2010-2022 Volkswagen Amarok Truck Starter, current supply, CCS User Manual
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Starter, current supply, CCS for Your Volkswagen Amarok Truck First Generation (2010-2022)

Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
27 – Starter, current supply, CCS  
1
Battery  
⇒ o1.1 verview – battery”, page 6  
⇒ a1.2 nd installing battery”, page 8  
⇒ a1.3 nd connecting battery”, page 11  
⇒ b1.4 attery”, page 13  
⇒ b1.5 attery”, page 13  
⇒ a1.6 nd installing earth wire with battery monitor control  
unitJ367”, page 13  
⇒ b1.7 attery monitor control unitJ367”, page 15  
1.1  
Assembly overview – battery  
⇒ o1.1.1 verview - vehicles without battery monitor control  
unitJ367”, page 6  
⇒ o1.1.2 verview - vehicles with battery monitor control  
unitJ367”, page 7  
1.1.1  
Assembly overview - vehicles without  
battery monitor control unit -J367-  
Warning notices and safety regulations  
All instructions and notes for this chapter are available in  
the workshop manual “Electrical system, General information”  
⇒ Electrical system, General information; Rep. gr. 27; Battery;  
Warning notices and safety regulations.  
Battery load test  
All instructions and notes for this chapter are available in  
the workshop manual “Electrical system, General information”  
⇒ Electrical system, General information; Rep. gr. 27; Battery;  
Battery terminal connection.  
6
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
1 - Earth wire battery terminal  
clamp  
❑ Comply with the in‐  
structions regarding  
threaded connections  
of the battery terminals  
⇒ page 6  
2 - Nut for earth wire battery  
terminal clamp  
❑ 6 Nm  
3 - Positive wire battery termi‐  
nal clamp  
❑ Comply with the in‐  
structions regarding  
threaded connections  
of the battery terminals  
⇒ page 6  
4 - Nut for positive wire bat‐  
tery terminal clamp  
❑ 6 Nm  
5 - Battery  
❑ Removing and instal‐  
ling ⇒ page 8  
6 - Clamping plate  
7 - Bolt for clamping plate  
❑ 20 Nm  
1.1.2  
Assembly overview - vehicles with bat‐  
tery monitor control unit -J367-  
Warning notices and safety regulations  
All instructions and notes for this chapter are available in  
the workshop manual “Electrical system, General information”  
⇒ Electrical system, General information; Rep. gr. 27; Battery;  
Warning notices and safety regulations.  
Battery load test  
All instructions and notes for this chapter are available in  
the workshop manual “Electrical system, General information”  
⇒ Electrical system, General information; Rep. gr. 27; Battery;  
Battery terminal connection.  
1. Battery  
7
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
1 - Battery earth terminal  
with integrated battery moni‐  
tor control unit -J367-  
❑ Comply with the in‐  
structions regarding  
threaded connections  
of the battery terminals  
⇒ page 7  
❑ Comply with instruc‐  
tions regarding battery  
monitor control unit -  
J367- (battery sensor)  
⇒ page 47 .  
2 - Nut for earth wire battery  
terminal clamp  
❑ 6 Nm  
3 - Positive wire battery termi‐  
nal clamp  
❑ Comply with the in‐  
structions regarding  
threaded connections  
of the battery terminals  
⇒ page 7  
4 - Nut for positive wire bat‐  
tery terminal clamp  
❑ 6 Nm  
5 - Battery  
❑ Removing and instal‐  
ling ⇒ page 8  
❑ Parametrising battery  
after replacement ⇒  
page 10  
6 - Battery tray  
7 - Clamping plate  
8 - Bolt for clamping plate  
❑ 20 Nm  
1.2  
Removing and installing battery  
⇒ a1.2.1 nd installing batteryA”, page 8  
⇒ b1.2.2 attery after replacement, vehicles with start/stop sys‐  
tem”, page 10  
1.2.1  
Removing and installing battery -A-  
Special tools and workshop equipment required  
   
8
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ Torque wrench -V.A.G 1331-  
Note  
♦ In vehicles with a battery sensor (start/stop system), the bat‐  
tery has to be parametrised after a new starter battery has  
been installed ⇒ page 10 .  
♦ The battery parametrisation sends the technical data of the  
new battery to the battery monitor.  
WARNING  
Always make sure to comply with the warning notices and  
safety regulations when working on the battery ⇒ Electrical  
system, General information; Rep. gr. 27; Battery.  
Removing  
– Disconnect battery ⇒ page 11 .  
– Detach hose for central gas venting system from battery, if  
part of original equipment.  
– Unscrew the 2 bolts from engine control unit bracket, and  
lay bracket together with engine control unit attached to one  
side ⇒ Power unit; Rep. gr. 23; Fuel preparation, injection;  
Engine control unit; Removing and installing engine control  
unit.  
– Unscrew bolt -arrow-, and remove battery tray.  
– Fold up battery handles -arrows-.  
1. Battery  
9
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Grip battery on handles and lift it out.  
Installing  
Install in the reverse order of removal, observing the following:  
Note  
♦ On vehicles with a battery sensor (start/stop system), the  
battery has to be parametrised after a new battery -A- has  
been installed ⇒ page 10 .  
♦ The battery parametrisation sends the technical data of the  
new battery to the battery monitor.  
♦ Ensure that hose for central gas venting (if fitted at all) is  
attached to the battery and is not pinched. Only then can the  
battery vent freely.  
– Connect battery ⇒ page 11 .  
Specified torques  
♦ ⇒ o1.1 verview – battery”, page 6  
1.2.2  
Parametrising battery after replace‐  
ment, vehicles with start/stop system  
Special tools and workshop equipment required  
♦ ⇒ Vehicle diagnostic tester  
Note  
♦ In vehicles with a battery sensor (start/stop system), the bat‐  
tery has to be parametrised after a new starter battery has  
been installed.  
♦ The battery parametrisation sends the technical data of the  
new battery to the battery monitor.  
– Connect vehicle diagnostic tester ⇒ Electrical system, Gen‐  
eral information; Rep. gr. 97; Vehicle diagnosis, testing and  
information systems; Connecting vehicle diagnostic tester.  
– Select operating mode “Guided Fault Finding” in vehicle di‐  
agnosis tester.  
– Using “GoTo” button, select “Functions/component” and then  
the following menu options in succession:  
♦ Body  
♦ Electrical system  
10  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ 01 – Self-diagnosis compatible systems  
♦ Battery monitoring  
♦ Battery monitoring function  
♦ Parametrising battery after replacement  
1.3  
Disconnecting and connecting battery  
⇒ a1.3.1 nd connecting battery, earth wire on negative battery  
terminal”, page 11  
⇒ a1.3.2 nd connecting battery”, page 12  
1.3.1  
Disconnecting and connecting battery,  
earth wire on negative battery terminal  
Special tools and workshop equipment required  
♦ Torque wrench -V.A.G 1331-  
Disconnecting  
– Loosen nut -1-.  
– Detach negative battery clamp -2-.  
– Disconnect electrical connector -3-.  
Connecting  
Connect in reverse order of removal, noting the following:  
– Perform initialisation (activation) of window regulator ⇒ Main‐  
tenance; Booklet 10.3.  
– Check time and adjust, if necessary.  
– Read event memory ⇒ Maintenance; Booklet 10.3.  
– Perform zero compensation of steering angle sender ⇒ Vehi‐  
cle diagnostic tester.  
1. Battery  
11  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
Specified torques  
♦ ⇒ o1.1 verview – battery”, page 6  
1.3.2  
Disconnecting and connecting battery  
Special tools and workshop equipment required  
♦ Torque wrench -V.A.G 1331-  
Note  
♦ The order in which the work steps is carried out should be  
followed carefully.  
♦ Disconnecting the battery earth strap (open circuit) provides  
a safe working environment for repairs to the electrical sys‐  
tem.  
♦ The battery positive wire need only be disconnected for  
removal of the battery. However, you should in any case  
observe the notes on connecting the battery.  
Disconnecting  
– Switch off ignition and all electrical consumers, and withdraw  
ignition key.  
Wait 60 seconds, and disconnect battery proceeding as follows:  
– Unscrew nut -arrow- at battery negative terminal.  
– Disconnect battery negative terminal.  
– Unscrew nut at battery positive terminal.  
– Disconnect battery positive wire from battery positive termi‐  
nal.  
12  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
Connecting  
Caution  
Battery terminal clamps must be fitted only by hand without  
force to prevent damage to battery housing.  
Battery terminals must not be greased.  
– Fit positive cable clamp onto battery positive terminal.  
– Tighten nut of battery positive terminal clamp.  
– Connect battery negative terminal clamp to negative terminal  
of battery.  
– Tighten nut of battery negative terminal clamp.  
– Work through steps listed in table.  
Procedure  
Performed  
Using ignition key, switch ignition:  
Switch on ignition and then switch off  
again.  
Read event memory:  
⇒ Guided Fault Finding with vehicle diag‐  
nostic tester  
Steering angle sender - perform zero  
compensation:  
⇒ Guided Fault Finding with vehicle diag‐  
nostic tester  
Clock:  
Check clock setting, adjust if necessary.  
Window regulators:  
Open all windows fully and close again.  
Functional check:  
All electrical consumers  
Specified torques  
♦ ⇒ o1.1 verview – battery”, page 6  
1.4  
Checking battery  
General information for checking batteries is available in  
the workshop manual “Electrical system, General information”  
⇒ Electrical system, General information; Rep. gr. 27; Checking  
battery.  
1.5  
Charging battery  
General information for checking batteries is available in  
the workshop manual “Electrical system, General information”  
⇒ Electrical system, General information; Rep. gr. 27; Checking  
battery.  
1.6  
Removing and installing earth wire with  
battery monitor control unit -J367-  
Special tools and workshop equipment required  
1. Battery  
13  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ Torque wrench -V.A.G 1331-  
Removing  
– Switch off ignition and all electrical consumers, and withdraw  
ignition key.  
– Disconnect electrical connector -1- on battery monitor con‐  
trol unit -J367-.  
– Loosen clamping bolt -1- on negative battery terminal, and  
detach negative terminal from battery.  
– Unscrew nut -1- from negative cable of battery.  
14  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Remove negative battery cable together with battery moni‐  
toring control unit from the engine compartment.  
Installing  
Install in the reverse order of removal, observing the following:  
Specified torques  
♦ ⇒ o1.1.2 verview - vehicles with battery monitor control  
unitJ367”, page 7  
1.7  
Adapting battery monitor control unit -  
J367-  
After the installation of a new battery -A- and/or a new bat‐  
tery monitor control unit -J367-, the battery monitor control unit  
-J367- must be adapted using the ⇒ Vehicle diagnostic tester.  
1. Battery  
15  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
2
Alternator  
⇒ o2.1 verview - alternator”, page 16  
⇒ a2.2 nd installing alternator”, page 17  
⇒ a2.3 lternator”, page 26  
⇒ a2.4 lternator”, page 27  
⇒ p2.5 oly V-belt”, page 32  
2.1  
Assembly overview - alternator  
⇒ o2.1.1 verview - alternator, diesel engines”, page 16  
⇒ o2.1.2 verview - alternator, petrol engines”, page 16  
2.1.1  
Assembly overview - alternator, diesel engines  
1 - Bolts  
❑ Qty. 2  
❑ 20 Nm  
2 - Alternator -C-  
❑ Removing and instal‐  
ling ⇒ page 17  
❑ Checking ⇒ page 26  
❑ Removing and instal‐  
ling poly V-belt pulley ⇒  
page 30  
❑ Repairing alternator -C-  
⇒ page 27  
3 - Threaded bushes  
❑ Qty. 2  
4 - Electrical connector  
5 - Nut  
❑ 20 Nm  
6 - Cover  
7 - Terminal 30/B+  
2.1.2  
Assembly overview - alternator, petrol engines  
16  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
1 - Alternator -C-  
❑ Removing and instal‐  
ling ⇒ page 17  
❑ Checking ⇒ page 26  
❑ Removing and instal‐  
ling poly V-belt pulley ⇒  
page 30  
❑ Repairing alternator -C-  
⇒ page 27  
2 - Electrical connector  
3 - Terminal 30/B+  
4 - Nut  
❑ 15 Nm  
5 - Cover  
6 - Bolts  
❑ Qty. 4  
❑ 25 Nm  
2.2  
Removing and installing alternator  
⇒ a2.2.1 nd installing alternatorC, 4-cylinder petrol engines”,  
page 17  
⇒ a2.2.2 nd installing alternatorC, 4-cylinder diesel engines”,  
page 20  
⇒ a2.2.3 nd installing alternatorC, 6-cylinder diesel engines”,  
page 25  
2.2.1  
Removing and installing alternator -C-,  
4-cylinder petrol engines  
Special tools and workshop equipment required  
2. Alternator  
17  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ Hose clamps, up to 25 mm -3094-  
♦ Torque wrench -V.A.G 1331-  
Removing  
– Disconnect battery ⇒ page 11 .  
Note  
Do not remove the entire poly V-belt, just detach it from the  
pulley of the alternator -C-.  
– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder  
block on pulley side; Removing and installing poly V-belt.  
– Detach hose clip -2-, and pull off charge air hose.  
– Unscrew bolt -1-, and lay charge air pipe to one side.  
– Clamp off coolant hose on upper radiator connection using  
hose clamps up to 25 mm -3094- and pull off.  
– Unscrew bolts -arrows-, and place bracket with radiator hose  
to one side.  
18  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Disconnect electrical connector -1-.  
– Unscrew bolts -arrows-.  
– Swing alternator -C- to side.  
– Unscrew nut -2-.  
– Remove alternator -C- upwards.  
2. Alternator  
19  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
Installing  
Install in the reverse order of removal, observing the following:  
– Connect battery ⇒ page 11 .  
– Start engine, and check belt running.  
Specified torques  
♦ ⇒ o2.1.2 verview - alternator, petrol engines”, page 16  
2.2.2  
Removing and installing alternator -C-,  
4-cylinder diesel engines  
Special tools and workshop equipment required  
♦ Torque wrench -V.A.G 1331-  
Removing  
– Disconnect battery ⇒ page 11 .  
Note  
Do not remove the entire poly V-belt, just detach it from the  
pulley of the alternator -C-.  
– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder  
block on pulley side; Removing and installing poly V-belt.  
– Remove charge pressure pipes -1- in area of alternator.  
– Unscrew bracket of coolant line from engine at top -arrow-.  
20  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Push coolant line -1- to one side and secure to fuel line  
using a cable tie -2-.  
Vehicles with auxiliary heater  
Note  
To ensure there is sufficient room for removing the alternator  
on vehicles equipped with an auxiliary heater, release the auxil‐  
iary heater far enough to be able to lift it with lines connected  
⇒ Heating, ventilation, air conditioning system; Rep. gr. 82; Aux‐  
iliary heater; Auxiliary heater; Removing and installing auxiliary  
heater.  
WARNING  
Risk of burns.  
Parts of the exhaust system may be hot.  
Before removing the exhaust system, let it cool down.  
– Remove auxiliary heater silencer together with bracket  
⇒ Heating, ventilation, air conditioning system; Rep. gr. 82;  
Auxiliary heater; Auxiliary heater; Removing and installing  
silencer with bracket.  
– Remove front left headlight -MX1- ⇒ page 105 .  
– Unscrew bolt -arrow- from bracket for coolant pipes -1-.  
2. Alternator  
21  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew nut -arrow- through opening in headlight, and re‐  
move coolant line -1-.  
Note  
For reasons of clarity, the following illustration shows the auxili‐  
ary heater bracket without the auxiliary heater.  
22  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew bolts -1-.  
– Unscrew bolt -2-.  
– Raise bracket and auxiliary heater with lines connected until  
there is sufficient clearance to be able to remove the alterna‐  
tor -C-.  
Continued for all vehicles  
– Disconnect electrical connector -1-.  
– Lever off deflector cap -2-.  
2. Alternator  
23  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew nut and B+ wire under it from connecting thread of  
alternator -C-.  
– Unscrew bolts -arrows-.  
– Remove alternator -C- from bracket, and turn it so rear side  
is facing upwards.  
– Use a long screwdriver to release retaining clip -arrow- of  
wiring connector from alternator -C-.  
– Remove alternator -C- -1- by removing it upwards from en‐  
gine compartment.  
Installing  
Install in the reverse order of removal, observing the following:  
Note  
To facilitate positioning of the alternator -C-, slide the bushes on  
alternator -C- slightly towards the rear.  
– Connect battery ⇒ page 11 .  
24  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Start engine, and check belt running.  
Specified torques  
♦ Specified torques for auxiliary heater ⇒ Heating, ventilation,  
air conditioning system; Rep. gr. 82; Auxiliary heater; Auxili‐  
ary heater; Removing and installing auxiliary heater.  
♦ ⇒ o2.1.1 verview - alternator, diesel engines”, page 16  
2.2.3  
Removing and installing alternator -C-,  
6-cylinder diesel engines  
Special tools and workshop equipment required  
♦ Torque wrench -V.A.G 1331-  
Removing  
– Disconnect battery ⇒ page 11 .  
Note  
Do not remove the entire poly V-belt, just detach it from the  
pulley of the alternator -C-.  
– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder  
block on pulley side; Removing and installing poly V-belt.  
– Lever off cover -1-.  
– Unscrew bolt -2-.  
– Remove idler roller.  
– Unscrew bolt -2- for air pipe.  
2. Alternator  
25  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew bolts -arrows-.  
– Remove alternator -C- -4- from bracket.  
– Unscrew nut -1-.  
– Remove B+ wire -3-.  
– Disconnect electrical connector -2-.  
Installing  
Install in the reverse order of removal, observing the following:  
Note  
To facilitate positioning of the alternator -C-, slide the bushes on  
alternator -C- slightly towards the rear.  
– Connect battery ⇒ page 11 .  
– Start engine, and check belt running.  
Specified torques  
♦ ⇒ o2.1.1 verview - alternator, diesel engines”, page 16  
2.3  
Checking alternator  
Check the alternator -C- using the ⇒ Vehicle diagnostic tester.  
26  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
2.4  
Repairing alternator  
⇒ a2.4.1 nd installing voltage regulatorC1, Bosch”, page 27  
⇒ a2.4.2 nd installing voltage regulatorC1, Valeo”, page 28  
⇒ a2.4.3 lternator carbon brushes”, page 30  
⇒ a2.4.4 nd installing poly V-belt pulley on alternator”, page 30  
2.4.1  
Removing and installing voltage regu‐  
lator -C1-, Bosch  
Special tools and workshop equipment required  
♦ Torque wrench -V.A.G 1331-  
♦ Torque screwdriver -VAS 6494-  
Removing  
– Remove alternator -C- ⇒ page 17 .  
– Unscrew nuts -1-.  
– Unscrew bolt -2-.  
– Remove protective cap -3-.  
2. Alternator  
27  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew bolts -arrows-.  
– Carefully remove voltage regulator -C1- from alternator.  
Installing  
Install in the reverse order of removal, observing the following:  
Specified torques  
Component  
Specified torque  
Nuts -1- of protective cap -3-  
Bolts -arrows-  
15 Nm  
2 Nm  
2.4.2  
Removing and installing voltage regu‐  
lator -C1-, Valeo  
Special tools and workshop equipment required  
♦ Torque screwdriver -VAS 6494-  
Removing  
– Remove alternator -C- ⇒ page 17 .  
– Lever protective cap -1- off alternator -C-.  
28  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew bolts -2-.  
– Remove voltage regulator -C1- -3- from alternator -C-.  
Installing  
Install in the reverse order of removal, observing the following:  
– Press protective cap for carbon brushes -A- in  
-direction of arrow- until it is flush with voltage regulator  
housing.  
Specified torques  
Component  
Specified torque  
4 Nm  
Bolts -2- for voltage regulator -C1-  
2. Alternator  
29  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
2.4.3  
Checking alternator carbon brushes  
Note  
The carbon brushes are permanently fixed to the voltage regu‐  
lator. If repairs are necessary, renew the voltage regulator.  
Checking  
– Removing voltage regulator -C1- ⇒ page 17 .  
– Measure length of carbon brushes, dimension -a-.  
Carbon brushes  
New  
Length -a-  
12 mm  
Wear limit  
5 mm  
Tolerances to one another  
+ 1 mm  
2.4.4  
Removing and installing poly V-belt  
pulley on alternator  
Special tools and workshop equipment required  
♦ Multipoint adapter -3400-  
30  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ Torque wrench -V.A.G 1332-  
Removing  
– Remove alternator -C- ⇒ page 17 .  
– Clamp alternator in a vice.  
– Lever protective cap off poly V-belt pulley.  
– Insert adapter -3400- -1- into poly V-belt pulley using 17 mm  
ring spanner.  
– Then insert multipoint bit -M10- -3- in alternator shaft.  
– Counterhold alternator shaft whilst releasing poly V-belt pul‐  
ley by turning it anti-clockwise with ring spanner.  
– Counterhold poly V-belt pulley by hand.  
– Turn alternator shaft until poly V-belt pulley can be removed.  
Installing  
Install in the reverse order of removal, observing the following:  
– Screw poly V-belt pulley by hand as far as stop onto drive  
shaft of alternator.  
Convert torque wrench -V.A.G 1332- as follows for installing  
poly V-belt pulley:  
– Release socket drive -1- and pull off grip -2-.  
2. Alternator  
31  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Turn torque wrench grip -2- by 180°, and reinsert socket  
drive -1-.  
– Set turning direction of torque wrench -V.A.G 1332- to anti-  
clockwise at socket drive.  
– Insert multipoint bit -M10- -1- into alternator shaft.  
– Counterhold multipoint adapter -3400- -1- using ring spanner  
(AF 17 mm).  
– Tighten poly V-belt pulley by turning alternator shaft anti-  
clockwise using torque wrench -V.A.G 1332-.  
Specified torques  
Component  
Specified torque  
80 Nm  
Poly V-belt pulley on alternator shaft  
2.5  
Checking poly V-belt  
– Crank engine at vibration damper on pulley using a socket.  
– Check poly V-belt for:  
♦ Sub-surface cracks (cracks, core ruptures, cross sectional  
breaks)  
♦ Layer separation (top layer, cord strands)  
♦ Eruptions on underbody  
32  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ Fraying of carcass  
♦ Flank wear (material wear, frayed flanks, flank brittleness  
-glassy flanks-, surface cracks)  
♦ Traces of oil and grease  
Caution  
In order to avoid failures and malfunctions, the poly V-belt  
must be replaced if it is damaged.  
2. Alternator  
33  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
3
Starter motor  
⇒ o3.1 verview – starter”, page 34  
⇒ a3.2 nd installing starter”, page 35  
⇒ s3.3 tarter”, page 46  
3.1  
Assembly overview – starter  
Assembly overview - starter, 4-cylinder diesel engines  
1 - Starter motor -B-  
❑ Removing and instal‐  
ling ⇒ page 35  
❑ Checking ⇒ page 46  
2 - Bolts  
❑ Qty. 2  
❑ 75 Nm  
3 - Earth cable  
❑ Depending on equip‐  
ment  
4 - Nut  
❑ Depending on equip‐  
ment  
❑ 20 Nm  
5 - Electrical connector  
6 - Nut  
❑ 20 Nm  
7 - Cover  
8 - Terminal 30/B+  
9 - Nut  
❑ Depending on equip‐  
ment  
❑ 20 Nm  
10 - Earth cable  
❑ Depending on equip‐  
ment  
11 - Bracket  
❑ For wiring harness  
Assembly overview - starter, 6-cylinder diesel engines  
34  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
1 - Starter motor -B-  
❑ Removing and instal‐  
ling ⇒ page 35  
❑ Checking ⇒ page 46  
2 - Bolt  
❑ 75 Nm  
3 - Electrical connector  
4 - Terminal 30/B+  
5 - Nut  
❑ 20 Nm  
6 - Bolt  
❑ Screwed from front or  
rear  
❑ 75 Nm  
3.2  
Removing and installing starter  
⇒ a3.2.1 nd installing starter, 4-cylinder diesel engine with man‐  
ual gearbox”, page 35  
⇒ a3.2.2 nd installing starter, 4-cylinder petrol engine with man‐  
ual gearbox”, page 38  
⇒ a3.2.3 nd installing starter, 4-cylinder diesel engine with auto‐  
matic gearbox”, page 42  
⇒ a3.2.4 nd installing starter, 6-cylinder diesel engine”, page  
45  
3.2.1  
Removing and installing starter, 4-cyl‐  
inder diesel engine with manual gear‐  
box  
Special tools and workshop equipment required  
3. Starter motor  
35  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ Torque wrench -V.A.G 1331-  
♦ Torque wrench -V.A.G 1332-  
Removing  
– Disconnect battery ⇒ page 11 .  
– Remove right engine mounting ⇒ Rep. gr. 10; Assembly  
mountings; Removing and installing engine mounting.  
– If fitted, remove underbody guard ⇒ General body repairs,  
exterior; Rep. gr. 66; Underbody guard; Removing and in‐  
stalling underbody guard.  
– Unclip sheathing of cable connections -arrows- to starter and  
pull down.  
– Disconnect electrical connector -1- of terminal 50 on starter.  
36  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew nut -2-.  
– Unscrew earth connection from starter -arrow-.  
Note  
♦ When removing and installing, the starter bolts can be  
reached without having to remove the diesel particulate filter,  
if one or more extensions are used.  
♦ To gain access to the upper starter bolt, work from gearbox  
end.  
♦ To gain access to the lower starter bolt, work from engine  
end.  
– Unscrew bolts -arrows- on starter -B-.  
– To remove starter -B-, unscrew bracket of coolant line from  
engine at top -arrow-.  
3. Starter motor  
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Amarok 2011 ➤, Amarok 2017 ➤  
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– Unscrew oil return pipe -1- and put it to one side. Wipe up  
any leaking engine oil with a cloth. Also unscrew bracket of  
coolant line -2-, and push coolant line upwards.  
– Release oil return line from turbocharger at bottom. Push oil  
return line a little away from cylinder block so that starter -B-  
can be guided out.  
– Rotate starter -B- -1- a little if required, and remove it to‐  
wards front.  
Installing  
Install in the reverse order of removal observing the following:  
Specified torques  
♦ ⇒ o3.1 verview – starter”, page 34  
3.2.2  
Removing and installing starter, 4-cyl‐  
inder petrol engine with manual gear‐  
box  
Special tools and workshop equipment required  
38  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
♦ Torque wrench -V.A.G 1331-  
♦ Torque wrench -V.A.G 1332-  
Removing  
– Disconnect battery ⇒ page 11 .  
– Removing catalytic converter ⇒ Rep. gr. 26.  
– Unscrew bolts -arrows- on heat shield above starter -B-, and  
remove heat shield.  
– Unscrew earth wire connection -arrow- on starter -B-.  
3. Starter motor  
39  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Detach guide tube for wires from starter -B- by unscrewing  
gearbox securing bolt -arrow-.  
– Unclip wiring connections on plastic bracket on top of gear‐  
box.  
– Separate electrical connector -arrow-.  
– Unscrew terminal 30 nut -arrow- on starter -B-.  
40  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew earth connection -arrow- on starter -B-.  
Note  
♦ To gain access to the upper starter bolt, work from gearbox  
end.  
♦ To gain access to the lower starter bolt, work from engine  
end.  
– Unscrew upper bolt -arrow- on starter -B-.  
– Unscrew lower bolt -arrow- on starter -B-.  
– Guide out starter -B- in direction of -arrow- between engine  
support and gearbox housing.  
Installing  
Install in the reverse order of removal, observing the following:  
When connecting terminal 30 on starter, it is essential that con‐  
nection terminal 30 -2- is turned on retaining pin in direction of  
3. Starter motor  
41  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
arrow until it comes into contact with plastic stop -1- on starter  
-B-. Tighten nut in this position.  
DANGER!  
If this is not done, the terminal 30 connection of the starter  
-B- may come into contact with the turbocharger housing,  
which in turn would cause a short circuit between the starter  
motor and the battery.  
Specified torques  
♦ ⇒ page 34  
3.2.3  
Removing and installing starter, 4-cyl‐  
inder diesel engine with automatic  
gearbox  
Special tools and workshop equipment required  
♦ Torque wrench -V.A.G 1331-  
♦ Torque wrench -V.A.G 1332-  
42  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
Removing  
– Disconnect battery ⇒ page 11 .  
– If fitted, remove underbody guard ⇒ General body repairs,  
exterior; Rep. gr. 66; Underbody guard; Removing and in‐  
stalling underbody guard.  
– Unscrew bolts of right engine support ⇒ Rep. gr. 10; Assem‐  
bly mountings.  
– Pull down sheathing of cable connections -1- on solenoid  
switch.  
– Disconnect electrical connector -2- of terminal 50 on starter  
-B-.  
– Unscrew nut -1- of terminal 30 on starter -B-.  
– Unscrew earth connection on starter -B- -1-.  
Note  
To gain access to the lower starter bolt, work from engine end.  
3. Starter motor  
43  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Unscrew lower bolt -1- on starter -B-.  
If necessary, use a long extension to unscrew the bolt through  
the engine mounting.  
– Unscrew upper bolt -1- from starter -B- using a long exten‐  
sion.  
– If fitted, detach bracket for exhaust gas recirculation cooler  
changeover valve -N345- from cylinder block.  
Vehicles with bi-turbo engine  
– Unscrew banjo bolt -2- for oil supply line -1-.  
– Catch any escaping oil with a cloth.  
Continued for all vehicles  
– Remove starter -B- by first moving it in -direction of arrow A-  
to remove it from gearbox housing and then pull it out up‐  
wards in -direction of arrow B-.  
44  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
Installing  
Install in the reverse order of removal, observing the following:  
Specified torques  
♦ ⇒ o3.1 verview – starter”, page 34  
3.2.4  
Removing and installing starter, 6-cyl‐  
inder diesel engine  
Special tools and workshop equipment required  
♦ Torque wrench -V.A.G 1331-  
♦ Torque wrench -V.A.G 1332-  
Removing  
– If fitted, remove underbody guard ⇒ General body repairs,  
exterior; Rep. gr. 66; Underbody guard; Removing and in‐  
stalling underbody guard.  
– Remove right engine support ⇒ Rep. gr. 13; Cylinder block,  
pulley end; Removing and installing engine support.  
3. Starter motor  
45  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
Version 1  
– Unscrew nut -3-.  
– Remove wire -4-.  
– Disconnect electrical connector -2-.  
– Unscrew bolts -5- and -6-.  
– Remove starter -1-.  
Version 2  
– Unscrew nut -3-.  
– Remove wire -4-.  
– Disconnect electrical connector -2-.  
– Unscrew bolts -5- and -6-.  
– Remove starter -1-.  
Installing  
Install in the reverse order of removal, observing the following:  
Note  
The specified torques must always be adhered to as otherwise  
the crankshaft sealing flange may be damaged.  
Specified torques  
♦ ⇒ o3.1 verview – starter”, page 34  
3.3  
Checking starter  
Check the starter -B- using the ⇒ Vehicle diagnostic tester.  
46  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
4
Start/stop system  
⇒ d4.1 escription - start/stop system”, page 47  
⇒ o4.2 verview - start/stop system”, page 48  
⇒ a4.3 nd installing start-stop operation button”, page 50  
⇒ a4.4 nd installing voltage stabiliser”, page 51  
4.1  
General description - start/stop system  
Note  
Additional information:  
⇒ Operating manual of vehicle  
⇒ Self-study programme No. 426; The start/stop system 2009  
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐  
tions  
General description:  
The start/stop system is used for reducing fuel consumption  
by automatically switching off the engine when the vehicle is  
stationary and automatically starting it when the driver wants  
the vehicle to move on. The start/stop mode is automatically  
activated when, after moving off, the vehicle is driven for about  
four seconds at a speed of at least 3 km/h. In towing mode, the  
start/stop system is switched off.  
Fault detection and fault display:  
The start/stop system as a function is integrated in the engine  
control unit -J623- software.  
The engine control unit -J623- features self-diagnosis to facili‐  
tate fault finding.  
For fault finding, use the systems described in chapter “Vehi‐  
cle diagnosis, testing and information system” in “Guided Fault  
Finding” mode ⇒ page 269 .  
Battery recharging or jump start on vehicles with start/stop sys‐  
tem:  
When recharging or jump starting vehicles with start/stop sys‐  
tem, note the following: first connect charging cable to battery  
positive terminal then body earth. This ensures that the battery  
monitoring control unit is not bridged. Charging the battery di‐  
rectly on the negative terminal causes the battery monitoring  
control unit to be bridged. The battery data is not collected by  
the battery monitoring control unit during the charging process.  
Then, the values concerning the battery state and saved in  
the data bus diagnostic interface would not correspond to the  
values of the charged battery.  
Replacing battery on vehicles with start/stop system:  
Because of its higher deep-cycle resistance, only an absorbent  
glass mat battery is used as a starter battery instead of the  
normal lead battery in vehicles with start/stop system.  
In case of repair, note correct part number designation in ETKA.  
The modified components for the start/stop system have no  
special markings. They do not differ externally, or hardly, from  
standard components.  
On vehicles with the start-stop system, the “Parametrising bat‐  
tery after replacement” procedure has to be performed after the  
4. Start/stop system  
47  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
battery is replaced to ensure that the start-stop system subse‐  
quently works properly.  
Following components are involved in the start/stop system:  
♦ Battery -A- ⇒ page 6  
♦ Alternator -C- ⇒ page 16  
♦ Voltage regulator -C1-  
♦ Starter -B- ⇒ page 34  
♦ Brake light switch -F-  
♦ Clutch pedal switch -F36-  
♦ Start/stop operation switch -E693- ⇒ page 50  
♦ Coolant temperature sender -G62-  
♦ Accelerator pedal position sender -G79-  
♦ Gearbox neutral position sender -G701-  
♦ Control unit for ABS with EDL -J104-  
♦ Climatronic control unit -J255-  
♦ Control unit with display in dash panel insert -J285-  
♦ Battery monitor control unit -J367-  
♦ Power steering control unit -J500-  
♦ Onboard supply control unit -J519- ⇒ page 263  
♦ Voltage stabiliser -J532- ⇒ page 51  
♦ Data bus diagnostic interface -J533- for vehicles up to  
06.2012 ⇒ page 265  
♦ Engine control unit -J623-  
Note  
♦ On vehicles up to 06.2012, there is a separate data bus  
diagnostic interface -J533- installed in conjunction with the  
start/stop system ⇒ page 265 .  
♦ In conjunction with the start/stop system, in all vehicles in‐  
cluding vehicles as of 07.2012 the data bus diagnostic inter‐  
face -J533- function is integrated into the onboard supply  
control unit ⇒ page 265 .  
♦ Removing data bus diagnostic interface -J533-, vehicles up  
to 06.2012 with start/stop system ⇒ page 265 .  
4.2  
Assembly overview - start/stop system  
Assembly overview - start/stop system up to model year 2017 ⇒  
page 48  
Assembly overview - start/stop system as of model year 2017 ⇒  
page 49  
Assembly overview - start/stop system up to model year 2017  
48  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
1 - Engine control unit -J623-  
2 - Start/stop operation switch  
-E693-  
❑ Removing and instal‐  
ling ⇒ page 212  
3 - Onboard supply control  
unit -J519-  
❑ Removing and instal‐  
ling ⇒ page 263  
4 - Diagnostics interface for  
data bus -J533-  
❑ On vehicles up to  
06.2012, there is a sep‐  
arate data bus diagnos‐  
tic interface -J533- in‐  
stalled in conjunction  
with the start/stop sys‐  
tem.  
❑ In conjunction with the  
start/stop system, in all  
vehicles including vehi‐  
cles as of 07.2012 the  
data bus diagnostic in‐  
terface -J533- function  
is integrated into the  
onboard supply control  
unit ⇒ page 265 .  
❑ Removing data bus  
diagnostic interface -  
J533-, vehicles up to  
06.2012 with start/stop  
system ⇒ page 265 .  
❑ Installed under dash  
panel in vicinity of  
steering column  
❑ Removing and instal‐  
ling ⇒ page 265  
5 - Voltage stabiliser -J532-  
❑ Installed in front left wheel housing  
❑ Removing and installing ⇒ page 52  
6 - Battery monitoring control unit -J367-  
❑ Installed near battery  
❑ Removing and installing ⇒ page 13  
Assembly overview - start/stop system as of model year 2017  
4. Start/stop system  
49  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
1 - Start/stop operation switch  
-E693-  
❑ Removing and instal‐  
ling ⇒ page 212  
2 - Onboard supply control  
unit -J519-  
❑ Removing and instal‐  
ling ⇒ page 263  
3 - Engine (motor) control unit  
-J623-  
❑ Removing and instal‐  
ling ⇒ Rep. gr. 23; En‐  
gine control unit; Re‐  
moving and installing  
engine control unit -  
J623-  
4 - Battery monitoring control  
unit -J367-  
❑ Removing and instal‐  
ling ⇒ page 13  
4.3  
Removing and installing start-stop op‐  
eration button  
⇒ a4.3.1 nd installing start-stop operation button up to model  
year 2017”, page 50  
⇒ a4.3.2 nd installing start-stop operation button as of model  
year 2017”, page 51  
4.3.1  
Removing and installing start-stop op‐  
eration button up to model year 2017  
Removing  
The start/stop operation switch -E693- -1- is located in the cen‐  
tre console switch unit. It is used to switch the start/stop system  
of manually.  
50  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Remove start/stop operation button -E693- ⇒ page 212 .  
Installing  
Install in reverse order of removal.  
4.3.2  
Removing and installing start-stop op‐  
eration button as of model year 2017  
Removing  
The start/stop operation button -E693- -1- is installed in the trim  
panel of dash panel. It is used to switch the start/stop system of  
manually.  
– Remove start/stop operation button -E693- ⇒ page 212 .  
Installing  
Install in reverse order of removal.  
4.4  
Removing and installing voltage stabil‐  
iser  
⇒ d4.4.1 escription - voltage stabiliser”, page 51  
⇒ a4.4.2 nd installing voltage stabiliserJ532”, page 52  
4.4.1  
General description - voltage stabiliser  
Note  
The voltage stabiliser -J532- has been installed until the end of  
2016.  
Role of voltage stabiliser:  
Voltage dips occur in the onboard supply system each time the  
engine is started due to the high current draw of the starter.  
4. Start/stop system  
51  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
To prevent any failure in the infotainment components and the  
dash panel insert when the engine is restarted, the voltage  
supply to the infotainment system and the dash panel insert is  
protected by means of voltage stabilisation. To do this, terminal  
30 is fed through a DC/DC converter during the starting process  
and the voltage is stabilised at 12V. The DC/DC converter is  
only active during the actual starting process (terminal 50). For  
other times, the converter is bridged with the aid of an internal  
relay and supply comes directly from the onboard supply sys‐  
tem (terminal 30).  
Effects in case of voltage stabiliser failure:  
When the starter is operated and the voltage supply is insuf‐  
ficient for devices like radio, radio navigation system or tele‐  
phone they will perform a reset. If, in start/stop mode, the men‐  
tioned electrical consumers are identified as causing a reset for  
each motor start, this indicates a defective voltage stabiliser.  
Direct entries concerning malfunction of the voltage stabiliser,  
e.g. in the event memory of the diagnostic interface or the on‐  
board supply control unit, are not done at present. If radio, radio  
navigation system and telephone units have failed together, first  
check fuse of voltage stabiliser.  
4.4.2  
Removing and installing voltage stabil‐  
iser -J532-  
Note  
♦ The voltage stabiliser -J532- has been installed until the end  
of 2016.  
♦ The voltage stabiliser is installed in the front left wheel hous‐  
ing.  
Removing  
– Switch off ignition and all electrical consumers, and withdraw  
ignition key.  
– Detach front left wheel housing liner.  
– Lower wheel housing liner; it is unnecessary to remove it  
completely.  
– Unscrew securing bolts -1- on voltage stabiliser.  
– Release and disconnect connector -1- on voltage stabiliser  
in -direction of arrow-.  
52  
Rep. gr.27 - Starter, current supply, CCS  
Amarok 2011 ➤, Amarok 2017 ➤  
Electrical system - Edition 12.2020  
– Remove voltage stabiliser from wheel housing.  
Installing  
Install in reverse order of removal.  
4. Start/stop system  
53  

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