. Volkswagen AG d
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Assembly sequence:
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– Lug -arrow- of cover cap -2- must be pressed down and en‐
Prote AG.
gage audibly in door lock -1-.
Amarok 2011 ➤
gen AG
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2.5 Assembly overview - cap
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Prote AG.

Amarok 2011 ➤
2.6 Assembly overview - window regulator motor
1 - Window regulator motor

⇒ page 101
2 - Bolt
❑ Qty. 3
3 - Manual drive unit
4 - Bolt
❑ Qty. 3
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2.7 Removing and installing window regula‐

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Prote AG.

Amarok 2011 ➤
Removing
Note
♦ Removal is described only for the right window regulator motor. Removal of left window regulator motor is
similar.
♦ Removal of manual window regulator -3- is similar.
AG. Volkswagen AG d
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Rep. gr. 70 ; Door trims .
rrectness of i
– Pull off inside door film.

l purpos
– Secure door window against sliding down with adhesive tape.

nf
ercia
– Disconnect electrical connector.

orm
m
atio
– Remove 3 bolts -2- (or bolts -4-).

om
n in
c
– Remove window regulator motor with control unit -1- (or win‐
or
thi
e
dow regulator -3-) from retainers.

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102
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Rep. gr.57 - Front doors, door components, central locking
agen
Prote AG.
Amarok 2011 ➤
Installing
Note
♦ Installation is described only for the right window regulator

motor. Installation of left window regulator motor is similar.
♦ Installation of manual window regulator -3- is similar.
WARNING
If a new window regulator motor is installed (door control unit),

the additional functions and the excess force limitation feature
have to be coded!
– Insert window regulator motor -1- into retainers. Move door

window slightly up and down so that the splines between motor
and cable drum engage easier.
– Secure electrical connector.
– A new window regulator motor is coded using vehicle diagno‐
sis, testing and information system -VAS 5051 A- .
– After coding, allow window regulators to move up to stop once
automatically. Then pull switch again for 2 seconds. This pro‐
grams the upper stop for the window regulator motor.
gen AG
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d wa oes
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– Then perform remaining installation dinbyreverse
V order of remov‐ gu
ara
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th
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Specified torques ss c
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nl
♦ ⇒ “2.6 Assembly overview - window regulator motor”, pt

du
page 101 . an
itte
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spec

es, in part or in w
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Removing Cop py
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Note
agen
Prote AG.
Removal and installation are described only for the right window regulator. The removal and installation of the
left window regulator is similar.

Amarok 2011 ➤
AG. Volkswagen AG d
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d b ara
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– Remove front door window ⇒ page 275 .

iv
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– Removing window regulator motor ⇒ page 101

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– Remove the 2 bolts -3-.
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– Unlock retaining hooks on cable drum. cop Vo
by lksw
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Prote AG.
– Swing window regulator -2- into door.
– Guide window regulator -2- to cut-out in door -1- and remove
it.
Installing
– Guide window regulator -2- through cut-out into door -1-.
– Guide window regulator to its installation locations.
– Insert thread of window regulator through door and tighten
bolts -3-.
– Push cable drum -1- through holes in door, retaining hooks
must audibly engage.

Amarok 2011 ➤
Volkswagen AG
– Then perform remaining installation in reverse orderageof
nAremov‐
G. does
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Vol not
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Specified torques oris eo
th
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c
♦ ⇒ “2.2 Assembly overview - window
ss regulator”, page 97 .
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nl
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du
2.9 Removing and installing door handle
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Note
, is n
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spec
Removal and installation are described only for the right door
es, in part or in w
handle. The removal and installation of the left door handle are
t to the co
similar.
rrectness of i
Removing
l purpos
– Remove lock cylinder ⇒ page 109 or remove housing

⇒ page 111 .
nf
ercia
– Pull door handle -1- backwards slightly out of retainer for bear‐
or
ing bracket.
m
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– Swing door handle around and remove from door -2- at right
o
n in
or c
angles.
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Installing
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– Insert door handle -1- into bearing bracket at right angles.
en
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– Swing door handle -1- into door -2-. t. C rig
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– Push door handle -1- forward with force into retainer in bearing
o Vo
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bracket.
agen
Prote AG.
Installing lock cylinder ⇒ page 109 or installing housing

⇒ page 111 .
• It is essential that the function then be checked with the door
open.
2.10 Removing and installing door lock

Removing
Note
Removal and installation are described only for the left door lock. The removal and installation of the right door
lock are similar.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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ara
ed
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aut ra
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le
un
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d
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es, in part or in w
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tion in
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– Removing front door trim ⇒ General body repairs, interior; by c lksw
cted agen
Rep. gr. 70 ; Door trim . Prote AG.

⇒ page 111 .
– Separate electrical connector (if present).
Note
Cover cap -3- for emergency locking need not be removed.

– Remove door lock -2- from door -1-.
Note
Release Bowden cables in door if required for subsequent work.
– Unclip Bowden cable -5- for door handle bracket

⇒ page 115 .

Amarok 2011 ➤
– Unclip Bowden cable for inner door handle ⇒ page 113 .

Installing
AG. Volkswagen AG d
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t to the co
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cial p
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Note
The fitting sequence specified for the bolts -4- must be adhered to.
The sequence in which the bolts -4- are tightened can be seen in
the illustration.
• Afterwards, the function must be checked, as an incorrectly
adjusted or incorrectly engaged cable cannot open the door
lock -2-.
Specified torques
Door lock bolts 20 Nm

Amarok 2011 ➤
2.11 Removing and installing window chan‐

nel
Removing
Note
Removal and installation are described only for the right window channel. The removal and installation of the
left window channel is similar.
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
du
an
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erm
ab
ility
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wit
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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ate
do
priv
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for
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t.
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by c lksw
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Prote AG.
– Remove exterior mirror ⇒ page 300 .

– Remove window slot outer seal ⇒ page 119 .
– Peel sealing lip of window channel off the door flange from the
outside.
– Pull window channel -1- off door flange uniformly all round.
– Pull window channel -1- out of supports.
Installing

Amarok 2011 ➤
– Push window channel -1- into mountings.

– First, roll outer sealing lip of window channel onto door flange.
– Fit window channel -1- onto door flange evenly all round.
Note
♦ Positioning marks -arrows- must rest on the frame section.

♦ To prevent wind noise, ensure window channel seats evenly
when installing.
• Carry out functional test function before installing door trim.
2.12 Removing and installing lock cylinder

Removing
lkswage es n
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Note d byV ua
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Removal and installation
au are described only for the right lock cylinder.ac Removal and installation of the left lock
ss
cylinder are similar.
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nl
pt
du
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erm
ab
ility
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es, in part or in w
t to the co
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at
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ion
c
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Prote AG.

Amarok 2011 ➤
lkswage es n
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d ran
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tho
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nl
pt
du
an
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ab
ility
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hole
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es, in part or in w
t to the co
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nform
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io
– Unclip cover cap -3- from lock cylinder -2-.

n
c
in t
or
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– Prise plug -4- out of opening.

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for
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– Screw out bolt -6- to stop.
Co
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– Push bolt -6- in again. Only then is the lock cylinder -2- re‐ yri
p by
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leased.
c by lksw
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– Pull door handle -1- off door in -direction of arrow-.
– Pull lock cylinder housing -2- out of door handle bracket at right
angles.
Installing
– Insert lock cylinder housing -2- into door handle bracket -3- at
a right-angle.
– Screw bolts -5- and -6- into door handle bracket.

Amarok 2011 ➤
Note
lkswage es n
Vo ot g
During installation, elock
d by cylinder housing -2- must be pressed ua
ran
against outer door
thor panel.
is tee
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nl
pt
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du
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Specified torques
erm
ab
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Lock cylinder housing bolts 2.5 Nm
spec
es, in part or in w
2.13 Removing and installing housing (with‐
t to the co
out lock cylinder)
rrectness of i
For vehicles with central locking
l purpos

♦ Assembly tool -T10389-
nform
mercia
at
om
ion
c
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Removing

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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aut ra
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ce
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un
pt
an
d
itte
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ab
pe
ility
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wit
, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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t.
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– Prise plug -4- out of opening. C py
t. rig
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yri
– Unclip cover cap -3- from housing -2-.
p by
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by c lksw
cted agen
– Insert assembly tool -T10389- -5- approx. 55 mm into door
Prote AG.
behind sliding link -6- of door handle bracket.

– Pull assembly tool -T10389- -5- backwards until hook of sliding
link -6- disengages.
– Pull housing -2- out of door handle bracket.
Installing

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
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erm
ab
ility
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is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
i
or
– Push housing -2- into door handle bracket.

thi
te
sd
iva
– Guide screwdriver -5- against sliding link of door handle brack‐

pr
cum
r
fo
et.
en
ng
t.
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op
– Press housing -2- against door. C py
t. rig
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yri by
– Press screwdriver -5- far enough in until hook of sliding link op Vo
by c lksw
engages. cted agen
Prote AG.
– Secure plug -4- and clip cover cap -3- onto housing -2-.
2.14 Removing and installing inner door han‐

dle
Note
Removal and installation are described only for the right inner
door handle. The removal and installation of the left side are sim‐
ilar.

AG. Volkswagen AG d
agen oes
Amarok 2011 ➤ Vol
ksw not
gu
by
ris
e exterior - Edition 10.2012
d ara
nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
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for
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
Removing
– Pull locking lever out of hole in inside door panel.
– Push inner door handle -1- out of clip in door -3-.
– Unclip Bowden cable out of door lock ⇒ page 98 .
– Remove inner door handle -1- from door -3-.
Driver side only
– Detach connector from button for inner door lock ⇒ Electrical
system; Rep. gr. 96 ; Removing and installing button for inner
door lock
– Unclip Bowden cable -2- from inner door handle -1-.
Installing

Amarok 2011 ➤
G. Volkswage
2.15 Removing and olks
installing
wage
nA
doorn Ahandle
G do
es n
ot g
bracket rised y V ua
b ran
t ee
tho or
sa
u equipment required ac
s
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♦ Torque wrench -V.A.G 1783- nl
pt
du
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itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Note
m
at
om
ion
c
in t
or
his
e
handle bracket. The removal and installation of the left door han‐
at
do
riv
dle bracket is similar.

p
cum
for
en
ng
t.
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Removing
Co
Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.

Amarok 2011 ➤
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

⇒ page 111 .
nform
ercia
– Remove door handle ⇒ page 105 .

m
at
om
io

n
c
in t
or
his
e
– Remove door handle bracket -1- from door.

at
do
priv
– Unclip Bowden cable -3- from door lock.

um
for
en
ng
t.
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Installing
Co
Cop py
t. rig
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ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Specified torques
Bearing bracket bolt 2.0 Nm

Amarok 2011 ➤
Note
Removal and installation are described only for the left striker.
The removal and installation of the right striker is similar.
Removing
– Unscrew bolt -2- and remove striker -1-.
Installing
– Place striker -1- on B-pillar and tighten bolts -2-.
– Adjusting striker pin ⇒ page 88 .
Specified torques
Striker 20 Nm
2.17 Removing and installing window slot

outer seal
Note agen
AG. Volkswagen AG d
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The removal is and installation sequence is only for the ntewindow slot
ed
or
outer aseal
ut
h on the right. Removal and installation of the eo
rwindow
ac
slot outer
ss seal on the left are analogous.
ce
le
un
pt
an
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Removing
itte
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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or
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pr
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t.
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117
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Prote AG.
2. Door components
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Amarok 2011 ➤rised ran
tee
o
General body au repairs, exterior - Edition 10.2012
th or
ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
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n in
or c
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.
– Remove exterior mirror ⇒ page 300 .
Note
Do not bend window slot seal -1- when removing.
– Pull window slot outer seal -1- evenly upwards -arrows- off
flange.
Installing
Note
♦ Do not bend window slot seal -1- when installing.

♦ It is permissible to apply grease and silicone-free substances to facilitate installation.
♦ Adhere to specified installation sequence -1- to -2-.
– Position window slot outer seal -1- at an angle -arrow a- and

evenly press onto flange firmly by hand.

Amarok 2011 ➤
After installation, the window slot outer seal -1- must be seated
flush -arrow b-.
2.18 Removing and installing window slot in‐

ner seal
Removing
Note
Removal and installation are described only for the window slot inner seal on the right. Removal and installation
of the window slot inner seal on the left are analogous.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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un
pt
an
d
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ab
pe
ility
ot
wit
, is n
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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
– Remove front door trim ⇒ General body repairs, interior; Rep. yri
gh by
ht
gr. 70 ; Trims, insulation; Door trims . cop Vo
by lksw
cted agen
Prote
– Pull window slot outer seal -1- evenly upwards off flange.
AG.
Take care not to bend window slot inner seal.

Amarok 2011 ➤
Installing
Only models with dust package . Volkswagen AG
gen AG does
swa
Bond front foam strip -1- and rearyfoam Volk strip -2-. not
gu
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Remove protective film before horis
installation. eo
aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
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l purpos
nform
mercia
at
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ion
c
in t
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do
priv
cum
for
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t.
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rig ht
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Prote AG.

serve the following
– First, position window slot inner seal -1- on right window frame
and then evenly press onto the flange firmly by hand
After installation, the window slot inner seal -1- must be seated
flush.

Amarok 2011 ➤
2.19 Removing and installing top door seal
Note
Removal and installation are described only for the top right seal.
Removal and installation of the top left seal is analogous.
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
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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
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en
ng
t.
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by
Removing Prote
cted AG.
agen
– Pull top door seal -1- off door complete with the clips -2-.
Note
When pulling off top seal -1-, bear in mind the adhesive strip -3-.

Amarok 2011 ➤
Installing
Note
♦ Check clips -2- for damage and renew if necessary.

♦ The bonding area for adhesive strips -3- must be dry and clean.
. Volkswagen AG
gen AG does
– Pull protective paper off adhesive strips -3- and press top doorVolkswa not
seal -1- together with clips -2- onto the door. ed
by gu
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2.20 Removing and installing bottom door ss
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Removal and installation are described only for the bottom right
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e
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Removing aut or
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– Pull bottom door seal -1- off door -3- complete with the clips
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Check clips -2- for damage and renew if necessary.
– Push bottom seal -1- with clips -2- onto door.
rrectness of i
2.21 Assembly overview - impact rail of front
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Impact rail Prote
cted 30 Nm AG.
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2.22 Removing and installing loudspeaker in

front door
♦ Special pop rivet pliers -V.A.G 1753A-
Note
Removal and installation are described only for the right side. Removal and installation on the left side are
analogous.

Amarok 2011 ➤
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Rep. gr. 70 ; Door trim . rrectness of i
Removing
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– Drill out pop rivet -2- using suitably sized drill bit.
– Remove loudspeaker -1- from front door and detach electrical
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Installing
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– Attach electrical connector to door loudspeaker -1-.

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Amarok 2011 ➤
58 – Rear doors, door components
AG. Volkswagen AG d
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1. Door 125
Amarok 2011 ➤
1 Door
⇒ “1.1 Assembly overview - door hinges on B-pillar”, page 126
⇒ “1.2 Assembly overview - door hinge on door”, page 127
⇒ “1.3 Removing and installing door”, page 128
⇒ “1.4 Adjusting striker”, page 129
⇒ “1.5 Removing and installing door hinge on B-pillar”,
page 130
⇒ “1.6 Removing and installing door hinge on door”, page 131
⇒ “1.7 Removing and installing door arrester”, page 132
⇒ “1.8 Removing and installing door inner seal”, page 133
⇒ “1.9 Removing and installing door outer seal”, page 134
1.1 Assembly overview - door hinges on B-pillar
Note
The right side is shown. The left side is analogous.
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126 Rep. gr.58 - Rear doors, door components

Amarok 2011 ➤
1.2 Assembly overview - door hinge on door
Note
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⇒ page 128
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3 - Bolt
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4 - Door lower hinge
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1. Door 127
Amarok 2011 ➤
1.3 Removing and installing door
Note
The removal and installation sequence is for the left door. The removal and installation of the right door is
similar.
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Prote AG.
Removing
– Release bellows -5- by pressing catch -arrow a- and pull off B-
pillar.
– Swing locking lever -6- downwards -arrow b- and disconnect
electrical connector from coupling station.
– Unscrew bolts -2- on top and bottom hinges.
– Unscrew bolts -4- for door arrester -3-.
– Lift door -1- upwards out of hinges.
Installing

Amarok 2011 ➤
– Observe front door gaps ⇒ Body Repairs; Rep. gr. 00 ; Tech‐

nical data; Body panel gaps/shut lines; Body - front .
Note
swage es n
Specified torque for bolt -4- differs according to strengthbyrating:
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Specified torques aut or
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Hinge bolt 23 Nm
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1.4 Adjusting striker
es, in part or in w
t to the co
Note
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♦ Threaded plate of striker pin is secured in pillar using a method
l purpos
which differs from the previous method.

♦ Bow outside of threaded plate is welded firmly to pillar. Webs
nform
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to threaded plate are plastically deformable.

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♦ Increased forces must be applied so that striker pin can be
ion in
adjusted with bolts loosened.
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♦ The door must lock fully when closing without any additional
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force being required and must not have any play.
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♦ The door must not be pushed up or down due to striker pin
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The following can be adjusted at the striker pin: cted agen
Prote AG.
• When the front door does not align with the rear door or the D-
pillar.
– Loosen striker -1- by loosening bolts -2- in C-pillar.
– Adjust the striker -1- with light taps (plastic hammer) so that
the rear door is flush with the C-pillar when shut (wind noise).
– Tighten bolts -2- of striker -1-.
Specified torques
Striker 20 Nm
1. Door 129
Amarok 2011 ➤
1.5 Removing and installing door hinge on B-pillar
Note
The removal and installation procedure is for the right side. The removal and installation of the left side is similar.
lkswage es n
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Prote AG.
Removing
– Remove B-pillar top trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Pillar and side panel trim .
– Remove B-pillar bottom trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Pillar and side panel trim .
– Remove rear door ⇒ page 128 .
Installing

AG. Volkswagen AG d
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ara Amarok 2011 ➤
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horis General body repairs, eexterior - Edition 10.2012
aut or
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Specified torques
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♦ ⇒ “1.1 Assembly overview - door hinges on B-pillar”,
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1.6 Removing and installing door hinge on door , is n
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Removing
– Remove bolts -3- or -5-.
– Remove upper door hinge -2- or lower door hinge -4- from rear
door -1-.
Installing
Specified torques
♦ ⇒ “1.2 Assembly overview - door hinge on door”, page 127 .
1. Door 131
Amarok 2011 ➤
1.7 Removing and installing door arrester

lkswage es n
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The removal and installation sequence is only for thessright
au door ac
arrester. Removal and installation of the left door arrester is sim‐
ce
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ilar.
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Removing
– Remove rear door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Door trim .
– Remove inner film of rear door ⇒ page 349 .
– Unscrew bolt -4- on B-pillar.
– Remove bolts -3- and remove door arrester -1- through open‐
ing in door.
Installing

Amarok 2011 ➤
Specified torques
Door arrester bolt -4- 20 Nm
Door arrester bolt -4- from 05.2012 33 Nm
Door arrester bolts -3- 9.0 Nm
1.8 Removing and installing door inner seal

During production, a sealant is applied to the door inner seals,
which are then placed on the door flange and rolled
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Note utho eo
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♦ When removing the seal, the sealant is distributed across the
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inside of the seal.
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♦ The edges are bent up slightly.
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♦ If the seal is then refitted, sealing and firm seating are no lon‐
, is n
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ger guaranteed.
hole
spec
♦ Therefore each seal which is removed completely should be
es, in part or in w
t to the co
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.
rrectness of i
♦ The removal and installation sequence is only for the right door
l purpos
inner seal. The removal and installation of the left door inner
seal is similar.
nf
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1. Door 133
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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Removing
ion
c
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or
– Remove necessary pillar trims ⇒ General body repairs, inte‐

his
ate
rior; Rep. gr. 70 ; Pillar trim .

do
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– Remove sill panel strip ⇒ General body repairs, interior; Rep.

f
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gr. 68 ; Interior equipment; Sill panel strips .
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Installing Prote
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– Align door inner seal -1- with mark -2- on fixing point -arrow-.
– Start installing inner door seal in upper radius of door aperture.
1.9 Removing and installing door outer seal
Note
♦ Removal and installation are described only for the right door
outer seal. Removal and installation of the left door outer seal
are similar.
♦ Check clips -2- for damage and renew if necessary.

Amarok 2011 ➤
AG. Volkswagen AG d
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Prote AG.
Removing
– Pull door outer seal -1- off door -3- complete with the clips
-2-.
Installing
– Push seal -1- with clips -2- onto door.
1. Door 135
Amarok 2011 ➤
lkswage es n
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AG. Volkswagen AG d
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olksw not
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ara
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- Edition 10.2012
ris
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2 Door components ss c
ce
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un
pt
⇒ “2.1 Assembly overview - door components”, page 137
an
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⇒ “2.2 Assembly overview - window regulator”, page 138
pe
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⇒ “2.3 Assembly overview - door lock”, page 139
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⇒ “2.4 Assembly overview - door lock cover”, page 140 hole
spec
es, in part or in w
⇒ “2.5 Assembly overview - cap”, page 141
t to the co
⇒ “2.6 Assembly overview - window regulator motor”, page 142
rrectness of i
⇒ “2.7 Removing and installing window regulator motor”,
page 142
l purpos
⇒ “2.8 Removing and installing window regulator”, page 144
nform
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⇒ “2.9 Removing and installing door handle”, page 146

m
⇒ “2.10 Removing and installing door lock”, page 146
a
com
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⇒ “2.11 Removing and installing housing (without lock cylinder)”,
r
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page 148
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⇒ “2.12 Removing and installing inner door handle”, page 150
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⇒ “2.13 Removing and installing door handle bracket”,
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⇒ “2.15 Removing and installing window channel”, page 153
⇒ “2.16 Removing and installing window slot inner seal”,
page 155
2.1 Assembly overview - door components

1 - Locking rod
❑ Clipped into door lock
-2-
2 - Door lock
⇒ page 146
❑ Door lock cover
⇒ page 140
3 - Cover
❑ Emergency locking
4 - Bolt
❑ Specified torque: 20
Nm.
❑ Qty. 2
5 - Cable
❑ From inner door handle
-6- to door lock -2-
6 - Interior door handle
⇒ page 150
7 - Cable
❑ From door lock to door
handle bracket.

Amarok 2011 ➤
8 - Door handle bracket

9 - Door handle
10 - Cover
❑ Removing and installing without lock cylinder ⇒ page 148 .
11 - Housing
❑ Without cylinder lock.
12 - Base
❑ Clipped into door
2.2 Assembly overview - window regulator

AG. Volkswagen AG d
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2 - Window regulator rise nte
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❑ Removing and sinstalling
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⇒ page 144
ce
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3 - Bolt
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❑ Qty. 2 ab
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❑ Specified torque: 9 Nm wit

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AG. Volkswagen AG d Amarok 2011 ➤
agen o s
Volksw General ebody
not repairs, exterior
gu
- Edition 10.2012
by ara
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2.3 Assembly overview - door lock tho eo
au ra
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nl
pt
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1 - Door lock
an
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⇒ page 146
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2 - Bowden cable
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spec
❑ To inner door handle
es, in part or in w
⇒ page 139
t to the co
3 - Bowden cable
❑ To door handle bracket
rrectness of i
⇒ page 152
l purpos
4 - Locking rod
❑ For mechanical door
nform
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lock
m
❑ The end of the rod must
at
om
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always point away from
on
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Prote AG.

Amarok 2011 ➤
2.4 Assembly overview - door lock cover
AG. Volkswagen AG d
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Assembly sequence:
– Fit cover cap -2- onto door lock -1-.
– Slide cover cap -2- downwards and at the same time guide
door lock -1- into U-profile.
– Lug -arrow- of cover cap -2- must be pressed down and en‐
gage audibly in door lock -1-.

AG. Volkswagen AG d
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olksw Amaroknot 2011 ➤
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General
rised
body repairs, exterior - Edition 10.2012
nte
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2.5 Assembly overview - cap ss c
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1 - Cap
ab
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❑ For vehicles without
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door seal
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spec
2 - Grommet
❑ For vehicles with door
t to the co
seal
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Prote AG.

Amarok 2011 ➤
2.6 Assembly overview - window regulator motor
1 - Window regulator motor

⇒ page 142
2 - Bolt
❑ Qty. 3
❑ Manual drive unit
❑ Removing
❑ Installing
4 - Bolt
❑ Qty. 3
❑ Specified torque: 3 Nm n AG. Volkswagen AG do
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Removing
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Note
c by lksw
cted agen
Prote AG.
♦ Removal is described only for the right window regulator motor. Removal of left window regulator motor is
similar.
♦ Removal of manual window regulator -3- is similar.

Amarok 2011 ➤
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– Removing rear door trim ⇒ General body repairs, interior;

nf
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rm
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– Secure door window against sliding down with adhesive tape.

te
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– Disconnect electrical connector.

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– Remove 3 bolts -2- (or bolts -4-).

t.
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. rig
– Remove window regulator motor with control unit -1- (or win‐
t
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dow regulator -3-) from retainers. cop Vo
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Prote
Installing
AG.
Note
♦ Installation is described only for the right window regulator

motor. Installation of left window regulator motor is similar.
♦ Installation of manual window regulator -3- is similar.

Amarok 2011 ➤
WARNING
If a new window regulator motor is installed (door control unit),

the additional functions and the excess force limitation feature
have to be coded!
– Insert window regulator motor -1- into retainers. Move door

window slightly up and down so that the splines between motor
and cable drum engage easier.
– Secure electrical connector.
– A new window regulator motor is coded using vehicle diagno‐
sis, testing and information system -VAS 5051 A- .
– After coding, allow window regulators to move up to stop once
automatically. Then pull switch again for 2 seconds. This pro‐
grams the upper stop for the window regulator motor.
– Then perform remaining installation in reverse order of remov‐
al.
Specified torques
♦ ⇒ “2.6 Assembly overview - window regulator motor”,
page 142 .

tor
Removing
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144
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Rep. gr.58 - Rear doors, door components Prote AG.
Amarok 2011 ➤
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Cop py
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Prote AG.
Note
Removal and installation are described only for the right window regulator. The removal and installation of the
left window regulator is similar.

– Remove rear window ⇒ page 277 .
– Removing window regulator motor ⇒ page 142
– Remove the 2 bolts -3-.
– Unlock retaining hooks on cable drum.
– Swing window regulator -2- into door.
– Guide window regulator -2- to cut-out in door -1- and remove
it.
Installing
– Guide window regulator -2- through cut-out into door -1-.
– Guide window regulator to its installation locations.

Amarok 2011 ➤
– Insert thread of window regulator through door and tighten

bolts -3-.
– Push cable drum -1- through holes in door, retaining hooks
must audibly engage.
al.
Specified torques
♦ ⇒ “2.2 Assembly overview - window regulator”, page 138
Note
handle. The removal and installation of the left door handle are
similar. . Volkswag AG en AG
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– Remove housing ⇒ tho 148 .
page eo
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– Pull door handle -1- backwards slightly out of retainer for bear‐
ce
le
un
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ing bracket.
an
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– Swing door handle around and remove from door -2- at right
erm
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angles.
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Installing
h re
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spec
– Insert door handle -1- into bearing bracket at right angles.
t to the co
– Swing door handle -1- into door -2-.

– Push door handle -1- forward with force into retainer in bearing
bracket.
rrectne
Install housing ⇒ page 148 .

ss o

cial p
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open.
nform
mer
atio
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2.10 Removing and installing door lock

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Removing
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The removal and installation sequence is only for the right door lock. The removal and installation of the left
pyri by
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door lock is similar.
lksw
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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
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– Remove housing ⇒ page 148 .

iv
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– Separate electrical connector (if present).

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Note
p by
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Prote AG.
Cover cap -3- for emergency locking need not be removed.

– Remove door lock -2- from door -1-.
Note
Release Bowden cables in door if required for subsequent work.
– Unclip Bowden cable -5- for bearing bracket ⇒ page 152 .

– Unclip Bowden cable for inner door handle ⇒ page 139 .

Amarok 2011 ➤
Installing
• Afterwards, the function must be checked, as an incorrectly
adjusted or incorrectly engaged cable cannot open the door
lock -2-.
Specified torques
Door lock 20 Nm
2.11 Removing and installing housing (with‐

wage
out lock cylinder)
by
Volks es n
ot g
ua
d ran
se
tho
ri equipment required tee
or
au ac
♦ Assembly tool -T10389-
ss
ce
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Removing
nform
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pyri by
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by
cted agen
Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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– Lever plug -4- out of opening.

erm
ab
ility
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– Unclip cover cap -3- from housing -2-.

wit
, is n
h re
– Guide assembly tool -T10389- -5- behind sliding link -6- of

hole
door handle bracket.

spec
es, in part or in w
t to the co
– Pull assembly tool -T10389- -5- backwards until hook of sliding

link -6- disengages.
rrectness of i
– Pull housing -2- out of door handle bracket.

l purpos
Installing
nf
ercia
orm
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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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nl
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ility
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es, in part or in w
t to the co

– Push housing -3- into door handle bracket.
rrectness of i
– Guide screwdriver -4- against sliding link of door handle brack‐

et.
l purpos
– Press housing -3- against door.

nf
ercia
– Press screwdriver -4- far enough in until hook of sliding link

rm
m
engages.
atio
om
n in
c
– Secure plug -5- and clip cover cap -2- onto housing -3-.
or
thi
te
sd
a
2.12 Removing and installing inner door han‐

iv
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Cop py
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Note cop Vo
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Prote AG.
Removal and installation are described only for the right inner
door handle. The removal and installation of the left side are sim‐
ilar.

Amarok 2011 ➤
AG. VGeneral body
olkswagen AG
doerepairs, exterior - Edition 10.2012
agen
olksw s no
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y V
b ara
ed nte
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nl
pt
du
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ility
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es, in part or in w
t to the co
rrectness of i
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nf
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cted agen
Prote AG.
Removing
– Pull locking lever out of hole in inside door panel.
– Push inner door handle -1- out of clip in door -3-.
– Unclip Bowden cable out of door lock ⇒ page 139 .
– Remove inner door handle -1- from door -3-.
– Unclip Bowden cable -2- from inner door handle -1-.
Installing

Amarok 2011 ➤

bracket
Note
handle bracket. The removal and installation of the left door han‐
dle bracket is similar.
AG. Volkswagen AG d
agen oes
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tion in
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rig ht
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Prote AG.
Removing
– Remove housing ⇒ page 148 .
– Remove door handle ⇒ page 146 .
– Remove door handle bracket -1- from door.
– Unclip Bowden cable -2- from door lock.

Amarok 2011 ➤
Installing
Specified torques
Bearing bracket 2.0 Nm
Note
striker. The removal and installation of the left striker is similar.
Removing lkswage es n
o ot g
byV ua
ed ran
– Remove bolts -2- and remove striker
oris -1-. tee
th or
u
Installing ss
a ac
ce
e
nl
– Place striker -1- on C-pillar and tighten bolts -2-.
pt
du
an
itte
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– Adjusting striker pin ⇒ page 129 .
erm
ab
ility
ot p
Specified torques
wit
, is n
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hole
spec
es, in part or in w
Striker 20 Nm
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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2.15 Removing and installing window chan‐

te
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nel
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Removing
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Note Prote
cted AG.
agen
Removal and installation are described only for the right window channel. The removal and installation of the
left window channel is similar.

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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Remove window slot outer seal ⇒ page 119 .

– Peel sealing lip of window channel off the door flange from the
outside.
– Pull window channel -1- off door flange uniformly all round.
– Pull window channel -1- out of supports.
Note
Do not bend window slot seal when removing.
Installing
– Push window channel -1- into mountings.
– First, roll outer sealing lip of window channel onto door flange.
– Fit window channel -1- onto door flange evenly all round.

Amarok 2011 ➤
Note
♦ Do not bend window slot seal when installing.

♦ Positioning marks -arrows a- must rest on the frame section.
♦ Window channel strip must be seated flush -arrow b-.
♦ To prevent wind noise, ensure window channel seats evenly
when installing.
• Carry out functional test function before installing door trim.
2.16 Removing and installing window slot in‐

ner seal
Removing
Note
Removal and installation are described only for the window slot inner seal on the right. Removal and installation
of the window slot inner seal on the left are analogous.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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nl
pt
du
an
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ility
ot p
wit
, is n
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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
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ate
do
priv
cum
for
en
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t.
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rig ht
py by
co Vo
155
by lksw
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Prote AG.
2. Door components
Amarok 2011 ➤

Rep. gr. 70 ; Trims, insulation; Door trims .
– Pull window slot outer seal -1- evenly upwards off flange.
Take care not to bend window slot inner seal.
Installing
Only models with dust package
Glue on front foam strip -1-.
Remove protective film before installation.
– First, position window slot inner seal -1- on window bar and
then evenly press onto the flange firmly by hand
After installation, the window slot inner seal -1- must be seated
flush.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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Prote AG.

Amarok 2011 ➤
60 – Sunroof
1 Tilting sunroof
Launch of the tilting sunroof is planned for a later point in time.
lkswage es n
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spec
es, in part or in w
t to the co
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l purpos
nform
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tion in
r
te o
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cted agen
Prote AG.
1. Tilting sunroof 157

Amarok 2011 ➤
61 – Convertible roof, hardtop, canopy

1 Hardtop
⇒ “1.1 Assembly overview - hardtop, aluminium rail”, page 158
⇒ “1.2 Assembly overview - seals and protective films, hardtop”,
page 159
⇒ “1.3 Assembly overview - protective films”, page 160
⇒ “1.4 Removing and installing hardtop”, page 161
⇒ “1.5 Preassembly of aluminium rail”, page 169
1.1 Assembly overview - hardtop, aluminium rail
Note
1 - Aluminium rail
❑ Left and right
2 - Bolt
3 - Washer
❑ Qty. 3 on each side agen
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4 - Hexagon nut d by ara
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❑ Qty. 3 on each side utho eo
ra
s a c
❑ Specified torque: 8.0 s
ce
le
Nm
un
pt
an
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itte
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5 - Hexagon nut
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ility

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is n

h re
Nm
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spec
6 - Washer
t to the co

7 - Clamp element upper part
rrectne

s
8 - Clamp element lower part

s o
cial p

inform
mer
9 - Bolt
atio
m

o
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cted agen
Prote AG.
158 Rep. gr.61 - Convertible roof, hardtop, canopy

Amarok 2011 ➤
1.2 Assembly overview - seals and protec‐

tive films, hardtop
♦ Roller -3356-
AG. Volkswagen AG d
agen oes
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Fitting notes
spec
es, in part or in w
♦ Seals cannot be removed without being damaged.
t to the co
♦ Use only adhesive remover to remove adhesive residue.
rrectness of i
♦ Ensure that the adhesive surfaces are free of dust and grease.
l purpos
♦ Remove backing only immediately before installation and then

bond seals.
nform
ercia
♦ Use roller -3356- to press down seals along entire length.

m
at
Seal dimensions: length × width × thickness
om
ion
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ate
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Prote AG.
1. Hardtop 159
Amarok 2011 ➤
1 - Seal
❑ 1 × 1596 + 5 × 20 × 6
mm
2 - Seal
❑ 2 × 110 + 3 × 20 × 6 mm
3 - Seal
❑ 2 × 160 + 3 × 15 × 6 mm
4 - Seal
❑ 2 × 486 + 5 × 20 × 6 mm AG. Volkswagen AG d
agen oes
ksw
5 - Seal by
Vol not
gu
ara
ed
❑ 2 × 160 + 3 × 15 × 6 mmhoris nte
eo
aut ra
6 - Seal ss c
ce
le
❑ 2 × 486 + 5 × 20 × 6 mm
un
pt
an
d
itte
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7 - Seal
erm
ab
ility
❑ 2 × 160 + 3 × 15 × 6 mm
ot p
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is n
8 - Seal
h re
ole,
spec
❑ 2 × 143 + 3 × 20 × 6 mm
t to the co
9 - Seal
❑ 2 × 152 + 3 × 10 × 6 mm
rrectness o
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1.3 Assembly overview - protective films
ht
pyri by
Vo
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cted agen
Prote AG.
♦ Roller -3356-
Fitting notes
♦ Protective films cannot be removed without being damaged.
♦ Use only adhesive remover to remove adhesive residue.
♦ Ensure that adhesive surfaces are free of dust and grease.

Amarok 2011 ➤
♦ Remove backing from protective film immediately before in‐

stallation and then bond protective films.
♦ Use roller -3356- to press down protective films along entire
length.
1 - Protective film
❑ Qty. 1 cross member
bulkhead top
2 - Protective film
❑ Qty. 1 side board left
3 - Protective film
❑ Qty. 1 side board right
4 - Protective film
❑ Qty. 1 rear lid
5 - Protective film
❑ Qty. 3 cross member
bulkhead
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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un
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rm
ab
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ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
1.4 Removing and installing hardtop

l purpos

nform
ercia

m
a
com
tion in
r
te o
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Prote AG.
Removing
1. Hardtop 161
Amarok 2011 ➤
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
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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
ercia
– Press covers -2- (qty. 3) at left and right onto retaining clips
m
and push down.

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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t.
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ht. rig
rig ht
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Prote AG.

AG. Volkswagen AG d
agen
olksw Amarok
oes
not 2011 ➤
yV gu
General
ised b body repairs, exterior - Edition 10.2012
ara
nte
or eo
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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
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rp
cum
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en
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Cop py
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Left and right (3 on each side).

– Unscrew hexagon bolt -4- and withdraw bolt -1- upwards.
– Slide clamp element lower part -3- sideways out of clamp el‐
ement upper part -2-.
1. Hardtop 163
Amarok 2011 ➤
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– Unscrew hexagon nut -3- from left and right of hardtop and
bulkhead cross member.
– Remove bolt -1- with washers -2- from left and right of hardtop
and bulkhead cross member.

Amarok 2011 ➤
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Amarok 2011 ➤
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– Place hardtop -1- on cargo box (at least 4 mechanics).

– Plug in connector -3- (2 plug connectors).
– Locate panel -2- on cab -4- at right, inserting at top first and
then clipping in at bottom.
– Slide hardtop -1- forwards.
– After placing hardtop -1- on cargo box, align it correctly.
Note
Pay particular attention to the sealing function between the tailgate and the hinged rear window.
– Plug in connection -5- on left inner side of side board.

Amarok 2011 ➤
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ility
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ment upper part -2-.

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hole
spec
element lower part -3-.

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t to the co
– Screw hexagon nut -4- onto bolt -1- and fix in slot of clamp
element lower section -3- to prevent it from turning.
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Specified torques
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Bolts for upper clamp element part 8.0 Nm
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1. Hardtop 167
Amarok 2011 ➤
AG. Volkswagen AG d
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– Insert washers -2- between hardtop and front bulkhead cross

member.
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– Insert bolt -1- between front bulkhead cross member, washer

-2- and hardtop.
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– Locate washer -3- on bolt -1- and tighten hexagon nut -4-.
nform
Specified torques
mercia

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Hexagon nut to hardtop 8.0 Nm

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Amarok 2011 ➤
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– Press cover -1- (qty. 3) onto retaining clip -2- -arrow a-.
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– Slide cover -1- up -arrow b-.

spec
– Locate lugs -arrow c- behind side cladding and retaining clip

t to the co
-2-.
– Slide cover -1- up until it engages.
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1.5 Preassembly of aluminium rail

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1. Hardtop 169
Amarok 2011 ➤
Note
Installation is described only for the left side. The right side is analogous.
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Assembling sequence:
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– Position aluminium rail -1- in hardtop and insert bolt -2- yri
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through hardtop and aluminium rail. by c lksw
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– Locate washer -3- on bolt -2- and tighten hexagon nut -4-.
– Move base plate -8- into contact with clamp element upper part
-7-.
– Insert clamp element upper part -7- with bolt -9- into aluminium
rail -1-.
Note
Ensure base plate -8- is seated correctly.
– Locate washer -6- on aluminium rail bolt -9-.

Amarok 2011 ➤
– Screw hexagon nut -5- onto bolt -9- by hand and tighten.
Specified torques
♦ ⇒ “1.1 Assembly overview - hardtop, aluminium rail”,
page 158 .
AG. Volkswagen AG d
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1. Hardtop 171
Amarok 2011 ➤
AG. Volkswagen AG d
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Amarok 2011 ➤
2 Lid for hardtop

⇒ “2.1 Assembly overview - hardtop lid”, page 173
⇒ “2.2 Assembly overview - hinge”, page 174
⇒ “2.3 Assembly overview - lid lock”, page 175
⇒ “2.4 Assembly overview - lid handle”, page 176
⇒ “2.5 Assembly overview - gas strut bracket”, page 177
⇒ “2.6 Assembly overview - striker for lid”, page 178
⇒ “2.7 Removing and installing hardtop lid”, page 178
⇒ “2.8 Removing and installing hardtop lid hinge”, page 180
⇒ “2.9 Removing and installing hardtop lid lock”, page 181
⇒ “2.10 Removing and installing hardtop lid handle”, page 183
⇒ “2.11 Removing and installing gas strut bracket”, page 185
⇒ “2.12 Removing and installing hardtop lid striker”, page 187
⇒ “2.13 Removing gas strut”, page 189
⇒ “2.14 Removing and installing lock cover”, page 190
⇒ “2.15 Removing and installing high-level brake light”,
page 191
⇒ “2.16 Hardtop lid seal”, page 193
2.1 Assembly overview - hardtop lid

1 - Lid
⇒ page 178 gen AG
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⇒ page 193
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4 - Lock cover
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spec
⇒ page 190
es, in part or in w
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5 - Bracket, gas strut top

⇒ page 185
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6 - Gas strut
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❑ Removing ⇒ page 189

7 - Bracket, gas strut bottom
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⇒ page 185
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⇒ page 187
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⇒ page 228
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2. Lid for hardtop 173

Amarok 2011 ➤
10 - Hinge
❑ Left and right.
2.2 Assembly overview - hinge
Note
Assembly overview is described only for the left hinge. Assembly overview of right hinge is analogous.
1 - Hinge
❑ Screwed to base plate
-4-
⇒ page 180
2 - Hexagon nut
❑ For base plate -4-
❑ Qty. 2
❑ Specified torques: 10 ±
1.5 Nm.
3 - Hexagon nut
❑ For hinge -1-
❑ Qty. 2
1.5 Nm. AG. Volkswagen AG d
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4 - Base plate ised b ara
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Amarok 2011 ➤
2.3 Assembly overview - lid lock
Note
G. Volkswagen
Only the left side is shown. The right
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⇒ page 190
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4 - Hexagon nut
❑ Qty. 2
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1.5 Nm.
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5 - Pull rod
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Amarok 2011 ➤
2.4 Assembly overview - lid handle
1 - Handle
⇒ page 183
2 - Seal
3 - Hexagon nut
❑ Specified torque:
10 ± 1.5 Nm
4 - Spring hanger
5 - Pull rods
❑ Left to lock
6 - Bolt
+ 90°
7 - Interior opening mechanism
8 - Pull rods
❑ Right to lock
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Amarok 2011 ➤
2.5 Assembly overview - gas strut bracket
Note
Assembly overview is described only for the left side. Assembly overview of right side is analogous.

⇒ page 185
2 - Hexagon nut
❑ Qty. 2
1.5 Nm.
3 - Striker
⇒ page 187
4 - Bracket, gas strut top
⇒ page 185
5 - Hexagon nut
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❑ Specified torques: 10 ± ed b ara
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Amarok 2011 ➤
2.6 Assembly overview - striker for lid
Note
Assembly overview is described only for the left side. Assembly overview of right side is analogous.
1 - Striker, lid
❑ Left and right
⇒ page 187
3 - Hexagon nut
❑ Qty. 2
1.5 Nm.
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2.7 Removing and installing hardtop lid

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Amarok 2011 ➤
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nf
Removing
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– Remove hardtop top panel ⇒ page 211

atio
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c
– Unplug electrical connectors -3-.

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– Release cable cover -4- from cable grommet.

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– Feed cable through opening in cable grommet.

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– Loosen hexagon nuts -2- on left and right hinges (do not re‐ C py
t. rig
move).
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179
Prote AG.
2. Lid for hardtop
Amarok 2011 ➤

– Remove gas strut ⇒ page 189 .
– Only now remove hexagon nuts -2- and lift lid -1- off hinges.
Installing
Specified torques
Component Specified torque
Hinge 10 ± 1.5 Nm

hinge
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Removal and installation are described for the right hinge only. Removal and installation of the left hinge are
rm
ab
similar.
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Amarok 2011 ➤
AG. Volkswagen AG d
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Removing s
ce
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nl
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– Loosen hexagonal nuts -3- on hinge -1- (do not remove).

an
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Have a second mechanic hold lid.

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– Only now unscrew hexagon nuts -3- and remove hinges -1-.
wit
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Installing
spec
es, in part or in w

t to the co

Specified torques
rrectness of i
♦ ⇒ “2.2 Assembly overview - hinge”, page 174

l purpos
2.9 Removing and installing hardtop lid lock

nform
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181
AG.
2. Lid for hardtop
Amarok 2011 ➤
AG. Volkswagen AG d
♦ Torque wrench -V.A.G
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Note
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The removal and installation sequence is only for the left lock -1-. The removal and installation of the right lock
-2- is analogous.
nform
mercia
a
com
tion in
r
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s
iva
do
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cum
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t.
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t. rig
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Prote AG.
Removing
– Remove lock cover -3- ⇒ page 190 .

Amarok 2011 ➤
– Unclip pull rod -5- from lock -1-.

– Unscrew hexagon nuts -4- and remove lock -1-.
Installing
AG. Volkswagen AG d
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Specified torques risedb ran
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♦ ⇒ “2.3 ut
Assemblys aoverview - lid lock”, page 175
or
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2.10 Removing and installing hardtop lid han‐

nl
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Amarok 2011 ➤
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Removing
t.
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– Unclip pull rods -5- and -8- from interior opening mechanism
t. rig
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-7-.
p by
co Vo
by lksw
cted agen
Prote AG.
– Remove interior opening mechanism -7-, spring hanger and

spring -4-.
– Unscrew hexagon nut -3- and remove handle -1- with seal
-2-.
Installing
– Insert handle -1- with base plate through rear window opening.
– Locate seal -2- and fasten with hexagon nut -3-.
– Locate spring hanger and spring -4-.
– Fit interior opening mechanism -7- and fasten with bolt -6-.
– Clip pull rods -5- and -8- to interior opening mechanism -7-.
• Check system for smooth movement.
Specified torques
♦ ⇒ “2.4 Assembly overview - lid handle”, page 176

Amarok 2011 ➤
2.11 Removing and installing gas strut brack‐

et
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Note
l purpos
The removal and installation sequence is only for the left side. Removal and installation of the right side is
similar.
nform
mercia
a
com
tion in
r
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thi
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AG. Volkswagen AG d
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Amarok 2011 ➤ ed b ara
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General body repairs, uexterior
tho - Edition 10.2012 eo
ra
s a c
s
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Prote AG.
Removing
– Remove left D-pillar trim ⇒ page 215 .
Bracket, gas strut bottom:
– Unscrew hexagon nuts -2- from striker -3-.
– Remove bottom gas strut bracket -1- and striker -3-.
Bracket, gas strut top:
– Remove hexagon nuts -5-.
– Remove top gas strut bracket -4- from lid.
Installing
Specified torques
♦ ⇒ “2.5 Assembly overview - gas strut bracket”, page 177

Amarok 2011 ➤

striker
Note
similar.
AG. Volkswagen AG d
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Prote AG.

Amarok 2011 ➤
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Removing yri
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Prote AG.

– Unscrew hexagon nuts -3- from striker -1-.
– Remove striker -1- and bottom gas strut bracket -2-.
Installing
Specified torques
♦ ⇒ “2.6 Assembly overview - striker for lid”, page 178

Amarok 2011 ➤
2.13 Removing gas strut
AG. Volkswagen AG d
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pt
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– Open lid.
wit
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– Insert a small screwdriver beneath spring clip -3-.

hole
spec
es, in part or in w
– Raise spring clip -3- until it can be moved over ball socket in
t to the co
direction of -arrow-.
– Pull gas strut -1- off ball-head pin -2-.
rrectness of i
After removing gas strut -1-, slide spring clip -3- back immediately.
l purpos
WARNING
nf
ercia
orm
Proceed with care if gas strut is reused. Spring clip must not
m
atio
m
be levered completely out of ball socket, as it will otherwise be

o
n in
c
damaged.
or
thi
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sd
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Gas strut will spring out of mounting, causing damage or injury

iv
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to operator.
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Prote AG.

Amarok 2011 ➤
Releasing gas from gas strut
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!
– Saw open strut cylinder in first third of total cylinder length,

starting from the reference edge on the piston rod side.
Note
♦ Wear protective goggles when sawing.

♦ Cover area of separating cut with a cleaning cloth.
♦ Dispose of oil and cloth via existing disposal channels.
lkswage es n
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2.14 Removing and installing lock cover utho
ir se tee
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Prote AG.

Amarok 2011 ➤
Removing
– Use small drift to press pin -3- inwards and unclip spreader
rivets -2- (qty. 4 top and bottom).
– Remove lock cover -1- from lid.
Installing
Note
Before installing, check fasteners for damage and renew if necessary.
2.15 Removing and installing high-level

brake light
♦ Torque screwdriver -V.A.G 1624-
AG. Volkswagen AG d
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Prote AG.

Amarok 2011 ➤
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mer
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Cop py
t. rig
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pyri by
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Prote AG.
Removing
– Unscrew bolts -4- from inside and remove trim -3-.
– Mask painted area on lid -2- above high-level brake light -1-
with commercially available masking tape to avoid damaging
paintwork.
– Insert wedge -T10039/1- between upper edge of high-level
brake light -1- and lid -2-.
– Press brake light down using wedge -T10039/1- and disen‐
gage upper lugs of brake light to rear.
– From inside lid -2- press through opening.
– Remove high-level brake light -1- to rear from lid opening -2-,
taking due account of connected cable lengths.
– Disengage and unplug connector and remove high-level brake
light -1-.

Amarok 2011 ➤
AG. Volkswagen AG d
Installing ksw
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not
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Note auth
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When installing high-level brake light -1-, ensure that seal is correctly seated. Seal must not be kinked or
un
pt
an
damaged. d
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ab
pe
ility
– Plug connector to high-level brake light -1-.
ot
wit
, is n
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– Clip high-level brake light -1- back into rear lid -2-, starting at
hole
lower edge.
spec
es, in part or in w
t to the co
Specified torques
rrectness of i
Trim 2.0 Nm
l purpos
2.16 Hardtop lid seal
nform
ercia

m
a
♦ Hot air blower -V.A.G 1416-
com
tion in
r
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Prote AG.
Fitting notes
Heat up lid seal using hot air blower -V.A.G 1416- before remov‐
ing.
If lid seal is removed and reattached, only use adhesive remover
-D 002 000 10- to remove the adhesive residue.
Ensure that adhesive surfaces are free of dust and grease.
Lid seal must be bonded in place immediately after cleaning.
Remove backing only immediately before installation and then
bond seal.
Working temperature is approx. 21°C.
Removing and installing hardtop lid seal
Note
Hardtop lid seal -1- cannot be removed without being damaged.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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spec
es, in part or in w
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nform
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tion in
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te o
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Heat lid seal -1- with hot air blower -V.A.G 1416- before re‐
moving and then peel off from lid -2-.
Installing
Follow installation instructions ⇒ page 193 .

Amarok 2011 ➤
3 Tailgate AG. Volkswagen AG d

agen oes
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⇒ “3.1 Assembly overview - anchor”, page by
V195
ol not
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ara
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is nte
⇒ “3.2 Assembly overview - tailgatethoseals”, page 196
r eo
au ra
c
⇒ “3.3 Removing and installing anchor”,
ss
page 196
ce
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nl
pt
du
3.1 Assembly overview - anchor
an
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Note
, is n
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spec
Only the right side is shown. The left side is analogous.
es, in part or in w
t to the co
1 - Tailgate
rrectness of i
⇒ page 45
l purpos
2 - Anchor
nf
ercia
❑ Right
orm
m
atio
3 - Tailgate trim, rear
om
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c

or
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⇒ General body repairs,

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interior; Rep. gr. 70 ;
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Removing and installing
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tailgate trim
t.
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4 - Anchor
t. rig
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❑ Left
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Prote AG.
5 - Base plate
❑ Right and left
6 - Threaded plate
❑ Right and left
7 - Bolt
8.0 ± 1.2 Nm
3. Tailgate 195
Amarok 2011 ➤
3.2 Assembly overview - tailgateswseals

agen
AG. Volkswagen AG d
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1 - Left seal tho eo
au ra
❑ Pushed onto edge of ss c
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load bed
nl
pt
du
an
itte
2 - Right seal
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erm
ab
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load bed
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3 - Tailgate seal
hole
spec
❑ Bonded on lower edge
es, in part or in w
t to the co
of tailgate
rrectness of i
l purpos
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at
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or
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ate
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Prote AG.
3.3 Removing and installing anchor


Amarok 2011 ➤
lkswage es n
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Cop py
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Prote AG.
Removing
– Remove tailgate trim -3- ⇒ General body repairs, interior; Rep.
– Unscrew bolts -7- and remove anchor -2- with base plate -5-.
– Pass threaded plate -6- out through tailgate opening -1-.
Installing
– Pass threaded plate -6- in through tailgate opening -1-.
– Bolt base plate -5- and anchor -2- in place.
– Install rear tailgate trim -3-.
Specified torques
♦ ⇒ “3.1 Assembly overview - anchor”, page 195
3. Tailgate 197
Amarok 2011 ➤
4 Glazing
⇒ “4.1 Assembly overview - glazing”, page 198
⇒ “4.2 Assembly overview - rear window”, page 199
⇒ “4.3 Removing and installing rear window”, page 199
⇒ “4.4 Removing and installing sliding window”, page 206
⇒ “4.5 Removing and installing front sliding window”, page 207
4.1 Assembly overview - glazing
1 - Hardtop
AG. Volkswagen AG d
⇒ page 161 ksw
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2 - Right-hand sliding window ised ara
nte
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❑ Removing and installing aut
h eo
ra
⇒ page 206 ss c
ce
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un
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3 - Rear window
an
d
itte
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ab
⇒ page 199
pe
ility
ot
wit
, is n
4 - Left-hand sliding window
h re
hole
spec
⇒ page 206
es, in part or in w
t to the co
5 - Front sliding window
rrectness of i
⇒ page 207
l purpos
nform
mercia
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tion in
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te o
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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
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4.2 Assembly overview - rear window
by
Vol
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1 - Rear window au ra
c
ss
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2 - Connection for heated rear
un
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an
d
window
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ab
❑ Right
ility
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3 - PUR adhesive sealant
is n
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❑ Adhesive bead cross-
spec
section: -width- = 6.5 urposes, in part or in wh
mm; -height- = 10 mm
t to the co
❑ The adhesive bead is
butted up against the
rrectne
side edge of the win‐
dow.
s
❑ Minimum curing period
s o
⇒ page 254 .
cial p
f inform
4 - Connection for heated rear
mer
window
atio
om
n
❑ Left.
c
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Prote AG.
4.3 Removing and installing rear window
Note
The removal of a bonded window is described using the Removal

kit for flush bonded windows -V.A.G 1474 A- . The respective tools
from Removal kit for flush bonded windows -VAS 6452- may also
be used.
4. Glazing 199
Amarok 2011 ➤

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter -V.A.G 1344-
♦ Cutting tool -V.A.G 1351-
♦ Windscreen removal kit -
V.A.G 1755-
♦ Cartridge gun -V.A.G 1628-
♦ Cartridge heater -
V.A.G 1939-
AG. Volkswagen AG d
agen oes
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pt
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ility
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es, in part or in w
t to the co
rrectness of i
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nf
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Cop py
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Vo
co lksw
by
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Prote AG.

Amarok 2011 ➤
♦ Electric cutter -
V.A.G 1561 A-
♦ Cutting blade -
V.A.G 1561/2-
♦ Scraping blade -
V.A.G 1561/8-
♦ Cutting blade -
V.A.G 1561/10-
♦ Cutting blade -
V.A.G 1561/19-
♦ Double cartridge gun -
VAS 5237-
AG. Volkswagen AG d
agen oes
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t to the co
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cial p
f inform
mer
atio
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n
c
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4. Glazing 201
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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un
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d
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ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
Removing
o
n
c
i
or
n thi
– Pull cutting cord end -3- through adhesive sealing material of

te
sd
a
rear window -1- to inside using awl -V.A.G 1474 A- -2-.

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lkswage es n
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o ot g
ua Amarok 2011 ➤
ran
ho
ir se General body
tee repairs, exterior - Edition 10.2012
ut or
a ac
ss
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
r
te o
thi
s
iva
do
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pyri by
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Prote AG.
– From inside, prevent end of cutting cord -2- from being pulled
out by attaching it to pull handle -V.A.G 1351/1- -3-.
– Place cutting cord -2- around rear window -1-.
Ensure that cutting cord -2- lies under window in corners.
4. Glazing 203
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Secure other end of cord to reel device -V.A.G 1654 A- -4-.

rrectness of i
– Cut rear window -1- free by appropriate movement of reel de‐

l purpos
vice -V.A.G 1654 - and counterhold using pull handle -V.A.G

1351/1- -3-.
nform
ercia
– Use wedge -V.A.G 1474/5- to press cutting cord -2- against

rear window -1 - while cutting to ensure clearance at window
m
at
om
flange.
ion
c
in t
or
Have a second mechanic hold rear window -1-.

his
ate
do
riv
Removing broken rear window

p
cum
for
en
g
– Protect body and interior from glass splinters.

n
t.
yi Co
Cop py
– Remove pieces of glass up to adhesive sealing material.
t. rig
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pyri by
Vo
o
– Pull off connections for rear window heating and aerial.
c by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Cover flange -2- all round with textile-reinforced adhesive

tape.
– Cut through adhesive seal (with pieces of glass) in window
aperture using electric cutter -V.A.G 1561 A- -1- and U-shaped
blade -V.A.G 1561- .
WARNING
Always wear safety goggles and leather gloves.
Installing rear window

Preparing old undamaged window for glazing ⇒ page 256
Preparing new window for glazing ⇒ page 257 .
Preparing body flange for glazing ⇒ page 257
Installation instructions ⇒ page 255 . AG. Volkswagen AG d
agen oes
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Minimum curing period ⇒ page 254 . d byV gu
ara
ise nte
or eo
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ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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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
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t.
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rig ht
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Prote AG.
4. Glazing 205
AG. Volkswagen AG d
agen oes
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Amarok 2011 ➤ by
Vol not
gu
d ara
General body repairs, exterior - Edition 10.2012 orise nte
h eo
aut ra
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4.4 Removing and installing sliding window s
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
ot p
wit
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Removal and installation are only shown for the left sliding window. The removal and installation of the right
h re
hole
sliding window is analogous.
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
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Removing
– Open side sliding window -1- at front and unscrew bolts -2-
(qty. 3) between window channel and window frame.
– Open side sliding window -1- at rear and unscrew bolts -2- (qty.
5) between window channel and window frame.
– Remove side sliding window -1- from hardtop window aper‐
ture.
Installing

Amarok 2011 ➤
Specified torques
Side sliding window 3.0 Nm
4.5 Removing and installing front sliding window
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d ran
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ce
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nl
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du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nf
ercia
or
– Release hardtop to rear and slide towards rear ⇒ page 161 .

m
m
atio
om
– Detach seal -2- from inside out over window flange -3- using
n in
or c
removing wedge -3409- .

thi
te
sd
iva
– Press front sliding window -1- with seal -2- out of window
o
r
rp
cu
aperture from inside.

o
m
f
en
ng
t.
yi Co
Installing Cop py
t. rig
gh ht
yri
– Spray seal -2- with soapy water. p by
co Vo
by lksw
cted agen
– Insert thread inserting tool -V.A.G 1818- around seal -2-.
Prote AG.
Further installation is possible only with the help of a second me‐

chanic.
4. Glazing 207
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Amarok 2011 ir se ➤
d ran
tee
o
Generalaubody repairs, exterior - Edition 10.2012
th or
ac
ss
ce
le
– Locate front sliding window -1- in window aperture using 2
un
pt
an
suction lifters -V.A.G 1344- .
d
itte
y li
rm
ab
– Pull out thread inserting tool for window seal -V.A.G 1818- all
pe
ility
round from inside and thereby pull sealing lip over window
ot
wit
, is n
flange -3-.
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
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en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
5 Trims, foam components

⇒ “5.1 Assembly overview - hardtop foam components, top”, page
209
⇒ “5.2 Assembly overview - foam components, top and side”,
page 210
⇒ “5.3 Removing and installing top panel”, page 211
⇒ “5.4 Removing and installing right D-pillar trim”, page 213
⇒ “5.5 Removing and installing left D-pillar trim”, page 215
⇒ “5.6 Removing and installing hardtop middle trim”, page 218
⇒ “5.7 Removing and installing hardtop securing bracket”,
page 224
⇒ “5.8 Removing and installing front trim”, page 225
⇒ “5.9 Removing and installing edge protector”, page 226
⇒ “5.10 Installing speed nuts”, page 227
⇒ “5.11 Removing and installing rear seal”, page 228
5.1 Assembly overview - hardtop foam components, top

Fitting notes
♦ Foam components cannot be removed without being dam‐
aged.
♦ Only use adhesive remover -D 002 000 10- to remove adhe‐ n AG. Volkswagen AG do
sive residue. olks
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♦ Remove backing from protective film -5- only immediately
ss
au be‐ ra
c
fore installation.
ce
le
un
pt
an
♦ Position foam components -4- relative to wooden rails -2- and
d
itte
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-3- as specified.
rm
ab
pe
ility
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wit
, is n
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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
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rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
5. Trims, foam components 209

Amarok 2011 ➤
♦ Press foam components down along entire length.
1 - Hardtop
2 - Middle wooden rail
3 - Wooden rail
❑ Left and right
4 - Foam element
❑ Qty. 4
AG. Volkswagen AG d
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spec
t to the co
5.2 Assembly overview - foam components, top and side
Fitting notes
rrectne
♦ Foam components cannot be removed without being dam‐
s
aged.
s o
cial p
f i
♦ Only use adhesive remover -D 002 000 10- to remove adhe‐

nform
sive residue.
mer
atio
m

o
n
c
i
or
n thi
♦ Remove backing from protective film -4- only immediately be‐

te
sd
a
fore installation.
iv
o
pr
cum
r
fo
♦ Position foam components -1-, -2- and -3- relative to window

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

Amarok 2011 ➤
♦ Press foam components down along entire length.
1 - Foam component, front side

❑ Right
2 - Foam component, front side
❑ Left.
3 - Foam component, front top
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t to the co
5.3 Removing and installing top panel

rrectne

ss

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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cum
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
– Remove right D-pillar trim ⇒ page 213 . uthor eo
ra
s a c
– Unscrew bolts -5- and remove load compartment light -4-. s
ce
le
un
pt
– Disconnect connector -6-.

an
d
itte
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erm
ab
– Unscrew bolts -3- (with spacers -2-) and -8-.

ility
ot p
wit
– Remove top panel -1-.

is n
h re
ole,
Installing
spec
– Locate snap nut -7- in area of light aperture.

t to the co
– Locate top panel -1- on roof frame and pass connector for in‐
terior light through.
rrectne
– Align top panel and fasten to metal bracket in light aperture

with bolt -8-.
ss o
cial p
– Position spacers -2- and screw bolts -3- into wooden rails.
inform
mer
– Plug in connector -6- and insert load compartment light -4- in

atio
top panel recess.

om
n
c
i
or
– Secure light with bolts -5-.

thi
te
sd
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Cop py
t. rig
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212
cop Vo
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Rep. gr.61 - Convertible roof, hardtop, canopy Prote
cted AG.
agen
Amarok 2011 ➤
Specified torques
Bolts -3- and -5- 2.5 Nm
5.4 Removing and installing right D-pillar

trim
AG. Volkswagen AG d
agen oes
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or eo
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nl
pt
du
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es, in part or in w
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Removing
– Detach right rear seal ⇒ page 228
– Remove bolts -2- and -3- with spacers -4-.
– Guide D-pillar trim -1- with cut-out over striker.
Installing
AG. Volkswagen AG d
agen oes
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au ra
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nl
pt
du
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ility
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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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
• Locate snap nuts on centre trim ⇒ page 227 .

– Guide D-pillar trim -1- with cut-out over striker -2-.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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un
pt
an
d
itte
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erm
ab
– Align D-pillar trim -1- and screw upper bolt to side trim.
ility
ot p
wit
is n
– Position spacer -4- and screw bolt -3- into wooden rail.
h re
ole,
spec
– Screw middle and lower bolts -2- to side trim.

t to the co
– Screw bolt -2- to lower part of D-pillar trim.

– Fit right rear seal ⇒ page 228 .
rrectne
Specified torques
ss o
cial p
D-pillar trim 2.5 Nm

inform
mer
5.5 Removing and installing left D-pillar trim

atio
om
n
c
i
or

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te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Removing
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
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au ra
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ce
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un
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an
d
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pe
ility
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wit
, is n
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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
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cum
fo
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t.
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Cop py
t. rig
– Detach left rear seal ⇒ page 228
gh ht
pyri by
Vo
co lksw
by
– Unclip momentary-contact switch -6- from D-pillar trim -1- and cted agen
Prote AG.
unplug connector -7-.
– Remove bolts -2- and -3- with spacers -4-.
– Guide D-pillar trim -1- with cut-out over striker.
Installing

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
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d
itte
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ab
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
• Locate snap nuts on centre trim ⇒ page 227 .
– Guide D-pillar trim -1- with cut-out over striker -2-.
– Route connector -4- for momentary-contact switch through D-
pillar trim -1-.
– Lay connecting cable -3- to cargo box in recess provided for
that purpose.

Amarok 2011 ➤
lkswage es n
o ot g
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d ran
ir se tee
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a ac
ss
ce
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un
pt
an
d
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Align D-pillar trim -1- and screw upper bolt -2- to side trim.
r
te o
thi
s
iva
– Position spacer -4- and screw bolt -3- into wooden rail.
do
r
rp
cum
fo
– Screw middle and lower bolts -2- to side trim.

en
ng
t.
yi Co
op
– Screw bolt -2- to lower part of D-pillar trim. C py
t. rig
gh ht
yri by
– Plug connector -7- into momentary-contact switch -6- and clip cop Vo
by lksw
momentary-contact switch to D-pillar trim -1-. cted agen
Prote AG.
– Install left rear seal ⇒ page 228

Specified torques
D-pillar trim 2.5 Nm
5.6 Removing and installing hardtop middle

trim
Removing

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove top panel ⇒ page 211 .

– Remove right D-pillar trim ⇒ page 213 .
– Remove left and right edge protectors ⇒ page 226 .
– Press cover -2- (quantity: 3) onto retaining clip -arrow a- and
slide down -arrow b-.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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om
n in
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iva
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f
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ng
t.
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op
– Remove bolts -2- and -3- (Qty. 9) with spacers -4-. C py
t. rig
gh ht
yri by
– Remove middle trim -1- from hardtop with aid of a second me‐ cop Vo
by lksw
chanic. cted agen
Prote AG.
Installing

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
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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
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
• Securing bracket is fitted ⇒ page 224 .

– Locate and align middle trim -1- in hardtop -2-.
Note
Ensure flush fit with front trim.
– Locate side elements and align relative to window aperture.

– Install remove left and right edge protectors ⇒ page 226 .

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Prepare middle front attachment point -3- first and secure with
bolt.
– Centre spacers -4- in any order in securing holes -2- in middle
trim -1- and secure with bolts.
Specified torques
Centre trim 2.5 Nm

Amarok 2011 ➤
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
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Press cover -1- (qty. 3) onto retaining clip -2- -arrow a-.
m
at
– Slide cover -1- up -arrow b-.

om
ion
c
in t
r
– Locate lugs -arrow c- behind side cladding and retaining clip

o
his
te
-2-.
a
do
priv
cum
or
– Slide cover -1- up until it engages.

f
en
ng
t.
yi Co
– Install top panel ⇒ page 211 Cop py
t. rig
gh ht
yri
– Install right D-pillar trim ⇒ page 213 . p by
co Vo
by lksw
cted agen
– Install left D-pillar trim ⇒ page 215 . Prote AG.

Amarok 2011 ➤
5.7 Removing and installing hardtop securing bracket
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
– Locate snap nuts -3- on fastening bracket -1-.

c
i
or
n thi
te
– Place fastening bracket -1- with contact surfaces on middle

sd
iva
o
r
wooden rail.
p
cum
r
fo
en
ng
– Locate bolts -2- and tighten.

t.
yi Co
Cop py
. rig
Specified torques
t
gh ht
pyri by
Vo
co lksw
by
Component Specified torque cted agen
Prote AG.
Securing bracket 2.5 Nm

Amarok 2011 ➤
5.8 Removing and installing front trim
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
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nl
pt
du
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itte
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ility
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, is n
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hole
spec
Removing
es, in part or in w
t to the co
– Pull sliding window seal -2- all round over trim.

– Remove adhesive tape -3-.
rrectness of i
– Remove front trim -1- from hardtop.

l purpos
Installing
nf
ercia
• Ensure that foam components are evenly seated

or
⇒ page 210 .
m
m
atio
om
– Locate front trim -1- in hardtop.

n in
or c
thi
e
– Position trim uniformly relative to window aperture.

t
sd
iva
o
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rp
cu
– Roll sliding window seal out -2- all round over front trim.
o
m
f
en
ng
t.
yi
– Remove backing -4- from Velcro tape -3- and press front trim
Co
op py
-1- down evenly over entire width.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
5.9 Removing and installing edge protector
Note
AG. Volkswagen AG d
similar. lkswagen oes
n o ot g
yV ua
edb ran
ris tee
tho or
au 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.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Peel edge protector -1- off trim.
Installing
– Locate edge protector -1- uniformly, starting at dividing point
-arrow-.
– Ensure correct seating contact in curved sections and do not
stretch edge protector -1- when fitting.

Amarok 2011 ➤
5.10 Installing speed nuts
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
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an
d
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ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
Assembling sequence:
or
n thi
te
sd
va
– Locate clamping snap nut -2- (qty. 3 on each side) on middle

i
o
pr
cum
trim -1-.
r
fo
en
ng
t.
yi
– Position thread of clamping snap nut -2- on rear of middle trim
Co
Cop py
-1-. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
5.11 Removing and installing rear seal
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
te
sd
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Peel rear seal -1- off flange.
Installing
– Press rear seal -1- onto flange.
– Fold cover lip of seal -1- over trim edges and ensure it runs
uniformly.

Amarok 2011 ➤
63 – Bumpers
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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ss c
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le
un
pt
an
d
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rm
ab
pe
ility
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wit
, is n
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Front bumper cover 229

Amarok 2011 ➤
1 Front bumper cover

⇒ “1.1 Assembly overview - front bumper”, page 230 wagen AG. Volkswagen AG doe
olks s no
yV t gu
⇒ “1.2 Assembly overview - front bumper cover,ed badd-on parts”, ara
page 231 horis nte
e t or
au ac
⇒ “1.3 Assembly overview - wheel arch trim,
ss bumper cover”, page
234
ce
e
nl
pt
du
an
itte
⇒ “1.4 Assembly overview - parking aid retainer”, page 235
y li
erm
ab
ility
⇒ “1.5 Assembly overview - substructure components”,
ot p
wit
page 236
, is n
h re
hole
⇒ “1.6 Removing and installing front bumper cover”, page 236
spec
es, in part or in w
⇒ “1.7 Removing and installing wheel arch trim, front bumper
t to the co
cover”, page 239
⇒ “1.8 Repairing bumper cover”, page 242
rrectness of i
⇒ “1.9 Installing brackets for parking aid system”, page 242
l purpos
1.1 Assembly overview - front bumper
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Nm
3 - Bolt
❑ Qty. 2
4 - Bolt
Nm
5 - Clip
❑ Qty. 4
6 - Bolt
❑ Left and right.
❑ Points upwards.
❑ Bolted to wing
Nm
7 - Bolt
❑ Left and right.
Nm.
❑ Bolted to wing
230 Rep. gr.63 - Bumpers

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1.2 Assembly overview - front bumper cov‐
es, in part or in w
t to the co
er, add-on parts
⇒ “1.2.1 Assembly overview - front bumper cover, add-on parts”,
rrectness of i
page 231 l purpos
⇒ “1.2.2 Assembly overview - front bumper cover, add-on pieces,

PR No. OFA ”, page 232
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⇒ “1.2.3 Assembly overview - front bumper cover, add-on pieces,
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PR No. OFX ”, page 233
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1.2.1 Assembly overview - front bumper cover, add-on parts

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⇒ page 236
2 - Left trim
❑ For fog light.
❑ Pull forwards out of de‐
tent.
3 - Right trim
❑ For fog light.
tent.

Amarok 2011 ➤
1.2.2 Assembly overview - front bumper cover, add-on pieces, PR No. “OFA”

⇒ page 236
2 - Left wheel arch trim
⇒ page 239
❑ Holes for positioning
pins notes -arrows-
⇒ page 238
3 - Fog light trim
❑ Left.
tent.
❑ Different versions. For
allocation see ⇒ Elec‐
tronic parts catalogue
“ETKA” . agen
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❑ Can be unclipped only uthor eo
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6 - Front spoiler t to the co

❑ Centre.
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7 - Front spoiler
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8 - Towing eye cover

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10 - Fog light trim
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❑ Right.
❑ Pull forwards out of detent.
11 - Right wheel arch cover
❑ Holes for positioning pins notes -arrows- ⇒ page 238
12 - Parking aid retainer
❑ Installing ⇒ page 235 .

Amarok 2011 ➤
1.2.3 Assembly overview - front bumper cover, add-on pieces, PR No. “OFX”

⇒ page 236
2 - Left wheel arch trim
⇒ page 239 .
3 - Fog light trim
❑ Left.
tent.
❑ Different versions. For
allocation see ⇒ Elec‐
tronic parts catalogue
“ETKA” .
4 - Decorative trim
removed -1-.
5 - Front spoiler
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7 - Front spoiler
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8 - Towing eye cover

❑ Engaged in front bumper cover -1- nform
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9 - Air intake grille

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11 - Right wheel arch cover
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❑ Removing and installing ⇒ page 239 .
12 - Parking aid retainer
❑ Installing ⇒ page 235 .

Amarok 2011 ➤
1.3 Assembly overview - wheel arch trim, bumper cover
1 - Wheel arch cover, bumper

cover
⇒ page 239
2 - Bolt
❑ Qty. 2
Nm
3 - Mounting lugs
4 - Bolt
❑ Points upwards.
Nm
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Assembly overview - parking aid retainer
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Note
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Observe slight deviations in the front bumper cover and parking aid brackets depending on model version.
h re
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es, in part or in w
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⇒ page 236 .
rrectness of i
2 - Parking aid senders in front
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bumper cover
❑ Installing brackets for
nform
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parking aid system

m
⇒ page 242
a
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tio
❑ Front left parking aid
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sender -G255-
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❑ Front inner left parking
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aid sender -G254-
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❑ Front right parking aid
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❑ General information and
work instructions for the
parking aid can be found
in ⇒ Electrical system;
Rep. gr. 94 ; Parking
aid .

Amarok 2011 ➤
1.5 Assembly overview - substructure components
1 - Guide bracket
❑ Laterally on left and right
wing
❑ Removing:
– Prise out clip -2- using a
screwdriver.
2 - Clip
3 - End plate
❑ For front bumper cover
❑ Attached to front bump‐
er carrier
4 - Foam element
❑ Pedestrian protection
5 - Support
❑ Right and left
❑ For front bumper cover
6 - Bolt
❑ Specified torque 8.0
Nm.
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1.6 Removing and installing front bumper

hole
spec
cover
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Amarok 2011 ➤
Note
♦ The removal and installation procedures for front bumper cover may have to be revised slightly depending
on model variations. agen
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Removing
– Remove fog light trims on left and right ⇒ page 231 .
– Prise out clip -5- using a screwdriver.
– Remove bolts -2- on left and right sides in area of wheel hous‐
ing liner.
– Unclip clip -6-(aligned upward) on left and right.
– Remove bolts -3- and -4- from front.
– Remove bolts -7- and -8- on left and right from below.
– With help of a second mechanic pull front bumper cover -1-
parallel off vehicle.

Amarok 2011 ➤
– Disconnect washer fluid hose connector (if present) ⇒ Elec‐

trical system; Rep. gr. 92 ; Headlight washer system
General information and work instructions for the parking aid can
be found in ⇒ Electrical system; Rep. gr. 94 ; Parking aid .
Installing
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♦ When positioning front bumper cover, ensure it is parallel to wing.

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♦ Depending on the wheel arch on the front bumper cover -2- and on the wing -1-, the positioning pins
cum
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-arrows- must be removed. It is possible that different sorts of pins have been fitted.
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ng
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pairs; Rep. gr. 00 ; Body gaps; Body, front .
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Specified torques
Specified torque of bolts ⇒ page 230

Amarok 2011 ➤
1.7 Removing and installing wheel arch

trim, front bumper cover
♦ Removal wedge -3409-
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Removing
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Note
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♦ The removal and installation procedure is for the left side. The right side is similar.
iv
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♦ Front bumper cover wheel arch trim -1- cannot be removed without damaging it.
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Amarok 2011 ➤
AG. Volkswagen AG d
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– Remove bolts -2- and -4- (pointing upwards).

h re
hole
spec
– Warm wheel arch trim, front bumper cover, -1- with hot air
es, in part or in w
blower -V.A.G 1416- before removing.

t to the co
– Lift one corner of wheel arch trim, front bumper cover, -1- using
removal wedge -3409- .
rrectness of i
– Grip under wheel arch trim, front bumper cover, -1- and care‐
l purpos
fully pull it off front bumper cover.

nf
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orm
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The mounting lugs -3- break off.

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Amarok 2011 ➤
AG. Volkswagen AG d
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Installation instructions for wheel arch trims ⇒ page 313 .
ole,
spec
Preparing new add-on part for bonding ⇒ page 314 .

Preparing body component for bonding ⇒ page 314 . t to the co
Installation instructions ⇒ page 315 .

rrectne
Observe minimum curing period ⇒ page 316 .

s
– Apply glass/paint primer -D 009 200 02- to bonding surface

s o
cial p
-3- of front bumper cover and allow to dry.

inform
mer
– The mounting lugs must be completely removed from the

atio
wheel arch trim, front bumper cover, -1-.

om
n
c
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or
– Using cartridge gun -V.A.G 1628- , apply bead -5- of 1-com‐

thi
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ponent glass adhesive -DA 009 100 A2- along entire length of
t
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wheel arch trim -1-.

pr
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Cross section of adhesive bead: -width- = approx. 5 mm,

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-height- = approx. 8 mm C py
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– Position wheel arch trim, front bumper cover, -1- on front copy Vo
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– Position bolts -2- and -4- (pointing upwards) and tighten.

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Amarok 2011 ➤ tho tee
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General body repairs, sexterior
s a
- Edition 10.2012 ac
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Note
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Check fit of wheel arch trim -1-.
h re
hole
spec
Specified torques
es, in part or in w
t to the co
Specified torque of bolts ⇒ page 234 .
1.8 Repairing bumper cover
rrectness of i
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Note
nform
ercia
If front bumper cover is damaged, determine whether plastic can

m
be repaired before renewing bumper.
a
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tion in
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thi
Description under: ⇒ General Information; Body Repairs, General
s
iva
Body Repairs ; Plastic repair procedures
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1.9 Installing brackets for parking aid sys‐
en
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♦ Installation tool for PDC bracket -VAS 6614-
Materials
♦ Cleaning solution -D 009 401 1) 1
04-
1) Observe manufacturer's instructions enclosed in the packaging.
Installing brackets
Note
The brackets are installed after the bumper cover has been pain‐
ted.

Amarok 2011 ➤
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The 4 markings for a bracket -1- can be found on the inside of the
form
mer
bumper cover.
atio
om
– If there are no markings, the centre point -2- must be deter‐

n
c
i
or
mined.
thi
te
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– The holes must be drilled from the inside to the outside with
i
o
pr
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the drill in the tool kit -3-.

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Amarok 2011 ➤
AG. Volkswagen AG d
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– Set hole puncher in position with bolt head -1-, washer -2- and
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thrust bearing -3- from inside bumper cover -5-.

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– Screw on punch -4-, not quite as far as bumper cover.

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– Press punch -4- against bumper cover.

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– Tighten hole puncher -1-.

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The punch -4- must not turn on the paint of the bumper cover.
– Pull the punch -4- through the material of the bumper cover
-5- -arrows- by turning the bolt head -1-.
– Remove hole puncher and make the next holes.

Amarok 2011 ➤
AG. Volkswagen AG d
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– Thoroughly clean bonding surfaces on bumper cover -4-.

– Push bracket -2- onto centring pin -1-.
– Pull backing off double-sided adhesive tape on bracket.
– Insert centring pin -1- into hole until the bracket is touching the
bumper cover -4-.
– Press bracket on forcefully in area of bonding surface -3-.
– Removing centring pin and repeat the procedure for all brack‐
ets.
– Further work can carried out on bumper cover only after min‐
imum curing period ⇒ page 245 .
Minimum curing period
Do not carry out any further work on the bumper cover or brackets
until the minimum curing period of 2 hours has expired.
The minimum curing period must be observed so that the adhe‐
sive tape can develop its full adhesive strength.
In this time, the bumper cover must remain where it is and should
not be moved.

Amarok 2011 ➤
2 Rear bumper olkswage

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⇒ “2.1 Assembly overview - rear bumper”,
ir se
d page 246 ran
tee
tho
or
⇒ “2.2 Assembly overview - bottom
ss
au
step”, page 248 ac
ce
e
⇒ “2.3 Assembly overview - rear bumper cover step”, page 248
nl
pt
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⇒ “2.4 Assembly overview - closing plate”, page 250
erm
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ility
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⇒ “2.5 Assembly overview - rear bumper carrier to 2011”,
wit
page 250
, is n
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⇒ “2.6 Assembly overview - rear bumper carrier from 2011”, page
spec
251
es, in part or in w
t to the co
⇒ “2.7 Repairing bumper cover”, page 253
2.1 Assembly overview - rear bumper
rrectness of i
l purpos

nform
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Note
The removal and installation procedures for rear bumper cover may have to be revised slightly depending on
model variations.

Amarok 2011 ➤
1 - Rear bumper cover

❑ Removing:
– Remove bottom step
⇒ page 248 .
– Remove bolts -2- and

-3-
– Remove rear bumper

cover.
2 - Bolt
❑ Qty. 7
❑ Specified torque 8 Nm.
3 - Bolt
❑ Specified torque 8 Nm.
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Prote AG.
2. Rear bumper 247

Amarok 2011 ➤
2.2 Assembly overview - bottom step
1 - Rear bumper cover

⇒ page 246
2 - Clip
❑ Qty. 2
3 - Bottom step
❑ Removing:
cover step
⇒ page 248 .
– Unclip clips -2- and -4-
on left and right.
– Pull rear bottom step

backwards off bumper
carrier.
4 - Clip
❑ Left and right.
5 - Cap
❑ Left and right.
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2.3 Assembly overview - rear bumper cover

t to the co
step
rrectness of i

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Amarok 2011 ➤
ag
General
en AG. Volkbody
swagerepairs,
n AG do exterior - Edition 10.2012
w es n
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1 - Rear bumper cover ris
ed
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❑ Removing and installing au
t or
ac
⇒ page 246 ss
ce
le
un
pt
2 - Rear bumper cover step
an
d
itte
y li
❑ Removing:
erm
ab
ility
ot p
– Unclip clip -3-.
wit
is n
h re
– Remove bolts -4-. ole,
spec
t to the co
cover step from rear
bumper carrier.
rrectne
3 - Clip
❑ Qty. 3
ss o
cial p
f
4 - Bolt
inform
mer
atio
❑ Specified torque 4.5
om
n
Nm.
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.
2. Rear bumper 249

Amarok 2011 ➤
2.4 Assembly overview - closing plate
1 - Rear bumper carrier

to 2011 ⇒ page 250
from 2011 ⇒ page 251
2 - Closing plate right
❑ Secured with adhesive
strips -4-
3 - Closing plate left
❑ Secured with adhesive
strips -4-
4 - Adhesive strips
Note
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
2.5 Assembly overview - rear bumper carri‐

t to the co
er to 2011
rrectne

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
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Note
♦ The assembly overview shows a rear bumper carrier without a towing bracket. The rear bumper carrier with
towing bracket is analogous.
♦ Removing and installing towing bracket ⇒ page 355 .
♦ Observe minor differences among rear bumper carriers depending on model year.

❑ Without trailer prepara‐
tion
❑ Removing:
– Remove bolts -2- on

right and left.
– With help from a second

mechanic, remove rear
bumper carrier.
2 - Bolt
+ 90° agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
an
d
itte
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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
ti
2.6 Assembly overview - rear bumper carri‐

on in
r
te o
er from 2011
thi
s
iva
do
r
rp

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Rear bumper 251

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Amarok 2011 ➤ autho eo
ra
General body repairs, exterior - Edition 10.2012 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
m
Note
o
n in
or c
thi
e
♦ The assembly overview shows a rear bumper carrier without a towing bracket. The rear bumper carrier with
t
sd
iva
o
towing bracket is analogous.
r
rp
cu
o
m
f
en
ng
♦ Removing and installing towing bracket ⇒ page 355 .

t.
yi Co
Cop py
♦ Observe minor differences among rear bumper carriers depending on model year.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

❑ Without trailer prepara‐
tion
❑ Removing:
– Remove bolts -2- on

right and left.
– With help from a second

mechanic, remove rear
bumper carrier.
❑ Installing:
– Install in reverse order
of removal. When doing
this, observe the follow‐
ing:
– Observe fitting se‐

quence 1-4!
2 - Hexagon nut
❑ Left and right
3 - Bolt
❑ Left and right
+ 180°
4 - Bolt
❑ Left and right
+ 90°

Amarok 2011 ➤
2.7 Repairing bumper cover
Note AG. Volkswagen AG d

agen oes
olksw not
yV gu
If rear bumper cover is damaged, determineised whether plastic can
b ara
nte
be repaired before renewing bumper. ut
hor eo
ra
s a c
s
ce
Details can be found under: ⇒ General Information; Body Repairs,
le
un
pt
General Body Repairs ; Work procedures; Plastic repair proce‐
an
d
itte
y li
dures .
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.
2. Rear bumper 253

Amarok 2011 ➤
64 – Glazing
1 Repair instructions
1.1 Minimum curing period
WARNING
Special standards must be adhered to when replacing bonded

windows. One of these standards is, for example, that a freshly
bonded windscreen must comply with the safety requirements,
even in an accident, following the minimum prescribed curing
period.
2-component adhesive
The minimum curing time for the 2-component adhesive is 2 hours
for all windows.
The operational safety of the vehicle is restored completely after
2 hours.
1-component adhesive AG. Volkswagen AG d
agen oes
olksw not
yV gu
The minimum curing time for the ise1-component
d b adhesive is 16 ara
nte
hours for all windows. hor eo
aut ra
s c
The vehicle is definitely safe
s to operate again after 16 hours if the
ce
e
1-component adhesive is used.

nl
pt
du
an
itte
y li
For 2-component adhesive and 1-component adhesive

erm
ab
ility
ot p
Irrespective of which adhesive is used, the vehicle can be moved

wit
, is n
again half an hour after the window has been installed.

h re
hole
Minimum curing period is the time from bonding the window until
spec
vehicle may be used (operational safety). During this time, the

es, in part or in w
t to the co
vehicle must stand on a level surface at room temperature (at

least 15 °C).
rrectness of i
WARNING
l purpos
It is safe to use vehicle only after the curing period is comple‐

ted.
nform
mercia
at
om
io
1.2 Window repair

n
c
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
♦ If windscreen is damaged, determine whether glass can be
. C rig
ht ht
rig
repaired before replacing. py by
co Vo
by lksw
cted
♦ Damaged windscreens can be repaired with the window repair
agen
Prote AG.
kit -VAS 6092- .
♦ This damage must not exceed a certain size or position.
♦ Each window repair kit comes with a set of instructions.
254 Rep. gr.64 - Glazing

Amarok 2011 ➤
♦ Window repair kit -VAS 6092-
lkswage es n
o ot g
yV
1.3 Installation instructions d b ua
ran
ir se tee
tho
u or
⇒ “1.3.1 Installation instructions
ss
a for bonded windows”, ac
page 255
ce
e
nl
pt
du
an
⇒ “1.3.2 Materials”, page 255
itte
y li
erm
ab
1.3.1 Installation instructions for bonded win‐
ility
ot p
wit
dows
, is n
h re
hole
spec
– Apply adhesive material to primed area -1- or to trimmed seal‐
es, in part or in w
ant bead, holding double cartridge gun -VAS 5237- at right
t to the co
angle to window.
rrectness of i
Note
l purpos
The first 10 cm of the adhesive bead must not be used.
nform
mercia
WARNING at
om
ion
c
in t
or
Window must be installed within 10 minutes, or adhesive prop‐

his
ate
erties of glass adhesive will be impaired.

do
priv
cum
or
Adhesive bead should not be applied too thick and windows

f
en
ng
t.
yi
should not be pressed too forcibly on body flange. Windows no
Co
op py
longer have sealing lips and therefore excessive adhesive will
t. C rig
gh ht
be visible in the joint area. pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Using 2 suction lifters -V.A.G 1344- , install glass pane in win‐

dow aperture, align to centre and press in onto spacing lip.
♦ Replace stickers (e.g. for airbag) which may be installed.
1.3.2 Materials
Note
The part numbers of the materials can be found in the ⇒ electronic

parts catalogue .
♦ 2K glass adhesive 1) 2) 3) 6)
♦ 1K glass adhesive 1) 2) 4) 5) 6)
♦ Activator 1) 6)
1. Repair instructions 255

Amarok 2011 ➤
♦ Glass and paint pri‐ 1) 6)

mer
♦ Cleaning solution AG. Volkswagen AG d 1) 6)

agen oes
olksw not
byV gu
ara
♦ Primer applicator 1)
rise6)
d
nte
ho eo
aut ra
♦ Adhesive removers s 1) 6) c
ce
e
nl
pt
du
♦ Cutting cord 1) 6)
an
itte
y li
erm
ab
♦ Mixing nozzle 1) 6)
ility
ot p
wit
, is n
h re
1)Observe instructions for use on the information sheet provided
hole
spec
by the manufacturer.
es, in part or in w
t to the co
2) Minimum curing period ⇒ page 254
3)
Double cartridge gun -VAS 5237- must be used to apply these
rrectness of i
materials.
l purpos
4)Heat according to manufacturer's instructions, using cartridge

heater -V.A.G 1939- .
nform
ercia
5)Small cartridge, 180 ml, for sealing and/or when a 400 ml dou‐
m
ble cartridge alone is not sufficient.
at
om
ion
c
in t
The part numbers of the materials can be found in the⇒ elec‐
or
his
e
tronic parts catalogue .

at
do
priv
cum
1.4 Preparing old undamaged windows for

for
en
ng
t.
yi
fitting
Co
Cop py
ht. rig
rig ht
Cutting back adhesive bead py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ If an undamaged window is being re-used, cut back the resid‐

ual adhesive sealant to 1 to 2 mm shortly before bonding it
back in. Do not damage primer and ceramic coating when do‐
ing this.
♦ Remaining material serves as adhesion base for newly ap‐
plied adhesive sealing compound.
WARNING
Exception: if bonding is performed later than one day after cut‐

ting back adhesive bead, the remaining residual material must
be activated with activator .
Apply activator evenly in one stroke using applicator .
Activator must not come in contact with paint, or the paintwork
will be damaged.
Drying time approx. 10 minutes
Exception:
If bonding is not performed immediately after cutting back, the
remaining residual material must be activated with activator -D
181 801 A1- .

Amarok 2011 ➤
1.5 Preparing new window without precoat‐

ing for glazing
Note
♦ The area on which the adhesive bead is applied is not pre‐

coated or primed.
♦ The sealing lip is included with a new windscreen.
♦ No windows are precoated.
– Clean all round edge of window over a width of 20 mm with

cleaning solution -D 009 401 04- .
– Then rub edge of window dry using a lint-free cloth.
WARNING
The ceramic coating on the window is not glass or paint primer!

The ceramic coating must be primed before application of ad‐
hesive sealing compound! Use only glass/paint primer
D 009 200 02!
– Using applicator -D 009 500 25- -1-, apply glass and paint pri‐
mer -2- evenly in one pass.
olkswagen AG
g en AG. V
♦ Drying time approx. 10
Vol
kminutes
swa does
not
y gu
db ara
rise nte
tho eo
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
rrectness of i
l purpos
1.6 Preparing body flange for fitting

nf
ercia
orm
m
atio
om
WARNING
n in
or c
thi
te
sd
a
Keep bonding surface free of dirt and grease.

iv
o
r
rp
cu
o
Do not treat bonding surface with activator immediately after

f
en
ng
t.
yi
cutting back. Do not prime. Do not treat with cleaning solution.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Cut back remaining material on body flange with U-shaped

blade -V.A.G 1561/3- , but do not remove completely.
Note
Remaining material serves as adhesion base for newly applied

adhesive sealing compound. Keep dirt and grease off of bonding
surfaces.
WARNING

be activated with activator .
Apply activator evenly in one stroke using applicator .
. Volkswage AG n AG d
agen oes
Activator must not come in contact withVol paint, or the paintwork
ksw not
gu
will be damaged. d by ara
ise r nte
ho eo
Drying time approx. 10 minutes
sa
ut ra
c
s
ce
le
un
pt
an
d
Exception: If bonding is not performed immediately after cutting

itte
y li
rm
back, the remaining residual material must be activated with ac‐
ab
pe
ility
tivator -D 181 801 A1- .
ot
wit
, is n
♦ If the window flange has been repaired or partially renewed,
h re
hole
the area concerned must be cleaned and primed again after
spec
painting.
es, in part or in w
t to the co
Note
rrectness of i
It is possible that a laser weld seam lies outside the area of the
l purpos
adhesive bead. In this case, the exposed weld seam must be

sealed with glass adhesive before bonding the window.
nform
mercia
– If laser weld seam -3- on metal flange -4- is not covered by

com
tion in
existing adhesive bead -1-, coat laser weld seam -3- with
r
te o
glass/paint primer -D 009 200 02- -3-. Then fill laser weld seam
thi
s
iva
with glass adhesive -DH 009 100 A2- -1-.

do
r
rp
cum
fo
Touching up paint damage

en
ng
t.
yi Co
op
Paint structure must be restored according to specifications in the C py
t. rig
⇒ “Paint” workshop manual .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7 Cleaning off excess adhesive

– Use adhesive remover -D 002 000 10- as a cleaning solution.
Observe the appropriate safety precautions when performing
this work.
WARNING
When cleaning freshly installed glass from the inside in the ve‐
hicle, do not press glass outwards.

Amarok 2011 ➤
– First clean painted surface as well as possible using a dry

cloth. Remove residue using adhesive remover -D 002 000
10- .
Clean plastic trim:
– Allow adhesive sealing compound to cure (approx. 1 hour) and
then pull off.
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 ➤
2 Windscreen
⇒ “2.1 Assembly overview - windscreen”, page 260
⇒ “2.2 Removing and installing windscreen”, page 261
2.1 Assembly overview - windscreen
1 - Windscreen
⇒ page 261
2 - Depth stop
❑ Qty. 5
❑ Cross section of bead:
-width- = 6.5 mm
-height- = 10 mm (in‐
cluding precoating, re‐
sidual material on win‐
dow glass and window
flange).
⇒ page 254 .
4 - Body flange
❑ Touch up paintwork
damage ⇒ page 258 .
5 - Windscreen adjuster
❑ Windscreen adjuster
-443 845 631 A-
6 - Windscreen seal AG. Volkswagen AG d
agen oes
olksw not
❑ Is part of windscreen. d by V gu
ara
rise nte
7 - Plenum chamber cover autho eo
ra
s c
❑ Removing and installing s
ce
le
⇒ page 12
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 ➤
2.2 Removing and installing windscreen
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
by ara
d
The removal of a bonded window is described using orithe
se Removal kit for flush bonded windows nt-V.A.G
ee 1474 A- .
The respective tools from Removal kit for flushs abonded windows -VAS 6452- may also be used.or ac
th
u
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
equipment required
ility
ot p
wit
, is n
h re
ded windows - hole
spec
V.A.G 1474 A- or Removal
es, in part or in w
kit for flush bonded win‐
t to the co
dows -VAS 6452-
rrectness of i
l purpos

V.A.G 1755-
nform
ercia

m
at
om
ion
c
V.A.G 1939-
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.
2. Windscreen 261
Amarok 2011 ➤
V.A.G 1561 A-
♦ Cutting blade -
V.A.G 1561/2-
♦ Cutting blade -
V.A.G 1561/8-
♦ Setting gauge -3371-
♦ Cutting blade -
V.A.G 1561/19-
VAS 5237-
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,
spec
t to the co
Removing
– Removing plenum chamber cover ⇒ page 12 .
– Remove interior mirror ⇒ General body repairs, interior; Rep. rrectne
gr. 68 ; Interior mirror
ss
– Remove A-pillar trim ⇒ General body repairs, interior; Rep.

o
cial p
gr. 70 ; Trim, insulation; Pillar trim .

inform
mer
– Removing front left and right grab handles ⇒ General body

atio
m
repairs, interior; Rep. gr. 68 ; Front grab handle .

o
n
c
i
or
– Removing left and right sun visors ⇒ General body repairs,

thi
te
sd
a
interior; Rep. gr. 68 ; Interior equipment; Compartments, cov‐

iv
o
r
ers and trims .

p
cum
r
fo
en
ng
t.
– Moulded headliner can now be lowered sufficiently to allow
yi Co
op
windscreen to be cut out without damage occurring to moulded
C py
t. rig
gh
headliner.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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
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
ht. rig
rig ht
py by
co Vo
by lksw
– Slide protective backing -V.A.G 1474/8- -1- between front Prote
cted AG.
agen
windscreen and dash panel.
– Pull cutting cord -3- through adhesive sealing material into in‐
side of vehicle using awl -V.A.G 1474/2- .
2. Windscreen 263
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
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.
– Secure inside end of cutting cord against falling out using Pull
toggle -V.A.G 1351/1- -3-.
– Use small tube -1- to insert cutting cord -2- around window
flange.
– Ensure that cutting cord lies under windscreen in corners.

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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
– Position reel device -V.A.G 1654 A- -1-.
AG.

– Turn reel device -V.A.G 1654 A- accordingly and cut wind‐
screen free.
– Counterhold with pull handle -V.A.G 1351/1- -3-.
– Use plastic wedge to press cutting cord -2- against windscreen
while cutting in order to have clearance at window flange and
dash panel.
Installing
Minimum curing period ⇒ page 254 .
Removing broken windscreen
Removing a broken windscreen is performed in the same manner
as removing a broken rear window ⇒ page 271 .
2. Windscreen 265
Amarok 2011 ➤
3 Rear window
⇒ “3.1 Assembly overview - rear window”, page 266
⇒ “3.2 Removing and installing rear window”, page 267
3.1 Assembly overview - rear window
1 - Rear window
rear window
⇒ page 267
❑ Cross section of bead:
-width- = 6.5 mm
-height- = 10 mm (in‐ n AG. Volkswagen AG do
cluding precoating, re‐ olkswage es n
ot g
sidual material on win‐ d byV ua
ran
dow glass and window o
ir se tee
flange). auth or
ac
ss
❑ The adhesive bead is
ce
le
un
butted up against the
pt
an
d
side edge of the win‐

itte
y li
erm
dow.
ab
ility
ot p
wit
is n
⇒ page 254 .
h re
ole,
spec
3 - Body flange
t to the co
4 - Clip
5 - Depth stop
rrectne
❑ Qty. 5
6 - Connectors for window
ss
heater
o
cial p
f i
❑ Left and right.
nform
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 ➤
3.2 Removing and installing rear window
Note
The removal of a bonded window is described using the Removal kit for flush bonded windows -V.A.G 1474 A- .
The respective tools from Removal kit for flush bonded windows -VAS 6452- may also be used.

equipment required
ded windows -
V.A.G 1474 A- or Removal
kit for flush bonded win‐
dows -VAS 6452-
V.A.G 1755-
V.A.G 1939-
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3. Rear window 267

Amarok 2011 ➤
V.A.G 1561 A-
♦ Cutting blade -
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♦ Cutting blade -
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Removing
Note
If the rear window is reused, make sure that the electrical connections for the rear window heating are not
damaged.
– Remove upper C-pillar trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Upper C-pillar trim .
– Pull off connectors for heated rear window (if installed) and
push connector tabs against rear window.
– Release upper real wall trim ⇒ General body repairs, interior ;
Rep. gr. 70 ; Upper real wall trim

AG. Volkswagen AG dAmarok 2011 ➤
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General
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V body repairs, exterior - Edition
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– Take trimming needle -1- from windscreen removal kit -V.A.G

1755- and use handle -2- to force it through adhesive bead.
Look for a place where the gap is the largest.
Note
Protect the paintwork at this place from damage.
– Unscrew handle -2- and thread cutting cord through eye of

needle.
– Pull trimming needle -1- and cutting cord -3- through to inside.
– Use pliers and gloves.
3. Rear window 269

Amarok 2011 ➤
AG. Volkswagen AG d
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– Secure end of cutting cord -2- against falling out using pull
handle -V.A.G 1351/1- -1-.
– Lay ends of cutting cord -2- around rear window and guide
second end of cord inwards as well.

Amarok 2011 ➤
AG. Volkswagen AG d
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– Position reel device -V.A.G 1654 A- -1-.

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spec
– Operate reel device -V.A.G 1654 A- accordingly and cut rear

window free.
t to the co
– Counterhold with pull handle -V.A.G 1351/1- -3-.

– Use plastic wedge to press cutting cord -2- against rear win‐
rrectne
dow while cutting in order to have clearance at window flange

and dash panel.
ss o
Installing
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mer
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Minimum curing period ⇒ page 254 .

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– Protect body and interior from glass splinters.
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– Remove pieces of glass up to adhesive sealing material.
3. Rear window 271

Amarok 2011 ➤
– Pull off connections for rear window heating and aerial.

– Cover flange -2- all round with textile-reinforced adhesive
tape.
– Cut through adhesive seal (with pieces of glass) in window
aperture using electric cutter -V.A.G 1561 A- -1- and U-shaped
blade -V.A.G 1561- .
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General body repairs, exterior ara- Edition 10.2012
ntee
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⇒ “4.1 Assembly overview - front door window”, page 273
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⇒ “4.3 Removing and installing front door window”, page 275
hole
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⇒ “4.4 Removing and installing guide rail”, page 276
es, in part or in w
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⇒ “4.5 Removing and installing rear door window”, page 277
4.1 Assembly overview - front door window
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The right side is shown. The left side is similar.
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⇒ page 275
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⇒ page 103
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3 - Spreader pin
4 - Spreader plug
4. Door windows 273

Amarok 2011 ➤
4.2 Assembly overview - rear door window
1 - Rear door window

⇒ page 277
⇒ page 144
3 - Spreader pin
4 - Spreader plug
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Amarok 2011 ➤
4.3 Removing and installing front door window
Note
Removal is described only for the right door window. Removal of left door window is similar.
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4. Door windows 275

Amarok 2011 ➤
– Screw a 5 mm bolt (approx. 70 mm long) into the spreader pinn AG. Volkswagen A
-4- and pull out from spreader plug -3-. olks
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– Pull spreader plug -3- out of window regulator guide -1- and
es, in part or in w
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therefore out of door window.
– Lift rear of door window -1- and swing forwards out of window
channels.
rrectness of i
Installing
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♦ Installation is described only for the right door window. Instal‐
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– Centre spreader plug -3- in the middle and insert spreader plug
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with the window -1- removed.
– Press spreader pin -4- flush into spreader plug -3-.
– Guide door window -1- into door -2- and insert door window
-1- into slot in window regulator guide.
– Make door window -1- engage in window regulator -2- by
pressing slightly from above.
al.
• Carry out functional test before fitting door trim.
4.4 Removing and installing guide rail

Removing
– Remove bolts -2- and remove guide rail -1- through opening
in door.
Installing
Specified torques
Guide rail 1.5 Nm

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4.5 Removing and installing rear door window
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Removal is described only for the right door window. Removal of left door window is similar.
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Removing
– Lower door window until spreader pin -4- and spreader plug
-3- in cut-out of window regulator are accessible.
Note
If the work sequence cannot be carried out because there is a fault with the electric window motor, remove
motor to slide window down.
4. Door windows 277

Amarok 2011 ➤
– Screw a 5 mm bolt (approx. 70 mm long) into the spreader pin

-4- and pull out from spreader plug -3-.
– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug
-3-.
Note
♦ When screwing bolt into spreader plug, do not apply excessive pressure on plug.
♦ It otherwise falls inwards into door.
– Pull spreader plug -3- out of window regulator guide -1- and
therefore out of door window.
– Put door window -1- down.
– Remove fixed door-window ⇒ page 281 .
– Guide door window -1- upwards out of door.
Installing
Note
♦ Installation is described only for the right door window. Installation of left door window is similar.
♦ When installing a door window, always renew spreader plug and spreader pin.
♦ Before inserting spreader plug -3- and spreader pin -4-, check window glass -1- for damage.
AG. Volkswagen AG d
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Amarok 2011 ➤
AG. Volkswagen AG d
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– Guide door window aut-3- downwards in door -2- and put it down. ra
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– Install fixed door-window -1- ⇒ page 281 .

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Cop py
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279
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4. Door windows
AG.
Amarok 2011 ➤
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– Centre spreader plug -3- in the middle and insert spreader plug
with the window -1- removed.
ss
– Press spreader pin -4- flush into spreader plug -3-.

o
cial p
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– Guide door window -1- into door -2- and insert door window
mer
-1- into slot in window regulator guide.

atio
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– Make door window -1- engage in window regulator -2- by

i
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pressing slightly from above.

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• Carry out functional test before fitting door trim.
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Prote AG.

Amarok 2011 ➤
4.6 Removing and installing fixed door-window
Note
Removal and installation are described only for the right fixed door-window. Removal and installation of the left
fixed door-window is analogous.
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Removing
– Remove window slot inner seal.
– Rotate window bar -2- 90°.
– Guide window bar -2- upwards out of window guide.
4. Door windows 281

Amarok 2011 ➤
AG. Volkswagen AG d
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– Roll window guide seal off sheet metal flange.

– Guide fixed door-window -1- upwards out of door -2-.
– Guide door window -3- upwards out of door -2-.
Installing

Amarok 2011 ➤
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– Guide door window -3- downwards into door -2-.

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– Roll window guide seal onto sheet metal flange.
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4. Door windows 283

Amarok 2011 ➤
AG. Volkswagen AG d
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– Rotate window bar -2- 90°.

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– Guide window bar -2- at an angle upwards into window guide.

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– Tighten bolts -3-. Specified torque: 9 Nm

h re
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– Install window slot inner seal.

t to the co

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AG. Volkswagen AG d
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General body gu repairs, exterior
ara - Edition 10.2012
ise nte
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66 – Exterior equipment
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1 Radiator grille and front trim
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⇒ “1.1 Assembly overview - radiator grille”, page 285
h re
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spec
⇒ “1.2 Removing and installing radiator grille”, page 286
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1.1 Assembly overview - radiator grille
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1 - Radiator grille
ss
⇒ page 286
o
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2 - Emblem
form
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⇒ page 311
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❑ Upper left
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4 - Trim strip
❑ Lower left
grille -1-.
moved
5 - Trim strip
❑ Lower right
grille -1-.
moved
6 - Trim strip
❑ Upper right
grille -1-.
with radiator grille -1- removed
7 - Clip
❑ Qty. 4
1. Radiator grille and front trim 285

Amarok 2011 ➤
1.2 Removing and installing radiator grille
AG. Volkswagen AG d
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Removing
– Pull radiator grille -1- parallel in -direction of arrow- out of
catches -arrows- in front bumper cover -2-.
Installing
286 Rep. gr.66 - Exterior equipment

Amarok 2011 ➤
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– Guide radiator grille -1- into front aubumper cover -2- in direction
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– With slight pressure, clip radiator grille -1- into front bumper
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wit
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287
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Prote 1. Radiator grille and front trim
AG.
Amarok 2011 ➤
2 Mouldings, trims, extensions

⇒ “2.1 Assembly overview - heat shield”, page 288
2.1 Assembly overview - heat shield
1 - Engine compartment heat

shield
❑ Removing:
❑ Removing parts of ex‐
haust system ⇒ Power
unit; Rep. gr. 26 ; Parts
of exhaust system
2 - Retainer
❑ Qty. 3
3 - Tunnel heat shield, front
❑ Removing:
❑ Removing parts of ex‐
haust system ⇒ Power
unit; Rep. gr. 26 ; Parts
of exhaust system
4 - Retainer
❑ Qty. 3
5 - Floor heat shield, rear
❑ Removing:
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❑ Qty. 4
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Cop py
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by lksw
cted agen
Prote AG.

Amarok 2011 ➤
3 Engine/gearbox guard
⇒ “3.1 Assembly overview - engine/gearbox guard”, page 289
⇒ “3.2 Removing and installing engine/gearbox guard”,
page 289
3.1 Assembly overview - engine/gearbox guard
1 - Engine/gearbox guard
⇒ page 289
2 - Bolt
❑ Qty. 4
3 - Bolt
❑ Qty. 2
4 - Bolt
❑ Qty. 2 wage
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mer
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3.2 Removing and installing engine/gear‐

t.
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box guard
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Special tools and workshop equipment required Prote
cted AG.
agen
3. Engine/gearbox guard 289

lkswage es n
Vo ot g
Amarok 2011 ➤ d by ua
ran
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tho exterior - Edition 10.2012 tee
or
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Removing
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Prote AG.
– Remove bolts -2-, -3- and -4-.

– Remove engine/gearbox guard -1- downwards.
Installing

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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Cop py
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pyri by
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Prote AG.
– Install engine/gearbox guard -1-.

Comply with installation sequence!
– First position bolts -4-, then bolts -2-, and then bolts -3-.
– ⇒ “3.1 Assembly overview - engine/gearbox guard”,
page 289
3. Engine/gearbox guard 291

Amarok 2011 ➤
4 Roof moulding and roof railing

⇒ “4.1 Renewing roof strip”, page 292
4.1 Renewing roof strip

Fitting notes
♦ Warm roof moulding with hot air blower -V.A.G 1416- before
removing.
♦ If a roof moulding is installed for the first time on a new vehicle
and newly painted surfaces, follow the procedure in ⇒ Work‐
shop manual "Paint"; ⇒Paintwork repairs; ⇒Paint finish; ⇒
Mouldings and film .
♦ If a roof moulding is removed and reinstalled, only use adhe‐ G. Volkswagen AG d
sive remover -D 002 000 10- to remove the adhesive remains. lkswagen A oes
not
Vo gu
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♦ Stick on roof moulding immediately after cleaning.s au ac
s
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♦ Remove backing only immediately before installation.

nl
pt
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an
itte
♦ Working temperature is approx. 21 ℃.
y li
erm
ab
ility
♦ Roof moulding cannot be removed without damage.
ot p
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, is n
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hole
Note spec
es, in part or in w
t to the co
Renewing roof moulding is described only for the left side. The right side is similar.
rrectness of i
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nf
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Cop py
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by
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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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y V gu
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Removing
ility
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– Heat roof moulding -1- with a hot air blower -V.A.G 1416- and
h re
pull it off roof -2-.
hole
spec
es, in part or in w
Installing
t to the co
– Follow installation instructions ⇒ page 292 .
– Thoroughly clean bonding surface immediately before sticking
rrectness of i
on.
l purpos
– Pull off backing -3- in -direction of arrow-.

– Position roof moulding -1- on front edge of roof (windscreen).
nf
ercia
orm
– Press roof moulding -1- on forcefully along the entire length.

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Prote AG.
4. Roof moulding and roof railing 293

Amarok 2011 ➤
5 Exterior mirror
⇒ “5.1 Assembly overview - exterior mirror”, page 294 agen
AG. Volkswagen AG d
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⇒ “5.2 Removing and installing mirror glass”, page 294 ed b y ara
nte
ris
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⇒ “5.3 Removing and installing housing frame”, page aut 297
h
ra
ss c
⇒ “5.4 Removing and installing mirror housing”, page 299
ce
e
nl
pt
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an
⇒ “5.5 Removing and installing exterior mirror”, page 300
itte
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5.1 Assembly overview - exterior mirror
ility
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Note
es, in part or in w
t to the co
rrectness of i
1 - Mirror mounting
l purpos

⇒ page 300
nform
ercia
2 - Bolt
m
at
om
i
❑ Qty. 3
on
c
in t
or
his
ate
Nm
do
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cum
or
3 - Lower trim
f
en
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t.
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❑ Removing and installing Cop py
⇒ page 299
t. rig
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pyri by
Vo
co
4 - Housing frame
by lksw
cted agen
Prote AG.
⇒ page 297
5 - Bolt
❑ Qty. 2
Nm
6 - Mirror housing
⇒ page 299
7 - Mirror glass
⇒ page 294
5.2 Removing and installing mirror glass


Amarok 2011 ➤
♦ Removal lever -80 - 200-
Note
The removal and installation sequence is only for the left mirror n AG. Volkswagen AG do
wage
glass. The removal and installation of the right mirror glass
yV
o is
lks es n
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similar. ise
d b ua
ran
r tee
ho
aut or
ac
ss
WARNING
ce
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nl
pt
du
an
itte
y li
When doing this repair work, always wear safety goggles and
erm
ab
leather gloves!
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
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sd
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Prote AG.
5. Exterior mirror 295

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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Removing
ng
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op py
– Protect housing edges to prevent damage to paintwork with, t. C rig
gh ht
for example, textile reinforced tape. pyri by
Vo
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– Press bottom of mirror glass -1- in -direction of arrow- into Prote AG.
mirror housing.
– Using removal lever -80 - 200- , press mirror glass -1- in
-direction of arrow B- out of adjustment unit.
Note
Clip -3- Qty. 6
– Swivel mirror glass -1- to side and detach connectors -2- for
electric anti-dazzle and mirror heating on back of mirror glass
-1-.
Installing
– Push contacts -2- for mirror heating onto mirror glass -1-.
– Push mirror glass -1- centrally onto adjustment unit in housing.
– Mirror glass -1- clicks audibly into clip -3-.

Amarok 2011 ➤
• Then check the function.
5.3 Removing and installing housing frame

AG. Volkswagen AG d
agen oes
olksw not
Note ed byV gu
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The removal and
ss a installation sequence is only for the left housing ra
cframe. The removal and installation of the
right housing frame is similar.
ce
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nl
pt
du
an
itte
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erm
ab
ility
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spec
es, in part or in w
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ion
c
in t
or
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ate
do
priv
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for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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nf
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Removing
agen
Prote AG.
– Remove mirror glass ⇒ page 294 .

– Remove 2 bolts -4-.
– Break off clips -2- (qty. 2) at top towards mirror housing.
– Release retaining hook -3- and pull housing frame -1- off for‐
wards.
Installing
– Push housing frame -1- centrally onto mirror mounting.
– Housing frame -1- engages audibly.
Specified torques
♦ Bolts -4- ⇒ Item 5 (page 294)

Amarok 2011 ➤
5.4 Removing and installing mirror housing
Note
♦ The removal and installation sequence is only for the left mirror housing. The removal and installation of the
right mirror housing is similar.
♦ If there is any damage on and inside the exterior mirror, the mirror housing and lower trim must be replaced.
The mirror housing needs to be painted depending on the equipment.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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un
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es, in part or in w
t to the co
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nform
mercia
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tion in
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do
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t.
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Cop py
t. rig
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Removing
op Vo
by c lksw
cted agen
Prote AG.
– Remove housing frame ⇒ page 297 .
– Detach connector -2-.
– Disconnect clips from mirror housing -1- and lower trim -4-
(qty. 5).
– To do this, press mirror housing -1- and lower trim -4- apart in
-direction of arrow-.
– Remove mirror housing -1- and lower trim -4- off mirror mount‐
ing -3-.

Amarok 2011 ➤
General body repairs,waexterior
gen AG - Editionn A
. Volkswage 10.2012
G do
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ks s no
Vol t gu
by ara
Installing ris
ed
nte
utho eo
– Press mirrorsshousing
lower trim -4- a -1- and together on mirror r ac
mounting -3- (clip engages audibly).
ce
e
nl
pt
du
an
Further installation is performed in the reverse order of removal.
itte
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erm
ab
5.5 Removing and installing exterior mirror
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The removal and installation sequence is only for the left exterior mirror. The removal and installation of the
right exterior mirror is similar.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove front door trim cover ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Door trims .
– Remove front door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims/insulation; Door trims .
– Disconnect earth cable and connectors -3- from subframe.
– Remove screws -2- and take exterior mirror -1- off door.

Amarok 2011 ➤
– Pull out cable through hole in door.

Installing
– Fit exterior mirror -1- and clip it in.
Tighten screws in following sequence:
– Pull off exterior mirror -1- frontwards and upwards.
– First tighten lower screw, then upper screw and finally centre
screw.
Further installation of mirror -1- is carried out in reverse order of
removal.
Specified torques
♦ Bolts -3- ⇒ Item 2 (page 294)
AG. Volkswagen AG d
agen oes
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wit
, is n
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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
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cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
6 Wheel housing liner

⇒ “6.1 Assembly overview - front wheel housing liner”,
page 302
⇒ “6.2 Assembly overview - fasteners for rear wheel housing lin‐
er”, page 303
⇒ “6.3 Assembly overview - rear wheel housing liner”,
page 304
⇒ “6.4 Removing and installing front wheel housing liner”,
page 304 n AG. Volkswagen AG do
lkswage es n
⇒ “6.5 Removing and installing rear wheel housing liner”, d byV
o ot g
ua
page 306 o
ir se
ran
tee
th or
u
6.1 Assembly overview - front wheel housing liner
a ac
ss
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itte
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Note
erm
ab
ility
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♦ Minor differences to the description may be encountered, depending on vehicle model.
spec
t to the co
1 - Front wheel housing liner
rrectne
⇒ page 304
ss
2 - Bolt
o
cial p
f i
❑ Qty. 11
nform
mer
atio
m
Nm
o
n
c
i
or
n
3 - Hexagon nut
thi
te
sd
va
❑ Qty. 2
i
o
pr
cum
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fo
4 - Bolt
en
ng
t.
yi Co
op
❑ Specified torque: 6.0 C py
t. rig
Nm
gh ht
pyri by
Vo
co
❑ Bolted to front bumper
by lksw
cted agen
cover.
Prote AG.
5 - Expanding nut
❑ Qty. 8

Amarok 2011 ➤
6.2 Assembly overview - fasteners for rear wheel housing liner
Note

1 - Expanding nut
2 - T-pin
3 - Buffer
❑ Buffer must be drawn
over T-pin.
AG. Volkswagen AG d
agen oes
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spec
t to the co
rrectness o
cial p
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mer
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or
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
6. Wheel housing liner 303

Amarok 2011 ➤
6.3 Assembly overview - rear wheel housing liner
Note

1 - Rear wheel housing liner

⇒ page 306
2 - Hexagon nut
❑ Qty. 3
AG. Volkswagen AG d
❑ Specified torque: l2.0
ksw
agen oes
not
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Vo gu
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ise
3 - Bolt ut
ho
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or
a ac
❑ Qty. 8ss
ce
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nl
❑ Specified torque: 2.0 pt

du
Nm an
itte
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ility
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hole
spec
es, in part or in w
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rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6.4 Removing and installing front wheel

housing liner

Amarok 2011 ➤
Note
♦ The removal and installation sequence is only for the left wheel housing liner. Removal and installation of
the right wheel housing liner are similar.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Removing
– Remove wheel ⇒ Running gear; Rep. gr. 44 ; Specified tor‐
ques for wheel bolts .
– Remove bolts -2- and -4-.
– Unscrew hexagon nut -3-.
– Pull wheel housing liner -1- out of wing.
Installing
Note
Check spreader nuts -5- for damage and renew if necessary.
– Insert wheel housing liner -1- into wing.

– Position bolts and hexagon nut and tighten.
Specified torques
♦ ⇒ “6.1 Assembly overview - front wheel housing liner”,
page 302 agen
AG. Volkswagen AG d
oes
olksw not
V gu
6.5 Removing and installing rear wheel by ara
d
rise nte
o
housing liner th eo
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
rrectness of i
l purpos
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
♦ The removal and installation sequence is for the rear left wheel housing liner only. Removal and installation
do
r
rp
of the rear right wheel housing liner is similar.

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

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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Remove wheel ⇒ Running gear; Rep. gr. 44 ; Specified tor‐

ques for wheel bolts
nf
ercia

orm
m
atio
– Unscrew hexagon nut -2-.

om
n in
c
– Pull rear wheel housing liner -1- out of wheel house.

or
thi
te
sd
iva
Installing
o
r
rp
cu
o
m
f
– Insert rear wheel housing liner -1- into wheel house.

en
ng
t.
yi Co
op py
Specified torques . C rig
ht ht
rig by
py
♦ ⇒ “6.3 Assembly overview - rear wheel housing liner”,
co Vo
by lksw
cted
page 304
agen
Prote AG.

Amarok 2011 ➤
7 Lettering and emblems

⇒ “7.1 Dimensions - lettering and emblems”, page 308
⇒ “7.2 Removing and installing radiator grille emblem”,
page 311
⇒ “7.3 Removing and installing emblem on tailgate”, page 312
7.1 Dimensions - lettering and emblems

Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
♦ Hot air blower -V.A.G 1416- olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
♦ Adhesive strip remover -VAS 6349-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ The vertical and horizontal dimensions of lettering for the dif‐

ferent engines is identical.
♦ When attaching the lettering, observe the fitting notes below.
Fitting notes
♦ Heat lettering or emblem with hot air blower -V.A.G 1416- be‐
fore removing.
♦ If lettering or an emblem is applied for the first time to a new
vehicle or a newly painted surface, follow the procedure de‐
scribed in ⇒ Workshop manual "Paint" ⇒ Paintwork repairs ⇒
Paint finish ⇒ Mouldings and film .
♦ If the lettering or emblem is removed and reinstalled, use only
adhesive remover -D 002 000 10- to remove residual adhe‐
sive.
♦ Remove existing adhesive residue of adhesive tape using ad‐
hesive strip remover -VAS 6349- .

Amarok 2011 ➤
♦ Lettering or emblem must be bonded in place immediately af‐

ter cleaning.
♦ Remove backing only immediately before installation.
♦ Working temperature is approx. 21°C.
♦ Bonded lettering or emblems cannot be removed without be‐
ing damaged.
AG. Volkswagen AG d
Rear lid lettering ksw
agen oes
not
Vol
by gu
d ara
rise nte
o eo
Note auth
ra
ss c
ce
le
Follow the fitting notes when applying the lettering ⇒ page 308
un
pt
an
d
itte
y li
rm
ab
pe
ility
1 - Lettering
ot
wit
, is n
h re
❑ Model designation.
hole
spec
2 - Rear lid
es, in part or in w
t to the co
3 - Height dimension
❑ 66 mm from edge in rear
lid to lettering.
rrectness of i
4 - Horizontal dimension
l purpos
❑ 31 mm from outer edge

of rear lid to lettering.
nform
ercia
5 - Lettering
m
a
com
tio
❑ Engine designation.
n in
r
te o
thi
s
iva
do
r

rp
cum
fo
lid to lettering.
en
ng
t.
yi Co
op
7 - Horizontal dimension C py
t. rig
gh ht
yri
❑ 41 mm from outer edge p by
co Vo
by lksw
cted agen
Prote AG.
Tailgate lettering, 4 MOTION
Note
Follow the fitting notes when applying the lettering ⇒ page 308
7. Lettering and emblems 309

Amarok 2011 ➤
1 - Lettering
❑ Engine designation.
2 - Lettering
❑ Model designation.
3 - Rear lid
❑ 12 mm gap between
edges of lettering.
lid to lettering.
6 - Horizontal dimension
❑ 41 mm from outer edge
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
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.

Amarok 2011 ➤
7.2 Removing and installing radiator grille

emblem
Removing
– Release hooks -arrows- on back of emblem -1-.
– Rotate emblem -2- slightly in -direction of arrow- and pull for‐
ward out of radiator grille -2-.
AG. Volkswagen AG d
agen
Installing olksw
oes
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
– Guide emblem -1- with its retaining hooks in notches into ra‐
l purpos
diator grille -2-.

– Turn emblem -1- slightly in -direction of arrow- until emblem
nf
ercia
-1- engages in radiator grille -2-.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Lettering and emblems 311

Amarok 2011 ➤
7.3 Removing and installing emblem on tailgate
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
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
Removing t. Cop py
rig
gh ht
yri
– Warm emblem -2- with hot air blower -V.A.G 1416- before re‐ p by
o Vo
by c
moving.
lksw
cted agen
Prote AG.
– Lever off emblem -2- from tailgate -1- using removing wedge
-3409- .
Installing
– Remove protective paper from adhesive foam tape.
– Position emblem -2- with centring pins in embossings
-arrows- on tailgate -1-.
– Press emblem -2- on firmly.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
8 Wheel arch trim (PR No. “0FA”)
yV
b gu
d ara
ise nte
or eo
h
ut
⇒ “8.1 Repair instructions”,
ss a page 313 ra
c
ce
le
⇒ “8.2 Removing and installing wheel arch trim, wing”,
un
pt
an
page 317
d
itte
y li
erm
ab
⇒ “8.3 Removing and installing wheel arch trim - left load bed”,
ility
ot p
page 321
wit
is n
h re
⇒ “8.4 Removing and installing wheel arch trim - right load bed”,
ole,
spec
page 325
t to the co
8.1 Repair instructions
⇒ “8.1.1 Safety requirements”, page 313
rrectne
⇒ “8.1.2 Installation instructions for wheel arch trims”, page 313
s
⇒ “8.1.3 Preparing new add-on part for bonding”, page 314
s o
cial p
f in
⇒ “8.1.4 Preparing body component for bonding”, page 314
form
mer
⇒ “8.1.5 Installation instructions for wheel arch trims”, page 315
atio
om
n
c
⇒ “8.1.6 Minimum curing period”, page 316
i
or
n thi
te
sd
a
⇒ “8.1.7 Touching up paint damage”, page 316

iv
o
pr
cum
r
fo
⇒ “8.1.8 Cleaning off excess adhesive sealing material”,
en
ng
t.
yi
page 316
Co
Cop py
ht. rig
⇒ “8.1.9 Cleaning guidelines”, page 317 rig ht
py by
co Vo
by lksw
8.1.1 Safety requirements
cted agen
Prote AG.
Caution
When removing extensions, use suitable gloves and protective

eyewear.
Do not use cutting wire to remove extensions.
Extensions must cure at least 3 hours after being bonded be‐
fore work on the vehicle is continued.
Note
♦ The following wheel arch trims have been developed to fulfil

the technical requirements of the respective models. These
extensions should always be replaced with the corresponding
genuine parts.
♦ Without these extensions, the vehicle does not comply with
traffic regulations.
8.1.2 Installation instructions for wheel arch

trims
The wheel arch trim is factory-bonded with double-sided adhesive
tape and 1-component PU adhesive.
The wheel arch trim is primed by the supplier and delivered with
double-sided adhesive tape.
Ensure that backing of double-sided adhesive tape strips remains
free of paint and paint mist when painting extensions.
8. Wheel arch trim (PR No. “0FA”) 313

Amarok 2011 ➤
Temperatures of the room, the work bay and the vehicle must be
approximately the same (18 °C and max. 30 °C).
Remove existing adhesive tape residues with adhesive remains
remover -VAS 6349- . n AG. Volkswagen A G do ge
es n swa
Always use a clean, lint-free
by
Vcloth
olk for cleaning. ot g
ua
ed ran
oris
Immediately before attaching add-on parts, clean bonding surfa‐ tee
th or
ces using adhesive
ss
aremover and then carefully remove dirt,
u ac
grease, wax and other impurities using plastic cleaner.
ce
e
nl
pt
du
an
• Observe the appropriate safety precautions when cleaning.
itte
y li
erm
ab
Remove backing only immediately before installation.
ility
ot p
wit
Before washing and preserving the vehicle, ensure that the wheel
, is n
h re
arch trims have been bonded for at least 3.5 hours.
hole
spec
8.1.3 Preparing new add-on part for bonding
es, in part or in w
t to the co
WARNING
rrectness of i
Before painting, use masking tape to precisely demarcate all
l purpos
priming and bonding surfaces.
nform
ercia
For 1-component glass adhesive

m
at
om
ion
– The bonding surfaces of the add-on parts must be prepared
c
in t
or
with plastic primer.

his
ate
do
riv
– Apply 1-component glass adhesive at specified positions on

p
cum
or
add-on parts using cartridge gun -V.A.G 1628- .

f
en
ng
t.
yi Co
op
8.1.4 Preparing body component for bonding
C py
t. rig
gh ht
pyri by
Vo
o
– Remove existing adhesive residue of double-sided adhesive by c lksw
cted agen
tape using adhesive strip remover -VAS 6349- . Prote AG.
– Cut back adhesive points of PUR adhesive to about 2 - 3 mm

without damaging paintwork.
– The cut surfaces do not require additional cleaning.
Note

adhesive sealing compound.
– Observe cleaning instructions for adjacent components

⇒ page 317 .
– New special add-on parts may be attached immediately at the
prescribed positions with the adhesive points.
If the body part has been repaired or partially renewed, the area
concerned must be cleaned and primed again after painting.
If a body part is fitted for the first time on a new vehicle or on newly
painted surfaces, follow the procedure in ⇒ Workshop manual
"Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings and film .

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Amarok 2011 ➤
u
ss
a
General body repairs, ac
exterior - Edition 10.2012
ce
le
un
pt
an
d
itte
y li
WARNING
erm
ab
ility
ot p
wit
is n
h re
ole,
be activated with activator -D 181 801 A1- .
spec
Apply activator evenly in one stroke using applicator.
t to the co
will be damaged.
rrectne
Drying time approx. 10 minutes.
ss o
cial p
f in
form
mer
trims
atio
om
n
c
i
or
n
thi
te
sd
iva
o
pr
cum
WARNING
r
fo
en
ng
t.
yi Co
op
Add-on parts should be installed within 10 minutes, or bonding
C py
t. rig
gh
properties of adhesive will be impaired.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Gaps/shut lines should be kept to an absolute minimum.

♦ Use adhesive tape to secure add-on parts in position during
minimum curing time.
♦ The surfaces to be primed must be free from impurities
♦ If no cleanser is specified in the respective repair procedure,
use silicone remover.
– Remove adhesive residue using adhesive remover.

– Clean application area for adhesive bead twice thoroughly us‐
ing cleanser named in repair procedure and allow to dry.
– Now apply glass/paint primer evenly in one stroke using ap‐
plicator.
♦ Drying time approx. 10 minutes
– Apply adhesive sealing material to primed areas of attachment
parts.
– Max. of 6 minutes waiting time between application of adhe‐
sive and fitting of add-on parts.
Materials
Note

parts catalogue .
♦ Activator 1) 5)
♦ Glass and paint primer 1) 5)

Amarok 2011 ➤
♦ Plastic primer 1) 5)
♦ Cleaning solution 1) 5)
♦ Primer applicator 1) 5)
♦ Adhesive remover 1) 5)
♦ Cutting cord 5)

3)Use cartridge gun -V.A.G 1628- to apply 1-component glass
adhesive.
5 The part numbers of the materials can be found in the ⇒ elec‐
tronic parts catalogue (ETKA) .
8.1.6 Minimum curing period

The minimum curing time is the time from bonding the add-on
AG. Volkswagen AG d
parts until the vehicle may be used. lksw
agen oes
n o ot g
yV ua
Wait 3.5 hours before continuing work when bonding
ris
edis done with
b ran
tee
double-sided adhesive tape and 1-component glass
ut
ho adhesive. or
sa ac
During this time, the vehicle must stand on a slevel surface and
ce
le
the room and object temperatures must be at least 18 ℃.

un
pt
an
d
itte
y li
Do not apply any direct load to bonding surfaces for at least 24
rm
ab
hours after installation.
pe
ility
ot
wit
, is n
h re
WARNING
hole
spec
es, in part or in w

t to the co
ted.
rrectness of i
8.1.7 Touching up paint damage

l purpos
Paint structure must be restored according to specifications in the

nform
mercia
8.1.8 Cleaning off excess adhesive sealing

a
com
tion in
material
r
te o
thi
s
iva
do
r
rp
cum
fo
Note
en
ng
t.
yi Co
op py
Use adhesive remover as a cleaning solution. Observe the ap‐
t. C rig
gh ht
yri
propriate safety precautions when performing this work. p by
co Vo
by lksw
cted agen
Prote AG.
– If necessary, lift off escaping adhesive with a piece of card‐
board.
– Clean painted surface as well as possible using a dry cloth.
– Remove residue using adhesive remover.

Amarok 2011 ➤
8.1.9 Cleaning guidelines

– Immediately before installing special add-ones, clean bonding
surface thoroughly with adhesive remover.
– Then use plastic cleaner to carefully remove dirt, grease, wax
and other contaminants.
• Always use a clean, lint-free cloth for cleaning.

trim, wing
♦ Removal wedge -3409- 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

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
Note
agen
Prote AG.
The removal and installation procedure is for the left side. The
right side is similar.

Amarok 2011 ➤
Assembly overview - application of adhesive to wheel arch trim,

wing
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
1 - Wheel arch trim, wing rised ara
nte
ho eo
2 - PUR adhesive sealant aut ra
ss c
ce
e
Bead section -a-
nl
pt
du
an
itte
❑ -Length- = approx.
y li
erm
ab
900 mm -height- = ap‐
ility
ot p
prox. 9.0 mm -width- =
wit
, is n
approx. 5.0 mm
h re
hole
spec
Bead section -b-
es, in part or in w
t to the co
❑ -Length- = approx. 500
mm -height- = approx.
12 mm -width- = approx.
rrectness of i
8.0 mm
l purpos
Bead section -c-

nf
ercia
or
6.0 mm -width- = ap‐
m
m
atio
prox. 3.0 mm
om
n in
or c
Section -d-
thi
te
sd
iva
❑ Distance of PUR sealing
o
r
rp
cu
material to hole, approx.
o
m
f
en
ng
15 mm (adhesive must
t.
yi Co
op
not enter hole) C py
t. rig
gh ht
yri
Section -e-
p by
o Vo
by c lksw
cted agen
Prote AG.
material to edge, ap‐

prox. 15 mm (adhesive
must not go over edge)
Removing
Note
♦ Wheel arch trim, wing, -1- cannot be removed without damaging it.
♦ Depending on wheel arch trim on front bumper cover, the locating pins -arrows- must be noted. It is possible
that the types of pins are mixed.

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
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
– Before removing wheel arch cover, wing -1-, heat the bonding
r
rp
cum
area -2- using hot air blower -V.A.G 1416- .

fo
en
ng
t.
yi
– Lift one corner of wheel arch trim, wing, -1- using removal
Co
Cop py
wedge -3409- .
t. rig
gh ht
pyri by
Vo
o
– Grip under wheel arch trim, wing, -1- and carefully but firmly
by c lksw
cted agen
pull from wing -3-.
Prote AG.
Installing

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
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
g
Preparing body component for bonding ⇒ page 314 .

n
t.
yi Co
Cop py
Installation instructions ⇒ page 315
t. rig
gh ht
pyri by
Vo
o
by c
– Apply PUR adhesive beneath rib (primed area) ⇒ page 318 .
lksw
cted agen
Prote AG.
Note
Depending on wheel arch trim, front bumper cover, the locating pins -arrows- must be removed.
– Insert the 2 locating pins -arrows- in the wheel arch trim, front
bumper cover.
– Position wheel arch trim, wing, -1- using swage line -3- and
check that edges are flush and aligned.
– Bolt on wheel arch trim, wing, -1- using wheel housing liner
bolts -5- ⇒ page 304 .
– Pull protective backing -4- off double-sided adhesive tape
-2-.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Press wheel arch trim by V -1- on forcefully in complete area
o gu of
ara
double-sided adhesive
rised
tape -2-, from front to rear. nte
ho eo
ut
– Tighten bolt
ss a -6-. ra
c
ce
e
nl
pt
du
an
itte
y li
Specified torques
erm
ab
ility
ot p
wit
, is n
h re
Bolt -6- 2.0 Nm
hole
spec
es, in part or in w
8.3 Removing and installing wheel arch trim
t to the co
- left load bed
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.

left load bed

Amarok 2011 ➤
1 - Wheel arch trim, left load

bed
Bead section -a-
prox. 3.0 mm
Bead section -b-
8.0 mm
Bead section -c-
prox. 5.0 mm
Bead section -d-
prox. 5.0 mm
Bead section -e-
8.0 mm
Bead section -f- wage
es n
olks ot g
❑ -Length- = approx. 50 byV ua
d ran
mm -height- = approx. ir se tee
ho
6.0 mm -width- = ap‐ aut or
ac
prox. 3.0 mm ss
ce
e
nl
pt
du
Section -g-
an
itte
y li
erm
ab
❑ Start of application, approx. 20 mm downwards.

ility
ot p
wit
Section -h-
, is n
h re
hole
❑ End of application, approx. 30 mm parallel to edge, distance approx. 15 mm.

spec
es, in part or in w
Section -i-
t to the co
❑ Distance of PUR sealing material to hole, approx. 15 mm (adhesive must not enter hole)
rrectness of i
Section -j-
l purpos
❑ Distance of PUR sealing material to edge, approx. 15 mm (adhesive must not go over edge)
nf
ercia
Removing
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
Wheel arch trim, left load bed, -1- cannot be removed without damaging it.
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 ➤
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
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.

– Before removing wheel arch cover, left load bed -1-, heat
bonding area -2- using hot air blower -V.A.G 1416- .
– Lift one corner of wheel arch trim, left load bed, -1- using re‐
moval wedge -3409- .
– Grip under wheel arch trim, left load bed, -1- and carefully but
firmly pull off from component.
Installing

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
ercia

m
at
om
io

n
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
yri
It is advisable to position wheel arch trim, left load bed -1- with the help of a second mechanic. p by
co Vo
by lksw
cted agen
Prote AG.
– Position wheel arch trim, left load bed, -1- using swage line
-6- and check flushness.
– Bolt on wheel arch trim, left load bed, -1- using rear wheel
housing liner bolts -4- ⇒ page 304 .
– Pull backing -7- off double-sided adhesive tape -2-.
– Forcefully press on wheel arch trim -1- along the entire area
of the double-sided adhesive tape -2-, starting from the centre
under the tank flap aperture and moving first towards the front
and then towards the rear.

Amarok 2011 ➤

Specified torques
Bolts -3- 2.0 Nm
8.4 Removing and installing owheel agen arch trim AG does

AG. gen Volkswa
lksw not
- right load bed
V gu
d by ara
ise n r tee
ho
Special tools and workshop equipment
sa
ut required or
ac
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
co lksw
by
cted agen
Prote AG.

right load bed

Amarok 2011 ➤
1 - Wheel arch trim, right load

bed
AG. Volkswagen AG d
Bead section -a- agen oes
olksw not
byV gu
ara
❑ -Length- = approx. 50 rised
nte
mm -height- = approx. ut
ho eo
ra
6.0 mm -width- = ap‐ ss a c
prox. 3.0 mm
ce
e
nl
pt
du
an
Bead section -b-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
7.0 mm
spec
es, in part or in w
Bead section -c-
t to the co
1,350 mm -height- = ap‐
rrectness of i
prox. 9.0 mm -width- =
approx. 5.0 mm
l purpos
Bead section -d-
nf
ercia
orm
m
atio
m
o
n in
c
6.0 mm
or
thi
te
sd
a
Bead section -e-

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
op py
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rig
prox. 3.0 mm py by
co Vo
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Section -f-
agen
Prote AG.

material to hole, approx.
15 mm (adhesive must
not enter hole)
Section -g-
❑ Distance of PUR sealing material to edge, approx. 15 mm (adhesive must not go over edge)
Removing
Note
Wheel arch trim, right load bed, -1- cannot be removed without damaging it.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.

– Before removing wheel arch cover, right load bed -1-, heat
bonding area -2- using hot air blower -V.A.G 1416- .
– Lift one corner of wheel arch trim, right load bed, -1- using
– Grip under wheel arch trim, right load bed, -1- and carefully
but firmly pull off from component.
Installing

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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
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te
sd
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t.
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Cop py
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Installation instructions for wheel arch trims ⇒ page 313 . cop Vo
by lksw
cted agen
Prote
AG.

Note
It is advisable to position wheel arch trim, left load bed -1- with the help of a second mechanic.
– Position and secure wheel arch trim, right load bed -1- using
threaded connection -7-.
– Position wheel arch trim, left load bed, -1- using swage line
-6- and check flushness.
– Bolt on wheel arch trim, right load bed, -1- using rear wheel

Amarok 2011 ➤
– Press on wheel arch trim -1- forcefully along entire area of

double-sided adhesive tape -2-, starting from middle and
working forwards and rearwards.
Specified torques
Bolts -3- 2.0 Nm
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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nl
pt
du
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erm
ab
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, is n
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spec
es, in part or in w
t to the co
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nf
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n in
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Cop py
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Prote AG.

Amarok 2011 ➤
9 Wheel arch trim (PR No. “0FX”)

⇒ “9.1 Repair instructions”, page 330
⇒ “9.2 Removing and installing wheel arch trim, wing”,
page 333
⇒ “9.3 Removing and installing wheel arch trim - left load bed”,
page 337
⇒ “9.4 Removing and installing wheel arch trim - right load bed”,
page 342
9.1 Repair instructions

gen AG
. Volkswagen AG
d
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olks not
byV gu
ara
ed nte
ris
9.1.1 Safety requirements
au
tho eo
ra
ss c
ce
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un
pt
Caution
an
d
itte
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rm
ab
When removing extensions, use suitable gloves and protective
pe
ility
eyewear.
ot
wit
, is n
h re
Do not use cutting wire to remove extensions.
hole
spec
Extensions must cure at least 3 hours after being bonded be‐
es, in part or in w
t to the co
fore work on the vehicle is continued.
rrectness of i
l purpos
Note
♦ The following wheel arch trims have been developed to fulfil

nform
ercia
the technical requirements of the respective models. These

m
extensions should always be replaced with the corresponding

a
com
tio
genuine parts.
n in
r
te o
thi
♦ Without these extensions, the vehicle does not comply with

s
iva
do
traffic regulations.
r
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cum
fo
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ng
t.
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Co
Cop py
t. rig
trims
gh ht
pyri by
Vo
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by
cted
The wheel arch trim is factory-bonded with double-sided adhesive
agen
Prote AG.
tape and 1-component PU adhesive.
The wheel arch trim is primed by the supplier and delivered with
double-sided adhesive tape.
Ensure that backing of double-sided adhesive tape strips remains
free of paint and paint mist when painting extensions.
Temperatures of the room, the work bay and the vehicle must be
approximately the same (18 °C and max. 30 °C).
Remove existing adhesive tape residues with adhesive remains
remover -VAS 6349- .
Always use a clean, lint-free cloth for cleaning.
Immediately before attaching add-on parts, clean bonding surfa‐
ces using adhesive remover and then carefully remove dirt,
grease, wax and other impurities using plastic cleaner.
• Observe the appropriate safety precautions when cleaning.

Amarok 2011 ➤
Before washing and preserving the vehicle, ensure that the wheel
arch trims have been bonded for at least 3.5 hours.
9.1.3 Preparing new add-on part for bonding
WARNING
Before painting, use masking tape to precisely demarcate all

priming and bonding surfaces.
For 1-component glass adhesive

– The bonding surfaces of the add-on parts must be prepared
with plastic primer.
– Apply 1-component glass adhesive at specified positions on
add-on parts using cartridge gun -V.A.G 1628- .
n AG. Volkswagen A
9.1.4 Preparing body component
Vol
ksw
age for bondingG does
not
g y ua
db ran
– Remove existing adhesive residue ris of double-sided adhesive
e
tee
utho
tape using adhesive strip remover -VAS 6349- . or
a ac
ss
– Cut back adhesive points of PUR adhesive to about 2 - 3 mm
ce
le
un
pt
without damaging paintwork.
an
d
itte
y li
rm
– The cut surfaces do not require additional cleaning.
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
adhesive sealing compound.
rrectness of i
– Observe cleaning instructions for adjacent components
⇒ page 317 .
l purpos
– New special add-on parts may be attached immediately at the

prescribed positions with the adhesive points.
nform
ercia
If the body part has been repaired or partially renewed, the area
m
concerned must be cleaned and primed again after painting.

com
tion in
r
If a body part is fitted for the first time on a new vehicle or on newly
te o
thi
painted surfaces, follow the procedure in ⇒ Workshop manual

s
iva
do
r
"Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings and film .

rp
cum
fo
en
ng
t.
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op
WARNING C py
t. rig
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pyri by
Vo
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c by lksw
cted agen
ting back adhesive bead, the remaining residual material must Prote AG.
be activated with activator -D 181 801 A1- .

Apply activator evenly in one stroke using applicator.
will be damaged.
Drying time approx. 10 minutes.
9. Wheel arch trim (PR No. “0FX”) 331

Amarok 2011 ➤

trims
WARNING
Add-on parts should be installed within 10 minutes, or bonding

properties of adhesive will be impaired. AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
Note au ac
ss
ce
le
un
pt
♦ Gaps/shut lines should be kept to an absolute minimum.
an
d
itte
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erm
♦ Use adhesive tape to secure add-on parts in position during
ab
ility
minimum curing time.
ot p
wit
is n
♦ The surfaces to be primed must be free from impurities
h re
ole,
spec
♦ If no cleanser is specified in the respective repair procedure,
use silicone remover.
t to the co
– Remove adhesive residue using adhesive remover.
rrectne
– Clean application area for adhesive bead twice thoroughly us‐
ing cleanser named in repair procedure and allow to dry.
ss o
– Now apply glass/paint primer evenly in one stroke using ap‐
cial p
f in
plicator.
form
mer
atio
♦ Drying time approx. 10 minutes
om
n
c
i
– Apply adhesive sealing material to primed areas of attachment
or
n thi
e
parts.
t
sd
iva
o
pr
– Max. of 6 minutes waiting time between application of adhe‐ cum

r
fo
en
ng
sive and fitting of add-on parts.

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

parts catalogue .
♦ Activator 1) 5)
♦ Glass and paint primer 1) 5)
♦ Plastic primer 1) 5)
♦ Cleaning solution 1) 5)
♦ Primer applicator 1) 5)
♦ Adhesive remover 1) 5)
♦ Cutting cord 5)


Amarok 2011 ➤

3)Use cartridge gun -V.A.G 1628- to apply 1-component glass
adhesive.
5 The part numbers of the materials can be found in the ⇒ elec‐
tronic parts catalogue (ETKA) .
9.1.6 Minimum curing period

The minimum curing time is the time from bonding the add-on AG. Volkswagen AG d
parts until the vehicle may be used. agen oes
olksw not
byV gu
ara
Wait 3.5 hours before continuing work when bonding is done
ris with
ed
nte
double-sided adhesive tape and 1-component glass adhesive.
ut
ho eo
r a ac
ss
During this time, the vehicle must stand on a level surface and
ce
e
nl
the room and object temperatures must be at least 18 ℃.
pt
du
an
itte
y li
Do not apply any direct load to bonding surfaces for at least 24
erm
ab
hours after installation.
ility
ot p
wit
, is n
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WARNING
hole
spec
es, in part or in w
t to the co
ted.
rrectness of i
9.1.7 Touching up paint damage
l purpos
Paint structure must be restored according to specifications in the
nform
ercia

m
9.1.8 Cleaning off excess adhesive sealing
at
om
ion
c
material
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
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Cop py
Use adhesive remover as a cleaning solution. Observe the ap‐ ht. rig
rig ht
propriate safety precautions when performing this work.
py by
co Vo
by lksw
cted agen
Prote AG.
– If necessary, lift off escaping adhesive with a piece of card‐
board.
– Clean painted surface as well as possible using a dry cloth.
– Remove residue using adhesive remover.
9.1.9 Cleaning guidelines

– Immediately before installing special add-ones, clean bonding
surface thoroughly with adhesive remover.
– Then use plastic cleaner to carefully remove dirt, grease, wax
and other contaminants.
• Always use a clean, lint-free cloth for cleaning.

trim, wing

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
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an
d
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ab
Note
pe
ility
ot
wit
, is n
The removal and installation procedure is for the left side. The
h re
hole

spec
es, in part or in w
t to the co
Assembly overview - application of adhesive

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
334
c by lksw
cted agen
Rep. gr.66 - Exterior equipment Prote AG.
Amarok 2011 ➤
1 - Wheel arch trim, wing

Bead section -a-
mm -height- = approx. 8
mm -width- = approx. 5
mm
Bead section -b-
mm -height- = approx. n AG. Volkswagen AG do
11 mm -width- = approx. lkswage es n
o ot g
8 mm byV ua
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o
Bead section -c- auth or
ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
mm
ility
ot p
wit
Section -d-
, is n
h re
hole
❑ Start of application, ap‐
spec
prox. 30 mm parallel to
es, in part or in w
t to the co
edge, distance approx.
15 mm
Section -e-
rrectness of i
❑ End of application, ap‐
l purpos
prox. 30 mm parallel to
edge, distance approx.
15 mm.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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f
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ng
t.
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op py
Removing
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Wheel arch trim, wing, -1- cannot be removed without damaging it.
♦ Depending on wheel arch trim on front bumper cover, the locating pins must be noted. It is possible that the
types of pins are mixed ⇒ page 238 .

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
– Warm wheel arch trim, wing, -1- with hot air blower -V.A.G
ab
ility
1416- before removing.
ot p
wit
is n
– Raise wheel arch trim, wing, -1- at one corner using removal
h re
ole,
wedge -3409- . spec

– Grip under wheel arch trim, wing, -1- and carefully pull off from
t to the co
wing -5-.
Installing
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.
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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
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

ss

o
cial p
f inform

mer
atio

om
n
c
i
or
– Apply PUR adhesive sealing material under the two-sided ad‐

thi
te
hesive tape -2- ⇒ page 334 .

sd
iva
o
pr
cum
r
– Position wheel arch trim, wing, -1- with the help of the posi‐
fo
en
ng
tioning tool -6- and the swage line -5- and that edges are flush
t.
yi Co
op
and aligned. C py
t. rig
gh ht
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– Bolt on wheel arch trim, wing, -1- using wheel housing liner
cop Vo
by lksw
bolts -3- ⇒ page 304 . cted agen
Prote AG.

– Press on wheel arch trim -1- forcefully along entire area of
double-sided adhesive tape -2-, from front to rear.

- left load bed

Amarok 2011 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
♦ Torque wrench -V.A.G 1783- 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
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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
1 - Wheel arch trim, left load

bed
Bead section -a-
mm
Bead section -b-
8 mm
Bead section -c-
mm
Bead section -d-
mm
Bead section -e-
mm -height- = approx. AG. Volkswagen AG d
agen oes
ksw
11 mm -width- = approx. by Vol not
gu
ara
8 mm rise
d
nte
tho eo
Bead section -f- ss au ra
c
ce
e
nl
pt
du
an
itte
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erm
ab
mm
ility
ot p
wit
, is n
Section -g-
h re
hole
spec
❑ Start of application, approx. 20 mm downwards.

es, in part or in w
t to the co
Section -h-
rrectness of i
Section -i-
l purpos
❑ Start of application, approx. 30 mm parallel to edge, distance approx. 15 mm

Section -j-
nform
ercia
❑ End of application, approx. 15 mm downwards

m
at
om
ion
c
in t
or
his
te
Removing
a
do
priv
cum
for
en
ng
t.
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Note
Co
Cop py
t. rig
gh ht
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Wheel arch trim, left load bed, -1- cannot be removed without damaging it. cop Vo
by 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
ercia

m
at
om
– Warm wheel arch trim, left load bed, -1- with hot air blower -
ion
c
V.A.G 1416- before removing.

in t
or
his
ate
– Lift one corner of wheel arch trim, left load bed, -1- using re‐
do
riv
moval wedge -3409- .

p
cum
for
en
ng
t.
– Grip under wheel arch trim, left load bed, -1- and carefully but
yi Co
op
firmly pull off from component.
C py
t. rig
gh ht
yri by
Installing cop Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
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.
Installation instructions for wheel arch trims ⇒ page 330

Preparing new add-on part for bonding ⇒ page 331
Preparing body component for bonding ⇒ page 331
– Position wheel arch trim, left load bed, -1- with the help of the
assembly tool -5- and the swage line.
– Check transition from wheel arch trim, left load bed, -1- to car‐
go box (swage line).
– Bolt on wheel arch trim, left load bed, -1- using rear wheel
– Pull backing -4- off double-sided adhesive tape -2- starting
from tank cut-out and working to left and right.
– Pull backing off double-sided adhesive tape under tank flap
cut-out.
– Press wheel arch trim -1- on forcefully in complete area of
double-sided adhesive tape -2-, starting from tank cut-out.

Amarok 2011 ➤

- right load bed
1 - Wheel arch trim, right load

bed
Bead section -a-
mm
Bead section -b-
7 mm
Bead section -c-
1,350 mm -height- = ap‐
prox. 8 mm -width- = ap‐
prox. 5 mm
Bead section -d-
AG. Volkswagen AG d
agen oes
❑ -Length- = approx. 400 olks
w not
yV gu
mm -height- = approx.ed b ara
nte
11 mm -width- ris
tho= approx. eo
6 mm ss
au ra
c
ce
e
Bead section -e-

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
mm
h re
hole
spec
Section -f-
es, in part or in w
t to the co
❑ Start of application,
30 mm parallel to edge,
distance approx.
rrectness of i
15 mm.
l purpos
Section -g-
nf
ercia
orm
m
atio
m
Removing
o
n in
or c
thi
te
sd
iva
o
r
Note
rp
cu
o
m
f
en
ng
t.
yi
Wheel arch trim, right load bed, -1- cannot be removed without damaging it.
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
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
– Warm wheel arch trim, right load bed, -1- with hot air blower -
V.A.G 1416- before removing.
nform
ercia
– Lift one corner of wheel arch trim, right load bed, -1- using
m
at
om
io
– Grip under wheel arch trim, right load bed, -1- and carefully
n
c
in t
r
but firmly pull off from component.

o
his
ate
do
riv
Installing
p
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
ss a c
ce
e
Preparing new add-on part for bonding ⇒ page 331

nl
pt
du
an
itte
y li
Preparing body component for bonding ⇒ page 331

erm
ab
ility
ot p

wit
, is n
h re

hole
spec

es, in part or in w
t to the co
– Position wheel arch trim, right load bed, -1- with the help of the
assembly tool -6- and the swage line.
– Check flushness with load bed -5- and swage line.
rrectness of i
– Bolt on wheel arch trim, right load bed, -1- using rear wheel
l purpos

– Pull protective backing -4- off double-sided adhesive tape
nf
ercia
-2-.
rm
m
atio
m
– Press wheel arch trim -1- on forcefully in complete area of

o
n in
c
double-sided adhesive tape -2-, starting from middle and

or
thi
working to left and right.

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
344
cted agen
Prote AG.
Rep. gr.66 - Exterior equipment
Amarok 2011 ➤
10 Protective film
⇒ “10.1 Fitting notes”, page 345
⇒ “10.2 Renewing window frame films”, page 346
⇒ “10.3 Removing and installing inner film of front door”,
page 348
⇒ “10.4 Removing and installing inner door film of rear door”, page
349
⇒ “10.5 Scuff protection film”, page 350
⇒ “10.6 Protective film, B-pillar”, page 351
⇒ “10.7 Anti-abrasion film, tailgate and D-pillar, load bed”,
page 353
10.1 Fitting notes

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
♦ Adhesive strip remover -VAS
ss a
6349- 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
Before removing the protective film, heat it with a hot air blower -
V.A.G 1416- .
nform
ercia
If the protective film is installed for the first time on a new vehicle
m
a
com
or on newly painted surfaces, follow the procedure in ⇒ Workshop

ion in
manual "Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings

r
te o
thi
and film .
s
iva
do
r
rp
If protective film is removed and re-fitted, use only adhesive re‐

um
fo
mover to remove the adhesive residue.

en
ng
t.
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op py
Remove existing adhesive residue of adhesive tape using adhe‐ t. C rig
gh ht
sive strip remover -VAS 6349- . yri
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by c lksw
cted
Ensure that the adhesive surfaces are free of dust and grease.
agen
Prote AG.
Glue on protective film immediately after cleaning.

10. Protective film 345

Amarok 2011 ➤
Working temperature is approx. 21 ℃.

The protective film cannot be removed without damage.
wage es n
10.2 Renewing window frame films olks ot g
byV ua
d ran
ir se tee
Special tools and workshop equipment required uth o
or
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ss
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nl
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erm
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ility
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, is n
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es, in part or in w
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rrectness of i
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nf
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o
Note
rm
m
atio
om
Renewing window frame films is described only for the left side. The right side is similar.
n in
or c
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f
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.

Amarok 2011 ➤
lkswage es n
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byV ua
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tho
u or
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Removing ss
ce
le
un
pt
– Heat window frame films -1- or -2- using hot air blower -V.A.G
an
d
itte
y li
1416- and pull off front door frame -3- or rear door frame -4-.
erm
ab
ility
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Installing
wit
is n
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ole,
spec
– Thoroughly clean bonding surface immediately before sticking

t to the co
on.
– Pull off backing.
rrectne
– Position window frame films -1- or -2- on front door frame -3-
or rear door frame -4-.
ss
– Smooth down window frame films using a plastic spatula wrap‐

o
cial p
ped in a soft paper towel.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
10.3 Removing and installingG.inner film of front door

Volkswage nA n AG d
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Volks not
gu
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Note ed nte
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h
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♦ Renewing inner door film is described only
s for the right side. The left side is analogous.
ce
e
nl
pt
du
♦ If corrective work is necessary, completely remove inner door film -1- and adhesive residue.
an
itte
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erm
ab
ility
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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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Pull inner door film -1- off door.
Use inner door film -1- once only.
Installing
– Position inner door film -1- at markings -arrows- and glue on
the area between the two markings without subjecting the film
to any stress.
– Pull inner door film -1- smoothly over the door aperture -2- and
position so that it does not have any wrinkles.

Amarok 2011 ➤
– Smooth inner door film -1- outwards, ensuring that it is free of

wrinkles.
Note
Make sure there are no creases in marked area -3-
10.4 Removing and installing inner door film of rear door
Note
♦ Renewing inner door film is described only for the right side. The left side is analogous.
♦ If corrective work is necessary, completely remove inner door film -1- and adhesive residue.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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un
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an
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erm
ab
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
va
Removing
i
o
pr
cum
r
fo
en
ng
– Pull inner door film -1- off door.

t.
yi Co
op py
Use inner door film -1- once only.
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Installing
– Position inner door film -1- at markings -arrows- and glue on
the area between the two markings without subjecting the film
to any stress.
– Pull inner door film -1- smoothly over the door aperture -2- and
position so that it does not have any wrinkles.
– Smooth inner door film -1- outwards, ensuring that it is free of
wrinkles.
Note
Make sure there are no creases in marked area -3-
10.5 Scuff protection film

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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un
pt
an
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erm
ab
ility
Note
ot p
wit
is n
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♦ Renewing scuff protection films is described only for the left side. The right side is similar.
ole,
spec
♦ The scuff protection film cannot be removed without damage.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.

Amarok 2011 ➤
lkswage es n
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Removing
erm
ab
ility
ot p
– Remove inner door seal in step area ⇒ page 84 .

wit
is n
h re
– Heat scuff protection film -1- using hot air blower -V.A.G 1416-
ole,
spec
and pull off from step area.

t to the co
Installing
rrectne
– Pull backing off scuff protection film -1-.

– Position scuff protection film -1- on reference point -arrow- and
ss
press it smooth using a plastic blade wrapped in a soft paper

o
cial p
f i
towel.
nform
mer
Further installation is performed in the reverse order of removal.

atio
om
10.6 Protective film, B-pillar

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
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Note
♦ Renewing protective film for the B-pillar is described only for

the left side. The right side is similar.
♦ The scuff protection film cannot be removed without damage.
Removing
– Heat scuff protection film of B-pillar -1- using hot air blower -
V.A.G 1416- and pull off from step area. AG. Volkswagen AG d
agen oes
Installing olksw not
byV gu
ara
ed
nte
– Follow installation instructions ⇒ page 345 . horis
eo
aut ra
– Pull backing off scuff protection film of B-pillar -1-. ss c
ce
le
un
pt
– Position protective film for B-pillar -1- in the radius of side
an
d
itte
member -2- and smooth it out without folds.
y li
rm
ab
pe
ility
ot
wit
, is n
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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 ➤
10.7 Anti-abrasion film, tailgate and D-pillar, load bed

1 - Tailgate
2 - D-pillar, load bed
AG. Volkswagen AG d
3 - Anti-abrasion film lksw
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not
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❑ Dimension -a- = 135 ± 2 d by ara
mm from lower edge of rise nte
tho eo
D-pillar to anti-abrasion s au ra
c
film. s
ce
le
un
pt
4 - Anti-abrasion film
an
d
itte
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❑ Dimension -b- = 88 ± 2 rm
ab
pe
ility
mm from lower edge of
ot
wit
anti-abrasion film -5- to
, is n
h re
edge of anti-abrasion
hole
spec
film -4-.
es, in part or in w
t to the co
5 - Anti-abrasion film
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
11 Buffer - rear cross panel

⇒ “11.1 Assembly overview - buffer, rear cross panel”,
page 354
11.1 Assembly overview - buffer, rear cross panel
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
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Press on buffer -1- from below.

l purpos
Note
nform
ercia
♦ Groove must make good contact with edge of the plate.

m
a
com
tio
♦ During mounting, pull rubber lip -arrow- back with your fingers.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
12 Towing bracket
⇒ “12.1 Assembly overview - towing bracket with ball head”, page
355
Note
♦ The specified torques refer only to factory-installed towing

brackets for up to 3.2 tonnes towing capacity.
♦ Request torque specifications for other towing brackets from
the manufacturers.
♦ If the rear bumper carrier has been modified, it may be nec‐
essary to perform additional work. Von the rear cross panel.
olkswag AG en AG
agen do
♦ Paint structure mustybe
Vol restored according to specifications
ksw es n
ot g in
the ⇒ “Paint” workshop
ise
db manual . ua
ran
r tee
tho
♦ However, it must
be noted that installing a new rear bumper or a
au
carrier does
ss not automatically increase the permitted towing c
ce
le
capacity.
un
pt
an
d
itte
♦ Information on electrics can be found under ⇒ Towing mode
y li
rm
ab
current flow diagram workshop manual .
pe
ility
ot
wit
♦ There is no engine-stop function when the towing bracket is in
, is n
h re
use.
hole
spec
♦ The towing bracket cannot be removed.
es, in part or in w
t to the co
12.1 Assembly overview - towing bracket rrectness of i
with ball head

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.
12. Towing bracket 355

Amarok 2011 ➤
1 - Towing bracket
❑ Towing bracket for 3.2
tonne towing capacity
Installation and bolting se‐
quence:
– Tighten bolts -4- (qty. 4)

to pre-tensioning torque
of 5 Nm.
– Tighten bolts -3- to

specified torque
⇒ Item 3 (page 356) .
– Tighten bolts -4- (qty. 4)

to specified torque AG. Volkswagen AG d
agen oes
ksw
⇒ Item 4 (page 356) . byV
ol not
gu
ara
ed
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2 - Bracket for electric socketutho eo
ra
a c
❑ With captive nuts (if ss
ce
e
present)
nl
pt
du
an
itte
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3 - Bolt
erm
ab
❑ Qty. 2
ility
ot p
wit
, is n
h re
Nm + 120°
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
being removed.
l purpos
4 - Bolt
nf
ercia

rm
m
atio

om
n in
Nm + 180°
or c
thi
te
sd
iva
o
r
WARNING
rp
cu
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f
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ng

t.
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placed by new ones after Cop py
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being removed. rig ht
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by lksw
cted agen
Prote AG.
5 - Seal
❑ For electric socket
6 - Electric socket
7 - Bolt
❑ Qty. 3
❑ For securing electric socket -6-
8 - Washer
❑ Qty. 3 (if present)
9 - Hexagon nut
❑ Qty. 3 (if present)
10 - Wiring harness

Amarok 2011 ➤
13 Spare wheel winch

⇒ “13.1 Assembly overview - spare wheel winch”, page 357
13.1 Assembly overview - spare wheel winch

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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1 - Spare wheel winch
ce
le
un
pt
an
d
❑ On rear cross member

itte
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rm
ab
2 - Spare wheel winch
pe
ility
ot
❑ On ladder frame
wit
, is n
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hole
3 - Bolt
spec
es, in part or in w
❑ Qty. 2
t to the co
4 - Bolt
rrectness of i
❑ Qty. 2
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.
13. Spare wheel winch 357

Amarok 2011 ➤
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 ➤
14 Mudflaps
⇒ “14.1 Assembly overview - front mudflap, without wheel arch
trim”, page 359
⇒ “14.2 Assembly overview - front mudflap, with wheel arch trim”,
page 360
⇒ “14.3 Assembly overview - rear mudflap, without wheel arch
trim”, page 361
⇒ “14.4 Assembly overview - rear mudflap, with wheel arch trim”,
page 362
⇒ “14.5 Assembly overview - rear mudflap bracket”, page 363
⇒ “14.6 Removing and installing front mud flaps, without wheel
AG. Volkswagen AG d
arch trim”, page 363 lkswagen oes
n o ot g
yV u
⇒ “14.7 Removing andris
einstalling
db front mud flaps, with wheel arch
ara
nte
trim”, page 365 utho eo
r
sa ac
⇒ “14.8 Removings
and installing rear mud flaps, without wheel
ce
le
arch trim”, page 366

un
pt
an
d
itte
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⇒ “14.9 Removing and installing rear mud flaps, with wheel arch
erm
ab
trim”, page 368
ility
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is n
14.1 Assembly overview - front mudflap, without wheel arch trim
h re
ole,
spec
t to the co
Note
♦ Only the left side is shown. The right side is analogous.

♦ Minor differences to the description may be encountered, depending on vehicle model. rrectness o

cial p
f inform

mer
⇒ page 304
atio
om
n
c
2 - Expanding nut
i
or
n thi
e
❑ Qty. 1
t
sd
iva
o
pr
cum
r
3 - Front mudflap
fo
en
ng
t.
yi
Co
op py
⇒ page 363 t. C rig
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pyri by
4 - Bolt
o Vo
by c lksw
cted agen
Prote
❑ Qty. 2
AG.

Nm
❑ These two bolts are in‐
cluded in the scope
“wheel housing liner at‐
tachment”.
5 - Bolt
❑ Qty. 1
Nm
14. Mudflaps 359

Amarok 2011 ➤
14.2 Assembly overview - front mudflap, with

wheel arch trim
Note


⇒ page 304
2 - Expanding nut
❑ Qty. 4
3 - Front mudflap
⇒ page 365
4 - Bolt
❑ Qty. 4
Nm
5 - Bolt
❑ Qty. 2
AG. Volkswagen AG d
❑ Specified torque: 2.0 lksw
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not
Nm byV
o gu
ara
ed
❑ These two bolts are horisin‐ nte
eo
aut
cluded in the scope ra
s c
“wheel housings liner at‐
ce
e
tachment”.
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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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 ➤
14.3 Assembly overview - rear mudflap, without wheel arch trim
Note


⇒ page 304
2 - Rear mudflap
⇒ page 366
3 - Bolt
❑ Qty. 2
Nm
❑ These two bolts are in‐
cluded in the scope
“wheel housing liner at‐
tachment”.
4 - Bolt
❑ Qty. 2
Nm
5 - Spreader rivet
❑ Qty. 1
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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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
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fo
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ng
t.
yi Co
Cop py
ht. rig
rig ht
by
361
copy Vo
by lksw
cted agen 14. Mudflaps
Prote AG.
Amarok 2011 ➤
14.4 Assembly overview - rear mudflap, with wheel arch trim
Note


❑ Removing and installing AG. Volkswagen AG d
agen
⇒ page 304 Volksw
oes
not
by gu
d ara
2 - Expanding nut orise nte
th eo
❑ Qty. 3 s au ra
c
s
ce
e
3 - Rear mudflap
nl
pt
du
an
itte
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erm
⇒ page 368
ab
ility
ot p
4 - Bolt
wit
, is n
h re
❑ Qty. 2
hole
spec
es, in part or in w
Nm
t to the co
❑ These two bolts are re‐
quired parts for attach‐
rrectness of i
ing wheel housing liner.
l purpos
5 - Bolt
❑ Qty. 5
nf
ercia
orm
Nm
m
atio
om
6 - Spreader rivet
n in
or c
thi
e
❑ Qty. 1
t
sd
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r
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
14.5 Assembly overview - rear mudflap bracket
1 - Rear mudflap bracket

❑ Remove rear wheel
housing liner
⇒ page 304
2 - Bolt
❑ Qty. 1
Nm
AG. Volkswagen AG d
❑ Securing points: cargo lksw
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not
box d by Vo gu
ara
rise nte
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au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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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.
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Cop py
t. rig
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by
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Prote
14.6 Removing and installing front mud flaps,
AG.
without wheel arch trim

14. Mudflaps 363

Amarok 2011 ➤
Note
♦ The removal and installation sequence is only described for the left side. Removal and installation of the
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
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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.
Removing
– Remove front mudflap -3- from front wheel housing liner -1-.
Installing
– Slide front mudflap -3- onto wing flange.
Specified torques
♦ ⇒ “14.1 Assembly overview - front mudflap, without wheel arch
trim”, page 359

Amarok 2011 ➤
14.7 Removing and installing front mud flaps,

with wheel arch trim
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
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e
nl
Note
pt
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erm
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ility
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right side is similar. wit

, is n
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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
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ng
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
14. Mudflaps 365

Amarok 2011 ➤
lkswage es n
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byV ua
d ran
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tho
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a ac
ss
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– Remove front mudflap -3- from front wheel housing liner -1-.
Installing
– Slide front mudflap -3- onto wing flange.
Specified torques
♦ ⇒ “14.2 Assembly overview - front mudflap, with wheel arch
trim”, page 360
14.8 Removing and installing rear mud flaps,

without wheel arch trim

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14. Mudflaps 367

Amarok 2011 ➤
Removing
– Unscrew bolts -3- and -4-
– Use small drift to press pin inwards and unclip spreader rivet
-5-.
– Remove rear mudflap -2- from front wheel housing liner -1-.
Installing
• Rear mudflap bracket is fitted ⇒ page 363 .
– Locate rear mudflap -2- and secure clip -5-.
Specified torques
♦ ⇒ “14.3 Assembly overview - rear mudflap, without wheel arch
trim”, page 361
14.9 Removing and installing rear mud flaps,

with wheel arch trim
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– Remove rear mudflap -3- from front wheel housing liner -1-.
Installing
• Rear mudflap bracket is fitted ⇒ page 363 .
– Locate rear mudflap -3- and secure clip -6-.
– Secure clip -6-.
Specified torques
♦ ⇒ “14.4 Assembly overview - rear mudflap, with wheel arch
trim”, page 362
14. Mudflaps 369

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2012 Volkswagen AG, Wolfsburg D4B8026F790

3.1 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.1 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2 Assembly overview - bonnet lock and release components . . . . . . . . . . . . . . . . . . . . . . . . 18

1.7 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.3 Removing and installing actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.3 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.4 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1.6 Removing and installing door hinge on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.9 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

2.3 Assembly overview - door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2.7 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

2.8 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

2.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2.11 Removing and installing housing (without lock cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . 148

61 - Convertible roof, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

5.8 Removing and installing front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

5.10 Installing speed nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

5.11 Removing and installing rear seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

1.3 Assembly overview - wheel arch trim, bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

1.5 Assembly overview - substructure components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

1.6 Removing and installing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

1.8 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi 242

1.9 Installing brackets for parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

2 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

4.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

4 Roof moulding and roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

5.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

5.2 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

5.3 Removing and installing housing frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

5.5 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

12 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

1.1 Assembly overview - lock carrier

1 - Front lock carrier

1.2 Assembly overview - support for lock carrier

1 - Support for left lock carrier

2 Rep. gr.50 - Body - front

❑ Install in reverse order

1.4 Assembly overview - bumper

1.5 Removing and installing front lock carri‐

4 Rep. gr.50 - Body - front

– Remove front bumper cover ⇒ page 236 .

– Remove lid lock -1- unclip ⇒ page 25 . h re

– Unfasten radiator at front lock carrier -1- ⇒ Engine cooling

cooling system; Draining and filling coolant .

– Remove bolts -2- on left and right.

– Remove front lock carrier -1- forwards.

Install in reverse order of removal. When doing this, observe the

1.6 Removing and installing support for lock

6 Rep. gr.50 - Body - front

– Remove bolts on lid lock ⇒ page 25 .

2.1 Assembly overview - wing

❑ Removing and installing

❑ Qty. 1, front wing

4 - Pop rivet nut

❑ Qty. 1, A-pillar top

❑ Insert using pop rivet nut