Service Training Vehicles Self-study programme 464 The Amarok - Powertrain and drive concept Design and function‘s464_002 With the Amarok, Volkswagen Commercial Vehicles is deliberately and self-assuredly taking part in the global ‘trend towards multifunctional vehicles. ‘As such, the company is making consistent use of its extensive experience in manufacturing vehicles with both rear ‘and front-wheel drive. The newly developed drive concept offers outstanding driving properties. Comfortable handling and operation similar to a possenger car are features of the Amarok. Magnificent assistance is given for everyday use through a range of support systems in order to provide road safety and handling benefits when offroad. In all cases and in all variants, the Amarok can be used both onroad and for heavy-duty offroad use. Depending on use, the four-wheel drive version of the Amarok is available either with permanently or nen-permanently engaged four-wheel drive. The Amarok is also avoilable in @ standord version with rear-wheel drive. The entire driveline of the Amarok is « new development and has been specifically adapted for use as a commercial vehicle. Please also refer to self-study programme no. 463 “The Amarok". ‘The cllstudy programme presents the Cuan esting, ting and repair insrctions design and function of on be found in ho provided ew davelopments! eres Inranira ‘The content will not be updoted.Ata glance = Introduction . Four-wheel drive development at Volkswagen Commercial Vehicles The drive concept of the Amarok . OO RR The driveline « Operation . D The operation . . The offroad drive programme . ar a 6-speed manual gearbox 0C6 . 16 The 6-speed manual gearbox - « D, The gearbox structure and function . 18 — The gearbox sectional view . 20 The powerflow The external selector mechanism . The internal selector mechanism . Transfer box .. The non-permanently engaged four-wheel drive with transfer box OC7 ... 32 The transfer box with limited-slip interaxle differential OBU. . o Rear final drive OCC . The rear final drive OCC Front final drive OC... The front final drive OCI na . 58 Test your knowledge ..Introduction Volkswagen Commercial Vehicles &4 Four-wheel drive development at Volkswagen Commercial Vehicles began to manufacture four-wheel drive vehicles in-house in 1983 inthe form of the LT] 4x4. This was an early response to the desire for as wide @ range of vehicle applications as possible — from driving on smooth roads through to use on very difficult ground. The four-wheel drive is better able to overcome traction problems when used in sports applications and, in particular, as @ commercial vehicle. Un bea from 1983C) a Volkswagen Commercial Vehicles markets vehicles all over the world, therefore the company is used to taking ‘account of special conditions, such as in remote areas and difficult open ground ~ four-wheel drive represents an ideal solution for this. Amarok 4MOTION from 2010 Caddy 4MOTION from 2009 5 4MOTION from 2004 $464_051Introduction The drive concept of the Amarok offers 3 different drive variants. The Amarok's powertrain is efficiently supported by intelligent vehicle dynamics programmes. CE The drive concept of the Amarok 464_058 Vehicle dynamics programmes The Amarok is equipped with the following vehicle dynamics programmes: © ABS (as standard) © Offroad drive programme (as standard) © TCS (as standerd) © Hill-descent assist MSR (as standard) © Hill-hold ossist EDL (as standard) © ESPRear final drive In the Amarok with rear-wheel drive, the power is. transmitted via a propshaft to the rear axle only. Even with only rear-wheel drive, the Amarok can be used on both consolidated and non-consolidated roads as well as offroad, Permanent four-wheel drive with limited-slip interaxle differential OBU In the Amarok with permanently engaged four-wheel drive, he powerflow to both driven axles is distributed by means of a transfer box with permanent engagement using a limited: This offers improved traction compared to rear-wheel drive, above all when offroad. interoxle differential Non-permanently engaged four-wheel drive with part- transfer box OC7 In the Amarok with non-permanently engaged four- whee! drive, the powerflow to the driven axle is distributed using a transfer box with electrically engaged front final drive. Iris also possible to engage « reduction stage (offroad ratio) in this transfor box. In this version, the Amarok is even better suited for vse on difficult ground. V Aéd_006 s464_074 464_005Introduction The driveline The Amarok has modular driveline in which the individual components such as manual gearbox, front final drive, transfer box ond rear final drive are independent subassemblies. Rear axle Gearbox ‘At present, the 6-speed manual gearbox OC6 is used for transmitting power from the engine Transfer box Power is distributed to the final drives either by means Rear fiol dive of the transfer box OC7 (non-permanently engaged four-wheel drive) or OBU (permanently engaged four-wheel drive). Propshafts Three different two-part propshatts are used for driving the rear axle. The front part of the propshaft has a length that is adapted to the particular drive version. is identical in both versions of the four-wheel drive. A one-piece propshat is fitted for driving the front axle, ThiRear final drive, front final drive The rear final drive OCC orranged in a symmetricel instellation position is used for driving the rear axle. The rear axle differential can be locked up. The front finel drive OCT is used for driving the front axle, and is available in two different designs. The front final drive is asymmetrically arranged. Rear propshaft Transfer box 6 speed manuel gearbox Front propshaft 464_007 Front final drive The illustration shows the drivetrain with non-permanently engaged four-wheel drive.10 Operation The operation Four-wheel drive, the reduction ratio (offroad ratio), the differential lock and the offroad drive programme are engaged and disengaged using « bution panel in the centre console. The status is displayed by warning lamps K181, K1B2 and K183. The four-wheel drive components are each electrically connected to the georbox. This means no additional selector levers are required for operating the four-wheel drive ranges. Centre console button assignments Key £631 Kiel K183 Kis E631 Running gear programme switch (switching on) Normal operation warning lamp in transfer box operating unit (4x2) Longitudinal lock-up warning lamp in transfer box operating unit (44 HIGH) Reduction geering warning lamp in transfer box operating unit (4x4 LOW) Running gear programme switch E256 TCS and ESP button (TCS deactivation) E121. Rear differential lock switch 598. Driving programme button (offroad driving programme) £256, E121 and E598 do not have function lighting In right-hand drive vehicles, button panel E631 is fitted con the other side of the selector lover.Displays on the dash panel insert Each of the four-wheel drive statuses thet are activated during operation is backlit in the button panel and also shown in the dash panel insert as a status display. » The status of 4x2 rear-axle mode is only displayed in the centre console. e @ “we Ka77—K243. Key K278 Longitudinal lock-up warning lamp (4x4 HIGH) K277 Warning lamp for gearbox low range K276 Warning lamp for rear transverse lock K47 ABS warning lamp (ABS fault or ABS deactivated) K86 Traction control system warning lamp (Fault, control or deactivated) 243. Driving programme warning light (offroad driving programme) 1Operation Four-wheel drive 4x4 HIGH Display in the dach panel insert «four-wheel drive is engaged (interaxle lock engaged) Qi ‘Switeh-on conditions Switch-off conditions © Terminal 15 "ON" © Terminal 15 "ON" © 631 (up) pressed > 05s © £631 (down) pressed > 05s © Can be engaged at any vehicle speed © Can be switched off at any vehicle speed © No undervoltage # No underveltage © No relevant error memory entry © No relevent error memory entry Offroad range 4x4 LOW Display in the dach panel insert .- four-wheel drive is engaged and LOW C) @ reduction ratio engaged $464_079 ‘Switeh-on conditions Switeh-off conditions Engine speed < 1500 rpm F631 (up) pressed > 05s Vehicle speed v <1 km/h 4x4 HIGH engaged No undervoltage No relevant error memory entry Engine speed < 1500 rpm £631 (down) pressed > 0.5 s Vehicle speed v-< Tkm/h No undervoltage No relevant error memory entry 12