Volkswagen Amarok (2013) Body builder guidelines

Body builder guidelines 2013

Body builder guidelines
Amarok

Table of contents

Table of contents .............................................................................................................................................................................................. 2

1 General information .................................................................................................................................................................................... 6

1.1 Introduction ............................................................................................................................................................................................ 6

1.1.1 Concept of these guidelines........................................................................................................................................................ 7

1.1.2 Means of representation ............................................................................................................................................................. 8

1.1.3 Vehicle safety ............................................................................................................................................................................... 9

1.1.4 Operational safety..................................................................................................................................................................... 10

1.2 General notes ................................................................................................................................................................................ 11

1.2.1 Product and vehicle information for body builders ............................................................................................................... 11

1.2.1.1 Contact ........................................................................................................................................................................... 11

1.2.1.2 Conversion Portal ......................................................................................................................................................... 12

1.2.1.3 Electronic Repair and Workshop Information from Volkswagen AG (erWin*) .................................................... 13

1.2.1.4 Genuine parts online ordering portal* ....................................................................................................................... 14

1.2.2 Body builder guidelines and consulting ................................................................................................................................. 14

1.2.2.1 Safety certificate ........................................................................................................................................................... 15

1.2.2.2 Application for the safety certificate .......................................................................................................................... 15

1.2.2.3 Legal entitlements ......................................................................................................................................................... 16

1.2.3 Warranty and product liability of the body builder .............................................................................................................. 16

1.2.4 Ensuring traceability .................................................................................................................................................................. 17

1.2.5 Trademarks ................................................................................................................................................................................. 17

1.2.5.1 Positions on rear of the vehicle ................................................................................................................................... 17

1.2.5.2 Appearance of overall vehicle .................................................................................................................................... 17

1.2.5.3 Non-Volkswagen trademarks .................................................................................................................................... 17

1.2.6 Recommendations for vehicle storage .................................................................................................................................... 18

1.2.7 Compliance with environmental rules and regulations ........................................................................................................ 19

1.2.8 Recommendations for inspection, maintenance and repair ................................................................................................. 20

1.2.9 Accident prevention ................................................................................................................................................................... 20

1.2.10 Quality system ......................................................................................................................................................................... 21

1.3 Delivery range ...................................................................................................................................................................................... 22

1.4 Advantages of the concept ................................................................................................................................................................ 23

1.5 Planning bodies ................................................................................................................................................................................... 24

1.5.2 Vehicle modifications ................................................................................................................................................................ 25

1.5.3 Vehicle approval ........................................................................................................................................................................ 25

2 Technical data for planning ...................................................................................................................................................................... 27

2.1 Base vehicle.......................................................................................................................................................................................... 27

2.1.1 Vehicle dimensions .................................................................................................................................................................... 27

2.1.1.1 Basic data Single Cab and Double Cab .................................................................................................................... 29

2.1.2 Overhang angle and ramp angle ............................................................................................................................................ 31

2.1.3 Vehicle centre of gravity ........................................................................................................................................................... 32

2.1.4 Bodies with a high centre of gravity ....................................................................................................................................... 32

2.1.4.1 Extremely high centres of gravity ( >800 mm) ......................................................................................................... 32

2.1.5 Determining centre of gravity .................................................................................................................................................. 33

2.1.6 Maximum dimensions ............................................................................................................................................................... 34

2.1.7 Steerability .................................................................................................................................................................................. 36

2.2 Running gear ........................................................................................................................................................................................ 37

2.2.1 Permitted weights and unladen weights ................................................................................................................................ 37

2.2.1.2 One-sided weight distribution .................................................................................................................................... 38

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2.2.2 Turning circle............................................................................................................................................................................... 39

2.2.3 Authorised tyre sizes ................................................................................................................................................................. 39

2.2.4 Modifications to axles ............................................................................................................................................................... 39

2.2.5 Modifications to the steering system....................................................................................................................................... 39

2.2.6 Brake system and brake control system ESP* ........................................................................................................................ 40

2.2.6.1 General notes ................................................................................................................................................................ 40

2.2.6.2 Vehicle stability and ESP* ............................................................................................................................................ 41

2.2.6.3 Influence of vehicle conversions on the function of the brake regulation system ESP* ....................................... 42

2.2.6.4 Downgrading ESP* ....................................................................................................................................................... 43

2.2.6.5 Activating the ESP* ....................................................................................................................................................... 43

2.2.7 Modification of springs, suspension mounting, dampers ..................................................................................................... 44

2.2.8 Wheel alignment settings ......................................................................................................................................................... 44

2.2.9 Wings and wheel houses .......................................................................................................................................................... 44

2.2.10 Overhang extension ................................................................................................................................................................ 45

2.2.10.1 Requirements for trailer operation with overhang extension ........................................................................................ 46

2.2.11 Wheelbase modification ......................................................................................................................................................... 47

2.3 Body-in-white ...................................................................................................................................................................................... 48

2.3.1 Roof loads/vehicle roof ............................................................................................................................................................ 48

2.3.1.1 Dynamic roof loads ...................................................................................................................................................... 48

2.3.1.2 Static roof loads ............................................................................................................................................................ 48

2.3.2 Modifications to the body-in-white......................................................................................................................................... 49

2.3.2.1 Screw connections ........................................................................................................................................................ 49

2.3.2.2 Welding work ............................................................................................................................................................... 50

2.3.2.3 Welded connections ..................................................................................................................................................... 50

2.3.2.4 Selection of welding process ....................................................................................................................................... 51

2.3.2.5 Spot welding ................................................................................................................................................................. 51

2.3.2.6 Shielding gas hole spot welding ................................................................................................................................ 52

2.3.2.7 Tacking ........................................................................................................................................................................... 53

2.3.2.8 Welding is not allowed ................................................................................................................................................ 53

2.3.2.9 Corrosion protection after welding ............................................................................................................................ 53

2.4 Interior ................................................................................................................................................................................................... 57

2.5 Electrics/electronics ............................................................................................................................................................................. 58

2.3.2.10 Corrosion protection measures ................................................................................................................................. 53

2.3.2.11 Planning measures ..................................................................................................................................................... 53

2.3.2.12 Component design measures .................................................................................................................................... 55

2.3.2.13 Coating measures ....................................................................................................................................................... 55

2.3.2.14 Work on the vehicle ................................................................................................................................................... 55

2.3.3 Tailgate ....................................................................................................................................................................................... 56

2.4.1 Modifications in the area of airbags ....................................................................................................................................... 57

2.4.2 Modifications in the area of seats ........................................................................................................................................... 57

2.4.3 Forced ventilation ...................................................................................................................................................................... 57

2.4.4 Acoustic insulation ..................................................................................................................................................................... 57

2.5.1 Lighting ....................................................................................................................................................................................... 58

2.5.1.1 Vehicle lighting devices ............................................................................................................................................... 58

2.5.1.2 Mounting special lights ................................................................................................................................................ 58

2.5.1.3 Installing 3rd brake light ............................................................................................................................................. 58

2.5.1.4 Additional load compartment light ............................................................................................................................ 58

2.5.2 Vehicle electrical system ........................................................................................................................................................... 58

2.5.2.1 Electrical cables/fuses .................................................................................................................................................. 58

2.5.2.2 Additional circuits ......................................................................................................................................................... 59

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2.5.2.3 Retrofitting electrical devices ...................................................................................................................................... 60

2.5.2.4 Electromagnetic compatibility ..................................................................................................................................... 60

2.5.2.5 Mobile communication systems .................................................................................................................................. 61

2.5.2.6 CAN bus ......................................................................................................................................................................... 61

2.5.3 Electrical interface for special vehicles ................................................................................................................................... 62

2.5.3.1 Position of the interface ............................................................................................................................................... 62

2.5.3.2 Assignment of the terminal strip (UF1) ...................................................................................................................... 64

2.5.3.3 Connector pin assignment and circuit diagrams for interface for special vehicles .............................................. 67

2.5.4 Vehicle battery ........................................................................................................................................................................... 68

2.5.3.1 Installation of additional battery ................................................................................................................................ 68

2.5.5. Digital tachograph (EC monitoring device) ........................................................................................................................... 68

2.6 Engine peripherals/powertrain ......................................................................................................................................................... 69

2.6.1 Engine/powertrain components .............................................................................................................................................. 69

2.6.2 Drive shafts ................................................................................................................................................................................. 69

2.6.3 Fuel system ................................................................................................................................................................................. 69

2.6.4 Exhaust system........................................................................................................................................................................... 70

2.7 Ancillary drives, engine/gearbox...................................................................................................................................................... 71

2.7.2. Driving an ancillary via the 2nd belt track*........................................................................................................................... 72

2.7.3. Specifications of standard refrigerant compressor ............................................................................................................... 73

2.7.3.1 Connection measurements of standard refrigerant compressor ............................................................................. 74

2.7.4 Installation and removal of the poly V-belt ........................................................................................................................... 78

2.7.4.1 Removal of the belt ...................................................................................................................................................... 78

2.7.4.2 Installation of the belt .................................................................................................................................................. 78

2.7.4.3 Working range of the belt tensioner: ......................................................................................................................... 79

2.7.4.4 Belt routing .................................................................................................................................................................... 80

2.8 Add-ons/units ...................................................................................................................................................................................... 81

2.8.1 Roof rack ..................................................................................................................................................................................... 81

2.8.2 Towing bracket .......................................................................................................................................................................... 82

2.8.3 Other accessories ....................................................................................................................................................................... 83

2.9 Lifting the vehicle ................................................................................................................................................................................. 83

3 Modifications to closed bodies ................................................................................................................................................................. 84

3.1 Body-in-white/bodywork .................................................................................................................................................................. 84

3.1.1 Side wall and rear wall cut-outs ............................................................................................................................................. 84

3.1.2 Installation of windows ............................................................................................................................................................ 84

3.1.3 Roof cut-outs .............................................................................................................................................................................. 85

3.1.4 Modifications to the roof .......................................................................................................................................................... 85

3.2 Interior ................................................................................................................................................................................................... 86

3.2.1 Safety equipment ....................................................................................................................................................................... 86

4 Modifications to open bodies ................................................................................................................................................................... 87

4.1 Removal of the cargo box .................................................................................................................................................................. 87

4.1.1 Removal of tail lights ................................................................................................................................................................ 88

4.1.2 Releasing the parking brake cable at the rear ...................................................................................................................... 88

4.1.3 Removal of the wheel housing liner ........................................................................................................................................ 89

4.1.4 Removal of the filler neck ......................................................................................................................................................... 90

4.1.5 Unscrewing securing bolts ........................................................................................................................................................ 91

4.1.6 Removal of the bumper ............................................................................................................................................................ 91

4.1.7 Recommendations for attaching the filler neck ..................................................................................................................... 92

4.1.7.1 Diesel filler pipe ............................................................................................................................................................ 93

4.1.7.2 Petrol filler pipe ............................................................................................................................................................. 94

4.1.8 Weight of cargo box ................................................................................................................................................................. 94

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4.2 Chassis frame ....................................................................................................................................................................................... 95

4.2.1 Ladder frame Amarok DC (Double Cab) ................................................................................................................................ 95

4.2.2 Ladder frame Amarok SC (Single Cab) .................................................................................................................................. 96

4.2.3 Sections, Amarok SC (Single Cab)/Amarok DC (Double Cab) ............................................................................................ 97

4.3 Standard mounting points for special bodies .................................................................................................................................. 98

4.4 Subframe (mounting frame) ............................................................................................................................................................. 100

5 Implementations of special bodies ........................................................................................................................................................ 101

5.1 Conversions for people with disabilities ........................................................................................................................................ 101

5.2 Refrigerated vehicles ......................................................................................................................................................................... 102

5.3 Shelf installation/workshop vehicles .............................................................................................................................................. 103

5.4 Conversions for caravans ................................................................................................................................................................. 104

5.5 Conversions for municipal vehicles ................................................................................................................................................. 105

5.6 Articulated vehicles ........................................................................................................................................................................... 105

5.7 Elevated work platforms .................................................................................................................................................................. 106

5.8 Crane superstructures and lift systems ........................................................................................................................................... 107

6 Technical data ........................................................................................................................................................................................... 108

6.1 Build dimension drawings ................................................................................................................................................................ 108

6.1.1 Amarok Double Cab................................................................................................................................................................ 108

6.1.2 Amarok Single Cab ................................................................................................................................................................. 108

6.2 Diagrams (foil templates) ................................................................................................................................................................. 109

6.2.1 Amarok Double Cab (all views) ............................................................................................................................................ 109

6.2.2 Amarok Single Cab (all views) .............................................................................................................................................. 109

6.2.3 Side view all derivatives ........................................................................................................................................................ 110

6.3 Circuit diagrams ................................................................................................................................................................................. 111

6.4 CAD models........................................................................................................................................................................................ 111

6.5 Weight tables ..................................................................................................................................................................................... 112

6.5.1 Weight tables Amarok Double Cab ...................................................................................................................................... 112

6.5.1.2 Amarok Double Cab .................................................................................................................................................. 112

6.5.1.3 Amarok Double Cab chassis/CabChassis ............................................................................................................... 114

6.5.2 Weight tables Amarok Single Cab ........................................................................................................................................ 116

7 Calculation ................................................................................................................................................................................................ 118

7.1 Determining the centre of gravity .................................................................................................................................................... 118

8 Listings ....................................................................................................................................................................................................... 125

8.1 List of changes ................................................................................................................................................................................... 125

6.5.2.1 Amarok Single Cab: ................................................................................................................................................... 116

6.5.2.2 Amarok Single Cab - chassis/CabChassis .............................................................................................................. 117

7.1.1 Determining the centre of gravity in x-direction .................................................................................................................. 118

7.1.2 Determining the centre of gravity in z-direction .................................................................................................................. 120

* Electronic Stabilisation Program

Table of contents

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 5 of 130

1 General information

1 General information

1.1 Introduction

These body builder guidelines provide body builders with important technical information whi ch must be complied with when
planning and manufacturing a body for road safety and operational reliability. The add-on, body, installation or conversion work
required for this is referred to below as "body activities".
Due to the vast number of body builders and body types, it is not possible for Volkswagen AG to predict all possible changes,
e.g. in driving properties, stabil ity, weight distr ibution, centre of gravity of the vehicle and its handling characteristics which can
occur due to the body activities. Theref ore, Volkswagen AG does not accept any liability for accidents or injuries arising from
changes of this kind made to its vehicles, especially if the changes have a negativ e effect on the vehicle as a whole. As a res ult,
Volkswagen AG only accepts liability for its own design, production and instruction servic es. The body builder itself is obliged to
ensure that its body activities are not faulty in themselves, and also that they cannot result in defects or dangers on the vehicle
as a whole. The body builder itself bears the product liability in the event that this obligation is viol ated.
These body builder guidelines are intended for professi onal body builders. As a result, these body buil der guidelines assume
corresponding background knowledge. Note that some work (e.g. welding on lo ad-bearing parts ) is only allowed to be
performed by appro priately qualif ied personnel. This requirement exists in order to avoid r isks of injury and to achi eve the
quality needed in t he body activities.

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1.1.1 Concept of these guidelines

The following body builder guideli nes are divided into 7 chapters so that you can find information r apidly:

1 General information
2 Technical data for planning
3 Modifications to closed bodies
4 Modifications to open bodies
5 Implementations of special bodies
6 Technical data
7 Listings

Information

For further inf ormation see 1.2.1. 1 " Contact", 1.2.2
"Body builder guidelines, consulti ng" and 1.3 "Delivery
range".

The limit values selected in chapter 2 "Technical data
for planning" must be complied with without fail, and
must be used as the basis for planning.

1 General information

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1.1.2 Means of representation

The following means of representation are used in these body builder guidelines :

Warning note

A danger note draws yo ur attention to possible
accident or injur y risks to which you or other persons
might be exposed.

Environmental note

An environmental note provides you wit h information
about environmental protection.

Practical note

This note draws your attention to a possible risk of
damage to the vehic le.

1 General information

More information

This note indicat es additional infor mation.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 8 of 130

1 General information

1.1.3 Vehicle safety

Warning note

Before installing external add-on s or mechanical uni ts,
it is essential that you read the chapters in these body
builder guidelines that are related to installation, as well
as corresponding chapters in the instructions and
information for the suppliers' mechanical units and i n
the detailed owner's manual for the base vehicle.
Otherwise you will not be able to recognise dangers,
and might expose your self or others to danger.

We recommend that yo u use parts, mechani cal units, conversion parts or accessories that have been tested by Volkswagen AG
for the correspondi ng vehicle type.
Have the vehicle's safety checked immediately if non-recommended parts, m echanical units, conversion parts or accessories
are used.

Practical note

It is essential to comply with national registration
regulations because body activiti es on the vehicle can
alter the vehicle type under registration regulations and
the operating permit may be invalidated. This applies in
particular t o:

– modifications which change the vehicle type approved

in the operating per m it,

– modifications which might be expect ed to endanger

road users or

– modifications which impair the exhaust or noise

emissions characteristics.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 9 of 130

1.1.4 Operational safety

Warning note

Incorrect int erventions in electronic components and
their software may result in these no longer functioning.
Due to the network ing of electronics, systems that were
not modified can be affected.
Malfunctions in the electronics can significantly impair
the operational s afety of the vehicle.
Have work on or modifications to electr onic
components perf ormed by a qualifi ed specialist
workshop which has the necessary spec ialist
knowledge and tools for performing the necessary
work.
Volkswagen AG recom m ends a Volkswagen AG
customer service workshop f or this purpose.
Service by a qualified specialist wor kshop is essential,
in particular for safety-relevant work and work on
safety-relevant systems.
Some safety syst ems only operate when the engine is
running. Therefore, do not switch the engine off when
driving.

1 General information

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 10 of 130

1 General information

Free hotline
(from a German landl ine)

0800

Letter:

Volkswagen Customer Support
Postfach 1998
38436 Wolfsburg

Contact form:

http://www.volkswagen-nutzfahrzeuge.de/de/kontakt/ihr_kontakt_zu_uns.htx

Contact for questions about
payload increases/reductions:

http://www.volkswagen

1.2 General notes

1.2.1 Product and vehicle information for body builders

1.2.1.1 Contact

If you have questions about vehicle m odels from Volkswagen Commercial Vehicles, you can contact us on the Internet on the
Conversion Portal of Volkswagen AG ( www.umbauportal.de

Per

-86228836.

) using one of the following methods:

-nutzfahrzeuge.de/de/kontakt/technische_frage.htx

For swift processing, we require a clearly legible copy of the vehicle document s, logbook or vehicle registration doc ument
together with your question.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 11 of 130

1 General information

1.2.1.2 Conversion Portal

The Conversion Portal of Volkswagen Nutzfahrzeuge AG offer s body builders not only a direct point of contact via the free
hotline, but also the opportunity to find out details about products, syst em s and topics relating t o all aspects of Volkswagen
commercial vehi cle bodies.

Information

The Conversion Portal of Volkswagen AG c an be
reached at the foll owing Internet address:

http://umbauportal.de/

In order to clarify your technical questions on the base vehicle, we offer you as a registered user the opportunity to use the
contact form on the Conversion Portal to make direct contact with support for commercial vehicl e body builders.

Information

The contact for m of Volkswagen AG can be reached at
the following Internet address:

http://umbauportal.de/kontaktformular

Volkswagen Nutzfa hrzeuge AG has developed an innovative partner system with the objective of intensifying cooperation with
you, and to make it easier for the customers and dealers of Volkswagen commercial vehicles to search for a suitable body
builder as easil y as possible. In the new C onversion Portal, you as a body builder have the opportunity to select between three
forms of cooperation:

– Registered user
– Integrated partn er
– Premium partner

Registered user

As a registered m em ber, you have access to a wide range of technical data and information, such as:

– CAD data

Here, you can order CAD data in Catia V5 and STEP f ormats for the corresponding vehicl es for delivery by post.
Please only request the CAD data for current conversion pr ojects because the dat a m odules are subject to updates.

– Additional technical information

The "Additional technical information" section provides you with detailed information about various topics. The descriptions
help you in planning a nd carrying out your c onversions.

– Marketing

In addition to the product catalogues, w e offer you as a registered user access t o the sales manuals incl. price informati on for
our model range in Ger m any and for export. F urthermore, you rec eive the current product information documents about
changes & new featur es on the vehicles in question, on a continuous basis. Using t he F leet Ordering Configurator, you can
access Group systems, and you have up-to-date i nformation for your vehicle configurations.

– List of questions ( technical FAQs)

This page contains a list of answers to the most frequently asked questions.

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1 General information

– Newsletter

Subscribe to the technical newsletter and receive regular e-mail notification about current topics. This includes current
technical modifications to Volkswagen commercial vehi cles, information about exhibitions , training courses and events as well
as news of general interest relating to bodies and conversions.

Make use of these possibilities and regi ster on the websit e: http://umbauportal.de/

using the link "B ecome a partner".

Integrated partner

– Your company will be pr esented to the user s of the Conversion Por tal as an integrated partner of Volkswagen C om m ercial

Vehicles. In this way, you can reach end users and dealers in a target ed w ay.
– We use your proposals and suggestions for model development.
– As an integrated partner, you have the opp ortunity to publis h your company information and contacts for your customer s and

the dealers of Volkswagen Commerci al Vehicles.
– Benefit from acc ess to additional inf ormation in the logon area for registered users:

Premium partner*

– Your company is presented as a selected specialist in the br anch in question, and can present its products in the Conversion

Portal.
– The products you display in the Portal must undergo a safety as sessment by Volkswagen Commercial V ehicles. In this way,

Volkswagen Commer cial Vehicles confirms that the body or conversion is technically safe. You can also use the safety

assessment for commercial purposes.
– Following prior agr eement, your products can be presented together with Volkswagen commercial vehicles at exhibitions.

Information

For more informat ion about the partnership system and
registration, refer to:

http://umbauportal.de/

* Advantages for integrated partners automatically also apply to premium partners.

1.2.1.3 Electronic Repair and Workshop Information from Volkswagen AG (erWin*)

Body builders can access repair and workshop information, e.g.
– Circuit diagrams
– Repair manuals
– Maintenance
– Self-study program mes
via the Electroni c Repair and Workshop Information from V olkswagen AG (erWi n*).

Information

Volkswagen AG workshop manuals and work shop
information can be downloaded from the Internet at
erWin* (Electronic Repai r and Workshop Information
from Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

* Information system from Volkswagen AG, subject to payment

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1 General information

1.2.1.4 Genuine parts online ordering portal*

For the purchase of spare parts and for the research of Volk swagen Genuine Parts, our latest parts c atalogues are available on
the Internet on the "Genuine Parts O nline Ordering Portal":

www.partslink24.com

* Information system from Volkswagen AG, subject to payment

1.2.2 Body builder guidelines and consulting

The body builder guidelines define the t echnical requirem ents for custom body bui lders and equipment fitters designi ng and
mounting bodies for base vehicles of the Volkswagen Commercial Vehicles br and.
The body builder guidelines must be s trictly adhered to when performing any modi fications to the vehi cle.
Ensure that no modification adversely affects the functional reliabili ty and safety of the runni ng gear, the body or t he electric
system. Modif ications must only be performed by qualified specialists and in accordance with the generally acknow ledged rules
of the automotive industry.
Prerequisites for modificati ons to used vehicles:
The vehicle shall be in a good overall condi tion, i.e. structural parts such as longitudinal and cross members, pillars etc. shall
not be corroded to such an extent that structural stability might be adversely affected.
Vehicles whose modi fications might affect the validi ty of the general certificate of roadworthiness must be presented to an
authorised testing centre for appr oval. It is recommende d to clarify in advance with the relevant a uthority whether approval is
required.
Please contact us if you have questions about proposed modif ications.

Information

Please use the online contact form:

http://umbauportal.de/kontaktformular

We require prec ise information from you in order to respond to your enquiry quickly and comprehensivel y.
When making enquiri es, please enclos e two sets of design draw ings of the complet e scope of the modifications, including all
weights, centre of gravity and dimens ions, which also clearly show how the body i s attached to the chassis. Please also provide
information about the intended operating conditions of the vehicle with your enquiry.

If bodies comply with the present body builder guidelines , no additional appr oval by Volkswagen AG is required for the
presentation of t he vehicle at the relevant authority e xamining roadworthi ness.
The work safety r egulations of the trade as sociation and the EC M achinery Direct ive apply.
When making modifications to vehicl es, all corresponding and applicable legal regulations, rules, laws and directives must be
observed.

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1 General information

1.2.2.1 Safety certificate

Volkswagen AG does not issue body approvals for non-Volks w agen bodies. It mer ely provides body builder s with important
information and technical specifications for dealing with the product in these guidelines. As a result, Volkswagen AG
recommends that al l work should be carr ied out on the base vehicle and the body in acc ordance with the current Volkswagen
body builder guidel ines applicabl e to the vehicle in quest ion.
Volkswagen AG does not recommend body ac tivities which
– are not conducted according to these Volkswagen body builder guidelines
– exceed the gross vehicle weight rati ng
– exceed the gross axle weight rating.

Volkswagen AG issues safety certificates on a voluntary bas is, as follows:
The assessment conducted by Volkswagen AG is exclusively based on the documents submitted by the body builder which is
carrying out the modifications. The inspection and safety assessment only rel ate to the express ly designated scope of w ork, its
basic compatibility with the designated chassis and it s interfaces or, in t he event of chassis modi fications, the f undam ental
admissibilit y of the design for the desi gnated chassis. T he safety certific ate does not relate to the design of the body overal l, its
functions or pl anned application. Safety is only provided i f the design, production and install ation are carried out by the body
builder performi ng the modificat ions in accordance with the state of the ar t and in accordance with the applicable body builder
guidelines of Vol kswagen AG - and assuming any deviations from these guidelines have been declared to be technically safe.
The safety certificate does not releas e the body builder who i s performing the modi fications from its responsibility or the product,
or from its obli gation to carry out it s ow n calculations, t ests and a trial of the ent ire vehicle in order to ensure that the operational
safety, road safety and driving proper ties of the overall vehicle it has manufactured are acceptable. Accordingly, it is necessary
to ensure that the body builder exclusi vely accepts its responsibility f or ensuring that its body activities are compatible with t he
base vehicle as w ell as the operational and road safety of the vehicle. It is expressly stated that the safety certificate from
Volkswagen AG does not represent a technical approval for the investigated changes.

Practical note

Country-specif ic laws, directives and approval
regulations shal l be observed!

1.2.2.2 Application for the safety certificate

In order for the eval uation to be carried out for the safety c ertificate, the following documents and dr aw ings shall be submitted to
the responsible department before the start of work on the vehicle (see 1.2 General notes):
– All deviations from these Volkswage n body builder guideli nes
– All data about dimensions, weight and centre of gravity (weighing certificates)
– Attachment of the body on the vehicle
– Application condi tions of the vehicle, e.g.

 on rough roads
 in very dusty condit ions
 at high altitudes
 at extreme outdoor temperatures

– Certificates (e-registration, seat tensile test)

Complete documentation avoids the need for clarification queries, and mak es the processing faster.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 15 of 130

1.2.2.3 Legal entitlements

– There is no legal enti tlement for a safety certificate to be issued.
– Due to further technical developments and their findings , Volkswagen AG can r efuse a safety certificate.
– The safety certificate can be restr icted to individual ve hicles.
– The subsequent issue of a safety certificate may be refus ed for vehicles that have already been compl eted or delivered.
– The body builder is solely responsibl e for

 the function and compatibility of its body activiti es w ith the base vehicle
 road safety and operational reliability
 all body activities and installed parts

1.2.3 Warranty and product liability of the body builder

The body builder's or fitter's warrant y conditions apply to the body builder's or fitter's scope of supply. Therefore, w arranty
claims associated with complaint s to this scope of supply cannot be made under t he w arranty conditions applicable to
Volkswagen Commer cial Vehicles.
Defects of bodies, installations and conversions pr ovided by third parties as well as defects of the vehicle caused by the said
bodies, instal lations or conversions are excluded from the Volkswagen warranty and also from the Volkswagen paint and body
warranty. This also applies to accessories which wer e not installed and/or s upplied by the vehicle manufacturer.
The body builder or fitter is solely responsible for the design and assembly of bodies and the execut ion of conversions.
All conversions must be documented by the body builder or fitter in the service schedule. This service schedule is provided with
every Volkswagen vehicle.
Due to the multitude of conversions and diversity of operating conditions, the information provi ded by Volkswagen AG i s subject
to the reservati on that modified vehicles are not tested by Volkswagen AG. Modifications may affect the properties of the
vehicle.
For reasons of liability, the body builders or fitters shall provide the fol lowing information in writing to thei r customers:

"Due to the modifi cations* to your Volkswagen Commercial V ehicles base vehicle, the properties of your base vehicle may have
changed". Please understand that Volkswagen AG does not assume any liability for any negative eff ects resulting from the
modifications* to the vehicle."

In individual cas es, Volkswagen AG reserves the right to demand proof of the information being pass ed on to the customer.

No general legal enti tlement for the approval of a body modif ication exists, even if such approval was previously granted. If
bodies comply with the present guidelines, no additional a pproval by Volkswagen AG is required for the presentation of the
vehicle at the relevant authority examining roadworthi ness.

* At this point, the term "modification" may be substituted by a more precise description of the work performed, e.g. by "camping equipment installation", "wheelbase extension", "box

body".

1 General information

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1 General information

1.2.4 Ensuring traceability

Body dangers only detected after delivery can mean that subs equent measures in the market will be necessary (customer
information, warning, call-back). To make these measur es as efficient as possible, it is necessary to be able to tr ace the product
after delivery. F or this purpose, and in order to be able to use t he central vehicle register (CVR) operated by the Federal Motor
Transport Authority or comparabl e registers abroad in order to trace the aff ected vehicle owners, we strongly rec om mend that
body builders should store the serial num ber/identific ation number of their body linked to the vehicle identification number of the
base vehicle in their databases. Also, it is recommended for the customers' addresses to be stored and to provide a means f or
subsequent owners to be registered.

1.2.5 Trademarks

VW badges and VW em blems are trademarks of Volkswagen AG. VW badges and VW emblems are not allowed to be removed
without authoris ation, or to be attached in a different l ocation.

1.2.5.1 Positions on rear of the vehicle

VW badges and VW em blems which are also supplied must be fitted in the location int ended by Volkswagen.

1.2.5.2 Appearance of overall vehicle

If the vehicle does not correspond to the appearance and the quality requirements set by Volkswagen AG, then Volkswagen AG
reserves the right to request removal of the Volkswagen AG trademarks.

1.2.5.3 Non-Volkswagen trademarks

Non-Volkswagen trademarks are not all owed to be attached ne xt to Volkswagen badges.

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1 General information

1.2.6 Recommendations for vehicle storage

Extended storage times cannot always be avoided. The followi ng measures are recommended to ensure that vehicle quality is
not affected by long-term storage:

At vehicle deliver y:
– Fill tank.
– Do not park the vehicle under trees, poles, etc.
– Open all ventilat ion flaps, set blower to maximum speed.
– Disconnect battery(ies).
– Remove dirt, s now and m oisture from vehicle (footwell).
– Close windows, door s, bonnet, rear lid and sunroof.
– On manual gearboxes select 1st gear and on automatic sel ect P. Do not engage revers e gear. Do not apply the parking

brake.
– Pull off windscreen wiper bags and clam p polystyrene block under the wiper arm. Please remove any other loose film. ("Aer o

wipers"*: remove and stor e in suitable location inside vehicle.)
– Check the tyre pressure.

Check vehicles weekly for contamination by aggressive medi a (e.g. bird droppings, industrial dusts) and clean, if required.
Check battery open-circuit volt age every three months. Open-circuit voltage means the voltage o f the disconnected battery after
a minimum storage period of 12 hours. Recharge battery in due time before it reaches an open-circuit voltage of 12.4 V ('magic
eye' changes from green to black). Bat teries with an open-circ uit voltage of less t han 11.6 V are in state of exhaustive discharge
and should be disposed of without delay.
Batteries shall be recharged only wit h current-controlled and voltage-lim ited chargers. A m axim um charging voltag e of 14.4 V
shall not be exceeded.
It is recommended t o check the tyre inflation pressure every three months.
Reconnect battery negative lead(s) before recommissioning the vehicle.

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1.2.7 Compliance with environmental rules and regulations

Environmental note

The following princ iples of environme ntally friendly
design and material selection should be f ollowed right
from the planning stage of fitted components or bodies,
including with r egard to the statutory requirements in
the EU Directive on End-of-Life Vehicles 2000/53/EC.

Fitters of accessories and body builders shall ensure that they comply with all applicable environmental rules and regulations,
especially EU Directive 2000/53/EC concerning end-of-life vehicles and EU Di rective 2003/11/EC relating to restrictions on the
marketing and use of certain dangerous substances and prepar ations ("low fl am m ability" and certain flame-retardant agents) for
closer defini tion of Directive 76/769/ EEC).
The vehicle owner must keep all assembly documentation conc erning the modification and hand t hem over together with the
vehicle to the dis m antler. This ensures that modified vehicles are processed in compliance wit h environmental rules and
regulations at t he end of their lifecyc le.
Materials which represent a potential risk such as halogen ad ditives, heavy met als, asbestos, CFCs and chlorinated
hydrocarbons s hall be avoided.

– EU Directive 2000/53/EC must be adhered to.
– Preferably, materials which allow valuable substance recycling and closed m aterial cycles shall be used.
– The material and production process shall be selected s o that only low amounts of easily recyclable waste are generated.
– Plastics shall only be used where these of fer advantages in terms of cost, func tion or weight.
– In the case of plastics, especially com posite materials, only mutually compatible substances from one material fam ily are

allowed to be used.
– With regard to com ponents that are relevant for recycling, the number of plastic types used shall be kept as low as possible.
– It is necessary to check whether a component can be manufact ured from recycled material or with rec ycled additives.
– Care shall be taken to ensure that recyclable components c an be removed easily, e. g. by means of snap-lock connections,

predetermined breaking points, good accessibility, use of standard tool s.
– Simple, environm entally friendly removal of the fluids shall be ensured by mea ns of drain plugs, etc.
– Wherever possible, the components shall not be painted or c oated; instead, dyed plastic parts shall be used.
– Components in areas at risk of accident shall be designed to be tolerant of damage, repairable and easy to exchange.
– All plastic par ts shall be identified according to the VDA material sheet 260 ("Components of motor vehicles; Identification of

materials"), e.g. "PP-GF30R".

1 General information

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1 General information

D-22765 Hamburg, Germ any

Telephone:

[phone] - 0

Fax:

[phone]

E-mail:

[e-mail]

Homepage:

www.bgf.de

1.2.8 Recommendations for inspection, maintenance and repair

Maintenance instructions or service schedules outlining inspection and servicing work should be provided for the modifications
performed by the bod y builder or accessories fitter. Thes e instructions or schedules must include the maintenance and
inspection int ervals as well as the required operating fl uids and materials and the spare parts . Parts and components with a
limited servic e life which must be chec ked at regular intervals to ensure service reliability and timely replacement m ust be
explicitly stated.
This should be supported by a repair manual including tightening torques, set tings and tolerances as well as other relevant
specificati ons. Special tools, including their source of supply, must also be stated.
The manual shall also state which type of w ork has to be performed only by the body builders and accessories fitters or their
authorised workshops.
If the body builder 's or accessory fitter's scope of supply includes electric, electronic or mechatronic, hydraulic or pneumatic
systems, curr ent flow diagrams and diagnosis routines or similar documentat ion facilitating a systematic sear ch for faults shall
be provided.

1.2.9 Accident prevention

Body builders shall ensure that the bodi es comply with applicable legal rules and regulations as well as all regulations regarding
work safety and ac cident prevention. All safety rules and the information material provided by accident insurance providers shall
be observed.
All technical ly feasible measures m ust be taken to prevent unsafe operation.
Country-specif ic laws, directives and approval regulat ions must be observed.
The body builder is responsible for t he compliance with t hese laws, rules and r egulations.
For further inf ormation about commercial freight tr affic in the Federal Republic of Germany plea se contact:

Berufsgenossens chaft für Fahrzeug haltungen, Fachaus schuss,
Verkehr,

Postal address:

Sachgebiet "Fahrzeuge"
Ottenser Haupts traße 54

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1 General information

1.2.10 Quality system

Worldwide competition, increas ed quality requirements by customers on the overall product of the transporter, national and
international product liabili ty legislation, new f orms of organisation and increasing pressure on costs are demanding effective
quality assurance systems in all areas of the automotive industry.
The requirements on a quality management system of this kind are described in DIN EN ISO 9001.
A VDA working group has prepared the guideline entitled "Quality management i n the automotive indus try - Minimum
requirements on a management syst em for trailer and body man ufacturers - System description and evaluation" for German
body builders, on t he basis of DIN EN ISO 9000 f f. Appeared as VDA Vol. 8 [VDA 8] (incl. CD -ROM), order no. A 13DA00080.
For the reasons s tated above, Volksw agen A G strongly recommends that all body buil ders should set up and mai ntain a quality
management system with the following m inimum requirements:
– Definition of responsibilities and authorisations including organisation plan.
– Description of the processes and procedures.
– Appointment of quality management representative.
– Performing contract and build feasibility checks.
– Performing product checks based on specified instr uctions.
– Regulating the handling of faulty products.
– Documentation and ar chiving of test results.
– Ensuring the quality records of employees are up to date.
– Systematic moni toring of test equipment.
– Systematic material and parts identification.
– Performing quality assurance measures at the supplier s.
– Ensuring the availability of process, working and tes t instructions, and t hat they are up to date, in the departments and in the

workplace.

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Volkswagen Technical Site: http://vwts.ru http://vwts.info

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

1.3 Delivery range

The vehicle drawings shown here are sym bolic representations. The vehicle drawings are not to scale.

Wheelbase

[mm]

Gross vehicle

weight rating

[kg]

Amarok Single Cab

2-seater

Amarok Double Cab

5-seater

1 General information

3095 2820

3,095 3040

Wheelbase

[mm]

3,095 3040

Information

Gross vehicle

weight rating

[kg]

Amarok Single Cab

Chassis*

2-seater

Amarok Double Cab

Chassis*

5-seater

Further information on the availabi lity of individual
combinations of gross vehicle weight rating, engine,
gearbox and body var iants and figures for
consumption, CO2 emissions and energy efficiency
classes can be found in the sales document s and the
configurator on t he V olkswagen website:

http://www.volkswagen-nutzfahrzeuge.de/de/cc5.html

or http://umbauportal.de/konfigurator

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1.4 Advantages of the concept

– One wheelbase.
– Two weight class es for Double Cab (DC): 2, 820 kg and 3,040 kg. For Single Cab (SC) 3,040 kg .
– Frame with cab body and cargo box.
– Large load bed with the largest dimensions in its class.
– Through-load width of 1,222 millimetres between the wheel houses. This means Euro pallets can be loade d crossways to

save space, whic h is a first in a mid-size pickup. Thanks to these impressive dimensions and a payload up to 1.15 metric

tonnes, it is also possible to transport sports equipment such as quad bikes or large implements.
– Four load securing points in the corners of the load bed for s ecuring the cargo whilst driving.
– Low, flat load bed.
– Max. trailer weight (12% uphill gradi ent) up to 3,200 kg possible.
– Drawbar weight 120 k g.
– Independent suspension at front and rigid axle at rear.
– cd peak value of 0.42.
– Powerful and economi cal engine range.
– 3 drive variants:

Basic version: rear-wheel drive (4 x2).

Optionally avail able: permanent f our-wheel drive (Double Cab) or non-permanent four-wheel drive (Single Cab + Double

Cab).
– Upshift recom m endation, standard feature in all Amaroks.
– High level of vehic le safety.
– ABS and TCS are standard features in the Am arok.
– Electronic differential locks (EDL).
– Offroad-ABS activated at the push of a button to significantly shorten braking di stances offroad and o n dirt roads.
– Electronic stabilisation program (ESP*, standard EU27) with brake assist system.
– All vehicles with ESP are equipped with a hill-hold assis t that holds the vehicl e stationary when performing a hill start until the

driver accelerates sufficiently to prevent it's rolling back.
– Low maintenance requirements.

– Heavy-duty spring pack (Single Cab: standard, Double Cab: o ptional).
– 80 litre tank.
– Extensive range of accessories – ranging from the styling bar, running boards, loadspace cover and m ulticonnect attachment

system (standar d from Trendline onwar ds) through to a rang e of alloy wheels.

* Electronic Stabilisation Program

1 General information

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1.5 Planning bodies

Practical note

During the planning of bodies, the right choice of
materials and thus the observance of corrosion
protection measures are important in addition to a user
and maintenance f riendly design (see chap. 2.3.2.10
"Corrosion protection measures").

1.5.1 Selecting the base vehicle

The base vehicle needs to be selected c arefully to ensure safe usage in the respective field.
The following must be taken into cons ideration during plan ning and adapted for the respective usage:
– Wheelbase
– Engine/gearbox
– Final drive ratio
– Gross vehicle w eight rating
– Centre of gravity
– Seating version (number and arrangement)
– Electrics – scope
– Ancillary dri ves

are taken into consideration during planning and are adapt ed for the respective application.

1 General information

Practical note

Before carrying out body building or conversion work,

the supplied base vehicle should be checked with
regard to the fulfilment of applicable requirements.

You will find more information on the avail able chassis and bod y versions in 1.3 "Del ivery range" or from the responsible
department (s ee 1.2.1.1 Contact, 1.2.1.2 Conversion Portal and 1.2.2 "Body builder guidelines, consulting").

Information

On the Volkswagen AG homepage, you can put your
vehicle together w ith the configurator and view the
available option al equipment:

http://www.volkswagen-nutzfahrzeuge.de/de/cc5.html

or http://umbauportal.de/konfigurator

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1 General information

1.5.2 Vehicle modifications

Before starting work on the body, the body builder should check whether
– the vehicle is suitable for the planned body
– the chassis type and the equipment als o correspond with the operating conditions after the conversion

Build dimension drawings, product information and technical data can be obtained from the respons ible department or via the
communication system for the planning of bodies (see chap. 1.2.1.1 "Contact" , 1.2.1.2 "Convers ion Portal" and 1. 2.2 "Body
builder guidelines, consulting").
Furthermore the optional equipment available from the factory should be noted (see 1.6 "Optional equipment").
Vehicles deliver ed from the factory c om ply with EC guidelines and the national laws (except for some vehi cles for countries
outside Europe).
The vehicles also need to meet the EC guidel ines and the national laws after the modifications have been m ade.

Practical note

Sufficient space must be provided in order to guarantee
the function and operating safety of the components.

Warning note

Do not modify the steering or brake sys tem!
Modifications to the steering and br ake system can result
in these system s no longer working correctly and failing.
This may result in the driver losing cont rol of the vehicle
and causing an acc ident.

Practical note

Modifications to the noise encapsulation can have effect s

which are relevant to registrati on.

1.5.3 Vehicle approval

The officially recognised apprais er or tester must be informed by the body builder about modific ations to the chassis.

Practical note

Country-specif ic laws, directives and approval
regulations shal l be observed!

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1 General information

1.6 Optional equipment

We recommend using the optional equipm ent from Volkswagen AG that can be obtained with a PR no. for optimum adaptation
of the body to the vehic le.
You can obtain information on the optional equipment provided by Volkswagen under P R nos. from your Volk swagen Customer
Service or in the advi ce for body builders (see chap. 1.2.1.1 " Contact", 1.2. 1.2 "Conversion portal" and 1.2.2 "Body bui lder
guidelines, consulting").
Please also note chapter 5 "Implementati on of special bodies".

Information

Furthermore you c an put your vehicle together with the
configurator on t he V olkswagen AG homepage and
look at the available optional equipment:

http://www.volkswagen-nutzfahrzeuge.de/de/cc5.html

or http://umbauportal.de/konfigurator

Optional equipment (e.g. reinforced springs, frame reinforcements , anti-roll bars etc.) or equipment fitted later increase the kerb
weight of the vehicle (see also chapter 5 "Implementation of special bodies" ).

The actual vehicle weight and the axle loads should be determined before the body is built.
Not all additional equipment can be buil t into any vehicle without problems. This applies in part icular if it is fitted later on.

We recommend using the reinforced s prings that are available from the factor y for bodies and conversions.

Practical note

Permanently installed components increase the
unladen weight of the vehicle, as a result of which the

suspension compression height on the r ear axle is
reduced accordingly. In order to ensure an optimum
rear ride height as well as stable r oad holding in the
case of weight increase, we recommend the heavy­duty suspension (gross vehicle weight rating 3.04 t).
This is available e x-works by means of PR no. 0WL.

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2 Technical data for planning

2.1 Base vehicle

2.1.1 Vehicle dimensions

2 Technical data for plann ing

Fig. 2.1.1.1 Vehicle dimensions of Amarok (views: side, front and rear)

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 27 of 130

Fig. 2.1.1.2 Plan view of Amarok DC (Double Cab)

2 Technical data for planning

Fig. 2.1.1.3 Plan view of Amarok SC (Single Cab)

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2.1.1.1 Basic data Single Cab and Double Cab

Vehicle length inc l. rear bumper

5254

5254

1261 (with bumper)

1,261 (with bumper)

cover)

bumper

bumper

bumper

bumper with st ep

exhaust system (petrol engine)

bumper

2 Technical data for planning

Basic data Amarok (all engines)

L101 Wheelbase with measuring load 1*

L103

L 104 Front overhang with m easuring load 1*

L 105 Rear overhang wit h m easuring load 1*

L505 Length of load bed 2,205 1,555

W103 Vehicle width

H 100 Height of body with measuring load 1* 1,820 1,834

W101-1 Front track width with measuring load 1* 1,648 1,648

W102-2 Rear track width w ith measuring load 1* 1,644 1,644

H156* Ground clearance with measuring load 1* 250 250

Vehicle length

Single Cab
[mm]

3,095 3,095

5181

898 898

1188

1,944
1,954 (with wheel

Double Cab
[mm]

5181

1188

1,944
1,954 (with wheel cover)

Dimensions

A116-2

A116-1

A117

Rear entry angle to gradients ML1 limited by

Rear entry angle to gradients ML1 without

Rear entry angle to gradients ML3 without

Rear entry angle to gradients ML3 limited by

Rear entry angle to gradients ML3 limited by

Front entry angle to gradients with ML1 28° 28°

Front entry angle to gradients ML3 limited by

Breakover angle ML1 wi th skid plate
Without skid plate

Breakover angle ML3 wi th skid plate
Without skid plate

23.6° 23.6°

28° 28°

15.4° 15.4°

18° 17.6°

15.6° 15.4°

29.8° 30.6°

21.4°
23°

16.4°
18°

21.4°
23°

16.7°

18.6°

Turning circle D102 Mi nimum turning circ le 12.95m 12.95m

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2 Technical data for planning

H196

W114R

Basic data Amarok (all engines)

Wheels / tyres. Basic tyres*

W200 Width of load bed max. 1,620 1,620*

load bed
dimensions

H502/1,

H503 Tail lift height 508 508

Rear load sill hei ght, measuring load 1* 780 780

W506 Through-load w idth 1222 1,222

Garage
dimensions

Max. width with doors opened 3,668 3668
W114-L /

Width incl. lef t/right exterior mi rror 2,228 2,228

Driver headroom 1,026 1,026

H61

Headroom 2nd seat row -- 1,008

Single Cab
[mm]

Small tyre
205/65 R16 C 110/108T
large tyre
245/65 R17 111T

Double Cab
[mm]

Small tyre
205/65 R16 C 110/108T
large tyre
245/65 R17 111T

Interior
dimensions

H115/1 Driver entry height 520 520

H115/2 Entry height 2nd seat row -- 529

L34-1 Legroom 1st seat row 1,019 1,019

L34-2 Legroom 2nd seat row -- 865

* Meas. loads ML1 and ML3 acc. to DIN 70020

Info from Volkswagen Commercial Vehicles intranet \Project Amarok\Basic data, status: 07.12.2009

* The vehicle dimensions concerning grou nd clearance and load bed differ from one another depending on the en gine and equipment vari ant.

** The permitted tyre size varies dependi ng on the engi ne and the gross vehicle weight rating.

Information

You will find additional technical data (dimensional
drawings, weight information and emissions figures) on
the Amarok according to the engine and equi pm ent
variant on the Internet at:

http://www.volkswagen­nutzfahrzeuge.de/de/downloads.htx

or

http://umbauportal.de/produktkataloge

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2.1.2 Overhang angle and ramp angle

Fig. 1 Overhang and ramp angles, Amarok DC (Double Cab)

2 Technical data for planning

Fig. 2 Overhang and ramp angles, Amarok SC (Single Cab)

The values for the overhang angle (A116) and the ramp angle A117 can be found in the basic data table for the Amarok Single
Cab and Double Cab in chap. 2.1.1.1.

* The values for the overh ang angle A116 may differ for petrol and diesel engines due to different exhaust systems.

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2.1.3 Vehicle centre of gravity

[mm]

[mm]

[mm]

[mm]

[mm]

Double Cab

3095

680

1444

~840

~796

Single Cab

3095

657

1350

~ 853

~805

2 Technical data for planning

Model L

h*

SV*

SR*

SL*

2.1.4 Bodies with a high centre of gravity

The driving properties of vehicles w ith a high body or with an elevated overall cent re of gravity can be expected to be restricted.
A centre of gravity height up to 800 mm above t he carriageway is not problematical (see also chap. 2.2.6 "B rake system and
brake control system ESP").

2.1.4.1 Extremely high centres of gravity ( >800 mm)

Centre of gravity hei ghts higher than 800 mm are only permitted following consultation with Volkswagen AG.
If necessary, the chassis and ESP** must be modified.
The vehicle needs to be taken to Volks w agen AG for an inspection of the vehicle modifications.

Information

Please use the online contact form for this:

* Position of centre of gravity measured on the vehicle without payload and without driver (status: 11.11.2010), ** Electronic stabilisation program

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2 Technical data for planning

2.1.5 Determining centre of gravity

Volkswagen recomm ends having the cent re of gravity determined by a recognised test institution w ith experience in thi s field
(for example, DEKRA, TÜV or others) .

For the body builder t o determine the cent re of gravity, we r ecommend following the procedures des cribed under 7.1
"Determining the c entre of gravity".

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2 Technical data for planning

2.1.6 Maximum dimensions

The ride height of t he frame may change if reinforced springs, comfort springs or tyre sizes other t han the standard sizes are
installed. The e xact heights shall be m easured prior to the start of conversion work.

Fig. 1: Max. dimensions of Amarok Double Cab

Fig. 2: Max. dimensions of Amarok Single Cab

Important notes:
– The minimum distance between the cab and body must be 20 mm.
– The minimum distance between the cab r oof and superstruc ture must be 30 mm.
– The front overhang of the body may not affec t the view of traff ic lights.

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It is possible to extend the overhang measurement (L105: 1, 188 mm) up to 1800 mm if certain requirements
are met (see chapt er 2.2.10 "Overhang extension").

The vehicle width is 1944-1954 mm (W 103) without mirrors! (See also 2.1.1 "Vehic le dimensions")

The aforemention ed body width is not allowed to be exceeded when standard exterior mirrors are used.

Please also compl y with the following chapt ers:
– Chap. 2.2.1. "Permi tted weights and unladen weights",
– Chap. 2.2.1.1 "One-sided weight distribution"
– Chap. 2.2.6 "Modif ications to the brake system"
– Chap. 2.2.10 "Overhang extension"
– Chap. 2.2.11 "Wheelbase extension"

2 Technical data for planning

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2 Technical data for planning

2.1.7 Steerability

Please note that the f ront axle load must be at least 38.8% of the actual gross vehicle weight rating for all load situations. The
gross axle weight ratings may not be excee ded and the minimum front axle load of 1000 kg m ust be met. (see also chap. 2.2.10
"Overhang extension")

The displacement of the overall centre of gravity towards the rear must be limited to retain the positive driving properties of the
Amarok in terms of self-steering effect, steering, br ake functions, driver assistance functions and body longitudinal incline.
The permitted displacement of the over all centre of gravi ty towards the rear is ensured by observing a mi nimum front axle load
depending on the utilised rear axle load.

The following diagr am illustrates this context:
– Up to 1575 kg rear axle load, the minimum fr ont axle load is 1000 kg.
– From 1575 kg to maximum 1860 kg rear axle load, the minimum front axle load must increase consistently.
–

Fig. 2: Minimum front axle load for Amarok (heavy-duty chassis)

FAmin - Minimum front axle load
RA - Rear axle load

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 36 of 130

2 Technical data for planning

2.2 Running gear

2.2.1 Permitted weights and unladen weights

Volkswagen AG offers vehicles with rear-wheel drive (4 x2) and four-wheel drive ( 4x4), with Single and Double Cabs, in t he
weight classes 2820 kg and 3040 kg.
The Amarok SC and Amarok DC are available with a GVWR of 2820 kg and 3040 kg.
See also chapter 2.8.2 "Towing bracket".

The permitted a xle l oads listed in the weight tables (see chapters 6.5.1 and 6.5.2) must be observed.

Petrol engines:

2.0 l / 118 kW TFSI

Diesel engines:

2.0 l / 90 kW TDI **

2.0 l / 103 kW TDI ***

2.0 l / 120 kW BiTDI *

2.0 l / 132 kW BiTDI 4M O T ION

2.0 l / 90 kW TDI 4MOTIO N **

2.0 l / 103 kW TDI *** (4MOTION non-permanent)

2.0 l / 120 kW BiTDI 4M O T ION *

2.0 l / 132 kW BiTDI B lueMotion 4MOTION

* End of variant calendar week 26/2012
** End of variant calendar week 30/2013
*** Launch of variant calendar week 31/2013

Information

Load ratings depend on the engine. Equipm ent
features can influence the payload or l oad w eight by
increasing/reducing the unladen weight. The weight
values in the techni cal data refer to the standard, basic
vehicle equipment. Weight tolerances of +5% in
production are permitted in accordance with DIN 70020
and must be taken into account if neces sary.
Installing optional equipment red uces the payload.

The actual payload of a vehicle that is calculated from
the difference bet w een the gross vehic le weight rating
and unladen weight can only be determined b y
weighing an indivi dual vehicle.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 37 of 130

2 Technical data for planning

Weighed axle load

1,860 kg

Wheel load left/right

893 kg / 967 kg

Difference in wheel load

74 kg

% deviation from higher value

7.7%

2.2.1.2 One-sided weight distribution

Warning note

The following weights shall not be exceeded under any
circumstances:

– Gross vehicle w eight rating
– Maximum front axle wei ght
– Maximum rear axle weight

(see chap. 2.2.1 "P ermitted weights and unladen
weights").

When planning add-ons/additions, make sure that a one-sided weight distribution is avoided – in par ticular involving
permanently sec ured add-ons.
The difference in actual wheel load between the left and ri ght wheels on an axle is not allowed to exceed 8% of t he higher wheel
load. The tyre load r atings must be observed.

Example:

Information

Please also refer to chap. 2.2.1. "Per m itted weights
and unladen weights" and chap. 2.1.6. O bserve "Max.
dimensions".

Fig. 1: One-sided weight distribution (rear view)

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 38 of 130

Fig. 2: One-sided weight distribution (side view)

2.2.2 Turning circle

See chapter 2.1.1 "Vehicle dimensions".

2 Technical data for planning

2.2.3 Authorised tyre sizes

See chapter 2.1.1 "V ehicle dimensi ons".

2.2.4 Modifications to axles

Modifications to the axles are not per mitted, because t hey can lead to an impairment in the driving proper ties and unstable
driving behaviour .

2.2.5 Modifications to the steering system

Modifications to the steering syst em are not permitted.
Exceptions, e.g. conversions for people with disabilities, shall be approved by Volkswagen AG prior to the conversion.

Please use the contact form on the Volkswagen Commercial Vehicles website for your enquiries:

http://umbauportal.de/kontaktformular or
http://umbauportal.de/ihr-kontakt-zu-uns

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2 Technical data for planning

2.2.6 Brake system and brake control system ESP*

2.2.6.1 General notes

Changes to the brak e system are not allowed under any circumstances:
– If the modification to the brake syst em goes beyond the scope of the operating permit.
– If the air inflow and outflow to and from disc brakes are modified.

Exceptions shall be approved by Volk swagen AG prior to the conversion, and shall be documented with an independent brak e
approval report.

Please use the contact form on the Volks w agen Nutzfahrzeuge AG website for your enquiry:

http://umbauportal.de/kontaktformular

or

http://umbauportal.de/ihr-kontakt-zu-uns

Warning note

Work performed improperly on brake hoses, lines and
cables can impair their function. This can lead to a
failure of components or safety-relevant parts.
Therefore, work on brake hoses, lines and cables
should only be performed by a qualified specialist
workshop.

Information

Since 1 January 1991, all commercial vehicles have
had to comply with the " EC Brake Systems Di rective
71/320 EEC". W hen this EC Directive was adopted into
national legislation (e.g. the Road Traffic Regulations
(StVZO) in Germany), the effect was that these

technical regul ations also had to be com plied with for
individual acc eptance.

Electronic stabilisation program

*

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2 Technical data for planning

2.2.6.2 Vehicle stability and ESP*

When the vehicle wi th the body mounted is presented for approval, it is a requirem ent of the EC Brakes Directive 71/320/EEC
and ECE R13 to provide mathematical proof of the height of t he centre of gravity when the vehicle is loaded.
Refer to chapter 2.1.3 "Vehicle centre of gravity" for the permitted centre of gravity heights.
Volkswagen does not make any statement about:
– Driving characteristics
– Braking behaviour
– Steering response and
– ESP control res ponse in bodies for loadi ngs with an unfavoura bly positioned centre of gravity (e.g. rear, high and side loads),

because these aspects are signifi cantly influenced by body activities and consequently can onl y be assessed by the body

builder.

Warning note

Whether for conver sions and installation, and also in
the ready-to-drive condit ion, the gross w heel and axle
weight ratings as well as the gross vehicle weight
ratings (see chap. 2.2.1) of the vehic le are not allowed
to be exceeded under any circumstances. If the gross
axle weight rati ngs are exceeded, the ESP* system in
vehicles with ESP w ill no longer be able to function
correctly. Thi s may result in the driver losing control of
the vehicle and causing an accident.

Practical note

From November 2014, E SP w ill be obligatory across
Europe for all newly r egistered vehic les (N1 and M1.
From June 2015, for N 2 vehicles). Without ESP*, it is

no longer possible for vehicles to be registered after
the cut-off date.

* Electronic Stabilisation Program

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 41 of 130

2.2.6.3 Influence of vehicle conversions on the function of the brake regulation system ESP*

Modification on the vehicle

2 Technical data for planning

Vehicle
overhang
extension
within limits
specified in
body builder
guidelines (<
1800 mm)

ESP sub-systems

ABS
Anti-lock brake system

Modification of

Wheelbase
modification

Extreme
raising of
centre of
gravity
> 800 mm

running gear
(springs,
dampers, anti­roll bars,
wheels, tyres,

Modification to
the brakes
(callipers, pads,
design)

Conversion
into tractor
unit 2

track, steering)

+ + + ++ + +

Offroad ABS + + + ++ + +

BAS
Brake assist system

EDL
Electronic differential lock

TCS
Traction control system

-- -- -- ++ -- --

+ + + +++ + +

++ + + - + +

ESP
Electronic stabilisation

++ +++ 1 +++ 1 +++ 1 ++++ +++

program

Trailer stabilisation
system

++ ++ +++ +++ ++++ ++++ 3

Hill Hold Control - - - ++ - -

Downhill driving assistant + + + ++ ++++ +

1 In particular , a significantly increased risk of tippi ng over
2 Downgrading required
3 A towing bracket cannot be fitted

-- No effect

- Very little effect
+ Noticeable effect, can be adapted if necessary
++ Significant effect, can be adapted if necessary
++ Very significant effect, can be adapted if neces sary
++++ No technical solution

* Electronic Stabilisation Program

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 42 of 130

2 Technical data for planning

Warning note

Vehicles with add-ons, bodies, inst alled components or
conversions in which the limit values of the specific
vehicle (posit ion of centre of gravit y, axle loads,
overhangs, etc.) are not complied with are regarded as
problematical and can result in an impairment of driving
behaviour. Therefore, they should not be operated.

If specific bas ic conditions are met, overhang
extensions, c hanges to the wheelbase an d conversion
into an articulated vehicle are pos sible to a limited
extent. (See chaps. 2.2.10 "Overhang extension",

2.2.11 "Wheelbase modification" and 5.6 "Articulated
vehicles".)

2.2.6.4 Downgrading ESP*

When the ESP is downgraded, the vehicle software needs to be upd ated to downgrade to t he basic functions of the ABS (anti­lock brake system ) including offroad ABS and EDS (electronic differential lock).
The hill hold assi st function can still be used. The downhill assist function is deactivated for technical reas ons.
The disabled ESP Off or TCS Off button needs to be replaced with a cap and the connector s in the vehicle elect rical system
secured.

* Electronic Stabilisation Program

2.2.6.5 Activating the ESP*

Practical note

If necessary, longer wheelbases c an be offered with all
functions of t he brake control system.

This is only permitted following consultation with
Volkswagen AG.

If necessary, the chassis and ESP shall be modified
according to the specifications of Volkswagen AG.

The vehicle needs to be taken to Volks w agen AG for
an inspection of t he vehicle modifications.

Please use the online contact form for this:

http://umbauportal.de/kontaktformular or
http://umbauportal.de/ihr-kontakt-zu-uns

* Electronic Stabilisation Program

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 43 of 130

2 Technical data for planning

2.2.7 Modification of springs, suspension mounting, dampers

The spring rates are never allowed to be mo dified.
We recommend using optimally matching springs from the Volkswagen delivery range for the vehicle with body.
Modifications to the springs must be assessed by a test c entre/monitoring organisation/technical service r esponsible for this
function, and can result in invalidati on of the operating per m it.

2.2.8 Wheel alignment settings

Changes to wheel alignment parameters are not permitted!

2.2.9 Wings and wheel houses

The required clearance for the wheels including snow chains must be complied w ith.

In some bodies, it is necessary to ensure there is suffici ent clearance for the wheel/tyre combination acc. to 92/23/EEC as well
as for adequate wheel coverage based on EC Directive 78/549/EEC.

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2 Technical data for planning

2.2.10 Overhang extension

The overhang extens ion should allow longer superstructures that do not significantly shift the overall centr e of gravity towards
the rear to be mounted on special vehicles.
Overhang extensi ons measuring up to a maximum of 1800 mm are permitted if the requirements list ed below are met:

– Load distribution

Please note that the f ront axle load must be at least 38.8% of the actual gross vehicle weight rating for all load situations. The

gross axle weight ratings may not be excee ded and the minimum front axle load of 1000 kg m ust be met. (see Figur e 1 M ax.

permitted overhang extension and Figur e 2 M inimum front axle load)
– Running gear:

Vehicles with overhang extensions shall always be equipped with the heavy-dut y chassis (perm. RA load: 1860 kg).
– Towing bracket:

Towing brackets m ay never be fitted to vehicles with overhang extensions.
– Rear departure angle:

A rear departure angle of at least 12 degrees should be ensured in all load situat ions.
– Centre of gravit y weig hts:

During body modifications involving an overhang extension, the maximum perm itted height of t he centre of gravity, which is

800 mm (see chapters 2.1.3 "Vehicle c entre of gravity" and 2.1.4 "Bodies with a high centre of gravity"), must also be

observed.

All traction c ontrol system functions are still available under these conditions.

Fig. 1: Maximum permitted overhang extension (heavy-duty chassis)

FAmin - Minimum required front axle load

max - Maximum permitted rear axle load

RA

* - Heavy-duty chassis

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2 Technical data for planning

The displacement of the overall centre of gravity towards the rear must be limited to retain the positive driving properties of the
Amarok in terms of self-steering effect, steering, br ake functions, driver assistance functions and body longitudinal incline.
The permitted displacement of the over all centre of gravi ty towards the rear is ensured by observing a mi nimum front axle loa d
depending on the utilised rear axle load.

The following diagr am illustrates this context:
– Up to 1575 kg rear axle load, the minimum fr ont axle load is 1000 kg.
– From 1575 kg to maximum 1860 kg rear axle load, the minimum front axle load must increase consistently.

Fig. 2: Minimum front axle load for Amarok (heavy-duty chassis)

FAmin - Minimum front axle load

RA - Rear axle load

2.2.10.1 Requirements for trailer operation with overhang extension

If the specifications mentioned above in chap. 2.2.10 regar ding axle loads
– and their distr ibution (minimum FA load) are taken into cons ideration,
– Suspension (heav y-duty RA springs)
– Gradient entry angle
– Centre of gravity hei ght
an Amarok with overhang extension can be used with a towing brac ket if the following conditions are met in addition:
– Overhang extensi on WITHOUT frame e xtension.
– Towing bracket in original position.
– The axle loads and their distribution (minimum FA load) incl. the axle load dis placement caused by the vertical load of the

trailer must be observed.
– The axle loads and their distribution (minimum FA load) must be observed also in conjunction with t he trailer (vertical load).
– Sufficient cl earance between extended body and trailer (see DIN 74058 "Coupling ball; dimensions, clearance").
– Possible loading of the extended body can be limited considerably by these restrictions when a tr ailer is towed.
– An improvement can be achieved by extending the wheelbase while maintaining the s tandard overhang.

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2 Technical data for planning

2.2.11 Wheelbase modification

Vehicles with m odified wheelbases should always be downgraded in terms of brake regulation functions. (See chap. 2.2.6
"Modifications to the brake system".)
This concerns all vehicles with ESP* and al l vehicles with TCS system (Traction Control System) and rear or non-permanent
four-wheel drive.

Downgrading:
The vehicle software needs to be updated to downgrade to the basic functions of the ABS (anti-lock br ake system) includi ng
offroad ABS and EDS (electronic dif ferential lock).
The hill hold assi st function can still be used. The downhill assist function i s deactivated for technical reasons.
The disabled ESP Off or TCS Off button needs to be replaced with a cap and the connector s in the vehicle elect rical system
secured.

If necessary, longer wheelbases c an be offered with all f unctions of the brake control system.
This is only permitted following consultation with Volkswagen AG.
If necessary, the chassis and ESP shall be modified accordi ng to the specifications of Volkswagen AG.

The vehicle needs to be taken to Volkswagen AG for an inspect ion of the vehicle modifications.

Please use the online contact form for this:

http://umbauportal.de/kontaktformular or
http://umbauportal.de/ihr-kontakt-zu-uns

* Electronic Stabilisation Program

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 47 of 130

2.3 Body-in-white

Amarok Double Cab (DC )

100 kg

Amarok Single Cab (SC)

50 kg

2.3.1 Roof loads/vehicle roof

2.3.1.1 Dynamic roof loads

Vehicle model Max. roof load

Risk of accident

Roof loads raise the centre of gravity of the vehicle and
lead to a high dynamic axle load shift. A lso, there is
greater body lean when driving on rough roads and
when cornering.

2 Technical data for planning

The driving characteristics are significantly impaired.
For this reason, we recommend that you avoid roof
loads as far as possible. Please also comply with
chapter 2.1.4 "Bodies with a high centre of gravity".

2.3.1.2 Static roof loads

The maximal stat ic roof load with the vehic le stationary (e.g. roof tent) is 225 kg for the Amarok Double Cab. The attachments
must be configured accordingly.

Please also compl y with chapters:

– 2.1.4 "Bodies wi th a high centre of gravi ty"
– 2.2.6.2 "Vehicle stability and ESP"
– 2.2.6.3 "Influence of vehicle conversions"

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2 Technical data for planning

2.3.2 Modifications to the body-in-white

Changes to the body ar e not allowed to impair the function and strength of units and operating devices of the vehicle, neither
may they reduce the s trength of weight-bearing parts.

During vehicle conversions and installation of bodies , it is not permitt ed to make any modificat ions which impair the function and
freedom of movement of the suspension (e.g. for maintenance and inspection wor k) or the accessibility to the same.

2.3.2.1 Screw connections

If series-production bolts / nuts have to be renewed, it i s only permitted for bolts / nuts to be used which have the:
– same diameter
– same strength
– same bolt standard or bolt type
– same surface coat ing (corrosion protection, coeffi cient of friction)
– same thread pitch.

Comply with VDI guid eline 2862 during all installations.
Shortening the free clamping length, changing over to waisted shank and use of bolts with a shorter free thread proportion are
not permitted.
Furthermore, take the settling behaviour of screw connections into account.
Components that are additionally clamped as well shall have the same or a higher strength than the previ ous clamped
combination.

Use of Volkswagen tightening torques assumes that the total coefficient of friction is in the range μtot = 0.08 to 0.14 for the
particular it ems being bolted toget her.

If bolts are tightened by torque and angle at Volkswagen, no change of design is possible.

Risk of accident

No safety-relevant bolted connect ions, e.g. wheel

guidance, steering and brake functions, are allowed to
be modified. Otherwise the designated function may be
impaired. This m ay result in the driver losing control of
the vehicle and causing an accident. The new
installation is to be carried out according to the
instructions of VW Customer Service, using suitable
standard parts. We recommend using gen uine
Volkswagen parts .

Information

Information about Volkswagen customer service
instructions can be provided by any Volkswagen
Customer Service.

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2 Technical data for planning

2.3.2.2 Welding work

Incorrectly under taken welding work can lead to a failure of safety-relevant components, and thu s cause accidents.
Therefore, the fol lowing safety measures must be complied with when welding work is performed:
– Welding work shoul d only be undertaken by p eople with appropriate qualificat ions.
– Before starting welding work, it is necessary to remove components which might contain gases representing a fire or

explosion hazard, e.g. fuel system, or else to protect them with a fireproof cover against airbor ne sparks. Gas containers

which could be damaged by airborne sparks during welding work must be removed.
– Before welding work starts in the area of seat belts, air bag sensors or the airbag control unit, the c om ponents must be

removed for the duration of the work. See chap. 2.4 "Interior" for important information on handli ng, transporting and storing

airbag units.
– Before starting welding work, cover springs and spring bellows to protect them against weld spatter. Springs are not allowed

to be touched with welding electrodes or welding tongs.
– No welding is allowed on mechanical uni ts such as the engine, gearbox, axles.
– Remove and cover the battery positi ve and negative terminal clamps.
– Directly connect the earth clamp of the welding machine to the part to be welded. The earth clamp is not allowed to be

connected to mechani cal units such as the engine, gearbox, axles.
– The housings of electronic component s (e.g. control units) and electric al cables are not allowed t o be touched with the

welding electrode or earth clamp of the w elding machine.
– The electrodes are only allowed to be used w ith direct current via the positive terminal for welding. Always weld from bottom

towards the top.

Risk of injury!

Welding in the area of the restraint s ystems (airbag or
belts) can lead to these system s ceasing to function
properly. W eldi ng in the area of restraint systems is
therefore prohibited.

Practical note

Disconnect the battery prior to star ting welding work.
Airbags, seatbelts, the airbag cont rol unit, airbag
sensors and fuel tanks shall be protected against weld
spatter, and removed if necessary.

2.3.2.3 Welded connections

In order to achieve hi gh-quality welds, the following basic recommendations are given:
– Thoroughly clean the areas to be welded.
– Apply several short weld beads, rather than one long one.
– Make symmetrical beads, in order to l imit shrinkage.
– Avoid making more than three welds at any one point.
– Avoid welding in work-hardened areas .
– Spot welds and stitch welding should be offset.

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2 Technical data for planning

sides

1

Shielding gas hole spot welding

2

Spot welding

2.3.2.4 Selection of welding process

The mechanical pr operties of welds depend on which welding process is selected, and on the geometry of the parts to be
connected.
If welding overlap ping metal panels , the welding process depends on the accessibility of the sides:

Accessible

Welding process

2.3.2.5 Spot welding

Spot welding is used for overlapping part s with access on both sides. Avoid spot welding of more than two layers of metal
panels.

Distance between spo t welds:

In order to avoid shunt effects, the specified distances between the spot welds must be maintained (d = 10e+10 mm).

Ratio between panel thickness and distance between welds
d Distance between spot welds
e Panel thickness

Distance from the edge o f the panel:

In order to avoid damage to the molten cor e, the specified dis tances from the edge of t he panel must be maintained (L = 3e+2
mm).

Ratio between panel thickness and distance from edge
e Panel thickness
L Distance from the edge of the panel

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2 Technical data for planning

D - hole diameter [mm ]

4.5 5 5.5 6 6.5

7

e - panel thickness [mm]

0.6

0.7 1 1.25

1.5

2

2.3.2.6 Shielding gas hole spot welding

If overlapping pan els can only be welded on one side, it is possible to achieve the connection by shieldi ng gas hole spot welding
or tacking. If the connection is achieved by punching or drilling and then spot weldi ng the hole, the drilling area must be
deburred before welding is carried out.

Ratio between panel thickness and hole diameter

The mechanical qual ity can additional ly be improved by usi ng slots (l = 2 x b).

Ratio between width and length of slots
b Width of slot
I Length of slot

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2.3.2.7 Tacking

If panels are > 2 mm t hick, overlapping panel s can also be connected by tacking
(30 mm < L < 40 x e; d > 2 L).

Ratio between panel thickness and distan ce between welds

d Distance between tack welds

e Panel thickness

L Length of tack weld

2 Technical data for planning

2.3.2.8 Welding is not allowed

Welding is not all ow ed:
– On mechanical units such as the engine, gear box, axles etc.
– On the chassis fram e except if there is a frame extension.
– On the A- and B-pillars.
– On the upper and lower chords of the frame.
– In bend radii.
– In the area of airbags .
– Hole welding is only permitted in the ver tical webs of the frame longitudinal mem ber.

2.3.2.9 Corrosion protection after welding

After all weldi ng work on the vehicl e, it is necessary to comply with the specified corrosion prot ection measures
(See chapter 2.3.2.10 "Corrosion pr otection measures")

2.3.2.10 Corrosion protection measures

Following conversion and installat ion work on the vehicle, surface and corrosion protection shall be applied to the affected
points.

Practical note

Only the corrosion protection agents tested and
approved by Volks w agen are allowed to be us ed for all
corrosion protection work.

2.3.2.11 Planning measures

Corrosion protection should be taken into account in the pl anning and design in the form of a suitable material selection and
component design.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 53 of 130

Information

If two different metallic materi als are connected
together by an electrolyte (e.g. moi sture from the air)
then this will give rise to a galvanic c onnection. The
result will be electrochemical c orrosion, and the less
noble metal will suffer damage. The electrochemical
corrosion will be all the greater the fur ther apart the
metals in question are in the electr ochemical series.

Therefore, the components must have a suitable
treatment or insulation applied to them in order to
prevent electrochemical corrosion, or the corrosion
must be kept at a low level by a suitable choi ce of
materials.

Avoidance of contact corrosion by electrical insulation

2 Technical data for planning

Avoidance of contact corrosion
1 Insulating washer
2 Insulating sleeve

Contact corrosion can be avoided by usi ng electrical i nsulation such as washer s, sleeves or tubes. Avoid welding work on
inaccessible cavities.

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2 Technical data for planning

A = Favourable

B = Unfavourable

(through-welded)

(gap)

2.3.2.12 Component design measures

Design measures, in particular in the design of connections between the same or different mater ials, can be used for providing
corrosion protection:
Corners, edges, beads and folds repr esent locations where dirt and moisture can collect.
Suitable surfaces, drains and the avoid ance of gaps at component connections represent means by which corrosion can be
counteracted by design measures.

Gaps at welded connections as a feature of the design, and how t o avoid them:

Application examples of welded connections

2.3.2.13 Coating measures

It is possible to protect the vehicle agai nst corrosion (see 2.3.10 "Paint work / corrosion protection measures") by applying
protective coatings (e.g. galvanizing, painting or hi gh-temperature zinc application).

2.3.2.14 Work on the vehicle

After all work on t he vehicle:
– Remove drilling chips
– Deburr edges
– Remove scorched paint and thoroughly prepare the surfaces for painting
– Apply a primer to all bare metal parts, and paint them
– Apply a wax-based corrosion protection agent to cavities
– Carry out corrosion protection meas ures on the underbody and frame components

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 55 of 130

2.3.3 Tailgate

The tailgate on the Amarok Double Cab and Single Cab has the following properties:
– Cannot be removed.
– Outer panel.
– Inner panel.
– Reinforcement parts (hinge/lock reinforcement left and right; lat eral reinforcement).
– Closing plate for installation openi ng.
– Hinges.
– Lock.
– No step in the tail gate.
– 180° opening (no rear bumper).
– Can be locked in 90° pos ition.

200 kg static load i n 90° position
(Please refer to the owner's manual for further information.)

2 Technical data for planning

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2 Technical data for planning

2.4 Interior

2.4.1 Modifications in the area of airbags

Modifications to the airbag system and the belt tensioner system are not permi tted
Furthermore, modi fications on and in the area of airbag components, the airbag sensors and the airbag control units are not
permitted. Please note chapter 5.1 "Conversions for peopl e w ith disabilities"
The interior fittings shall be designed so that the airbag de ployment areas are l eft unobstructed (see also chap. 3.2 "I nterior").
For information about the deployment zones of the airbags , refer to the owner's manual of the vehicle.

Warning note

Modifications or incorrectly per formed work on
seatbelts and seatbelt anchor points, belt tensi oners or
airbags or their cabling could impair the correct functi on
of these component s. They might be acti vated
inadvertently or fail in the event of an ac cident.

2.4.2 Modifications in the area of seats

Modifications to the seat system or attachment of seat s on the wheel housing are not permitted, becaus e the seats might be
torn out of the anchor ing points in the event of an accident.

The strength data for seats available ex-works is only val id in conjunction wit h the original attac hm ent elements.

It is essential not to exceed the height of the centre of gravit y (H-point) if retrofitting seats.

If reattachi ng seatbelts, make sur e that the specified bol ts are tightened with the original torque.

2.4.3 Forced ventilation

Outlet vents may be c losed through modif ications only if new outlets are created, e.g. in the cab doors.
Air inlets and outlets are not allowed to be fitted in the immediate vicinit y of sources of noise or exhaust gases.

2.4.4 Acoustic insulation

Pay attention to minimising interior noise levels as part of conversions, in order to avoid modifyi ng the noise level of the vehicle.
The converted vehicle shall comply wi th the values for exter nal noise given in EC Di rective 70/157/EEC .
Specialists such as the manufactur er and suppliers of acoustic material should be contacted for advice on achieving the
optimum acousti c protection for bodies.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 57 of 130

2 Technical data for planning

2.5 Electrics/electronics

Incorrect int erventions in electronic components and their software may result in these no longer functioning correctly. Due to
the networking of el ectronics, s ystems that were not modif ied can be affected.
Malfunctions in the electronics can significantly impair the operational safety of your vehicle.

Work on or modific ations to electroni c components, in particular work on safety-relevant sys tems, is only allowed to be
performed by a qualified specialist workshop, and by qualified specialist personnel who have the necessary specialist
knowledge and tools for performing the necessary work.

Interventions i n the vehicle electrical system/vehicle electronics can result in invalidat ion of the warranty/operating permit.

2.5.1 Lighting

2.5.1.1 Vehicle lighting devices

Comply with the registration provisions of the country in question with regard to the complete lighting devices (lighting and turn
indicator devic es). Failing to comply can result in the operating permit bei ng invalidated.
Comply with the basic headlight setting (see type plate).
The use of LED lights is not intended by the ma nufacturer.
Installing LED l ights instead of the ori ginal VW lights can cause the bulb failure check to issue a warning because the lighting
system is not configured for this. The bul b failure check function cannot be activated.
We recommend using Vol kswagen Genuine rear lights or a product with "e" test symbol and conventional bulbs.

2.5.1.2 Mounting special lights

Comply with the registration provisions of the country in question when installing special li ghts.
Comply with the following chapters during the conversion:
– 3.1 "Body-in-white"
– 3.1.4 "Modifications to the roof"
– 2.5.2.4 "Retrofitting electr ical devices"

2.5.1.3 Installing 3rd brake light

When higher bodies are fitted, it may be necessary to integrate the 3rd brake light into the body.
A cover (7H0.971.3 41) for the 3rd brake light is available f rom the factory to cover the original brake light aperture. F or more
information, pl ease contact your Vol kswagen partner.
Please note that installing another brake light is only possible in place of the genuine brake light, and only with the same power.

2.5.1.4 Additional load compartment light

If an additional load compartment li ght is required, we recommend installing an additional switch and separate wiring (see chap.

2.5.2.1 "Electrical cables / fus es" ; chap. 2.5.2.2 "Additional circuit s"
and chap. 2.5.2.4 "R etrofitting electrical devices"). A solution using a relay with the original lighting wiri ng is not recommended
because the interi or light is dimmed and s w itched off by means of PWM (signal).
No additional wires maybe connected t o the existing lighting wiring fitted by Volkswagen AG.

2.5.2 Vehicle electrical system

2.5.2.1 Electrical cables/fuses

The following point s shall be complied wi th if routing modif ications are required:

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 58 of 130

– Avoid routing over sharp edges.

Max. continuous c urrent [A]

Rated current of
fuse [A]

Wire cross

0 – 4

51 0.35

4.1 – 8

101 0.5

8.1 – 12

151 1

12.1 – 16

201 1.5

16.1 – 24

301 2.5

24.1 – 32

402 4

32.1 – 40

502 6

40.1 – 80

100

10

80.1 – 100

125

16

100.1 – 140

175

25

140.1 – 180

225

35

180.1 – 240

300

50

– Avoid routing insi de excessively narrow cavities and close to moving parts.
– Only lead-free PVC-jacketed cables wi th an insulation limit temperature > 105 °C are allowed to be used.
– Connections s hall be made professionally and water-tight.
– The cable shall be dimensioned according to the current drawn and protected by fuses.

2 Technical data for planning

1

Shape C; DIN 72581 flat connector

2

Shape E; DIN 72581 flat connector

Warning note

No additional elec trical cables or hose lines are allowed
to be secured to existing lines such as brake or fuel
lines or cables, because standard holder s might
otherwise be overloaded. An independe nt attachment
solution must be found.

-section [mm²]

2.5.2.2 Additional circuits

If additional circuits are requir ed, we always recommend using the electrical interface for external use (PR no. UF1) (see chap.

2.5.3).
Additional cir cuits shall be safeguarded against the main circuit by means of suitable fuses.
Cables shall be dimensioned accordi ng to the load, and protected against pulling off and the effects of impacts and heat .

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 59 of 130

2 Technical data for planning

2.5.2.3 Retrofitting electrical devices

Note the following f or retrofitting additional electrical loads:
– No further loads are allowed to be connected to occupied fuses.
– No additional cabl es are allowed to be c onnected to existing cables (e.g. with insulation-pier cing terminals).
– Protect loads adequately by means of addi tional fuses.
– All installed electrical devices shall be checked acc. to EU Directive 72/245/EEC and shall bear the "e" mark.

Warning note

Please note that in vehicles with towing brackets, the
socket for supplyi ng the trailer electrical system
influences the control functions of t he brake system
(ABS/TCS/ESP*), and it is exclusively provided for
supplying power to the trailer.

When the trailer socket is occupied

– The offroad button has no effect (no offroad ABS and

hill descent assist is no longer poss ible (ESP* vehicles

only)).
– ESP* functions respond more sensiti vely.
– The hill start as sist becomes more robust.

We recommend using the interface for special vehicles to provide electrical power to special vehicle conversions. (see also
chap. 2.5.2.3 "Electrical inter face for special vehicles")

Electronic Stabilisation Program

*

2.5.2.4 Electromagnetic compatibility

Electromagnetic compatibility refers to the proper ty of an electrical system to remain neutral whilst maintaining full functi ons in

the presence of other systems.
Active systems in the surrounding area are not disrupted by the system, nor is the system itself impaired.

Electrical i nterference in motor vehicle electric al systems is caused by the individual loads. At Volkswagen AG, the factory-fitted
electronic components have been checked for their elec tromagnetic compatibility in the vehicle.

When electric al or electronic syst em s are retrofitted, it is also necess ary to check and demonstrate their electrom agnetic
compatibility.

Volkswagen does not issue a manufacturer's declarati on for electromagnetic compatibility when additional devices are
subsequently installed by body builders.

Devices that are regarded as "elect rical/electroni c subassemblies" (ESA) as defined by EC Directive 72/245/EEG in the current
version shall be t ype-approved and shall bear the "e" mark.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 60 of 130

2 Technical data for planning

2.5.2.5 Mobile communication systems

In order to avoid subsequent disrupti ons to operation, it is necessary to take account of the follow ing points when retrofitting
mobile communication systems (e.g. telephone, CB radio):
– The devices shall possess a type approval acc. to EU Direct ive 72/245/EEC in the current version, and shall bear the "e"

mark.

– All devices to be f itted shall possess a type approval acc. to EU Directive 72/245/EE C in the current version, and shall bear

the "e" mark.
– The maximum transmission power is not allowed to be exceeded.
– The devices and holders shall be located outside the deploym ent range of the airbags.
– They shall be perman ently installed.
– Mobile devices w ithin the cab are only allowed to be operated vi a an external aerial i nstalled in such a way as to eliminate

reflections.
– The transmitter shall be install ed in a separate locati on from the vehicle electronics.
– The device shall be protected against moisture and severe mechanical shocks; comply with the permi tted operating

temperature.

2.5.2.6 CAN bus

Interventions i n the CAN bus and connected components are not permitted.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 61 of 130

2 Technical data for planning

2.5.3 Electrical interface for special vehicles

The special vehicles interface provi des selected vehicle electrical system potentials.
These interfaces are only allowed to be used by authorised specialist pers onnel. Inappropriate interventions c an result in
damage to the vehic le and breakdowns, and may also invalidate the operating permi t.

Subject to technical modificati ons.

The following point s shall be adhered to:
– Various VDE guidel ines for configurat ion and fitting of electrical cables and components (cable cross sections, fuses, etc.).
– Only components (cables, housings, contacts) approved by Volkswagen are allowed to be used for adapting to the vehicl e

electrical s ystem. The part numbers of these components can be found in this description.
– Only the potential nam es normally used in VW are used in this description.
– It is not known what additional units w ill be connected; ther efore the company fi tting out the vehicle w ith the interface shall

ensure a balanced current distributi on.
– EMC safety for connections after t he interface is the res ponsibility of the c om pany fitting out the v ehicle.
– The cable cross sections of the interf aces shall be maintained throughout the entire circuit, i. e. no cross-section reductions

are permitted after the interfac e.
– Energy supply to the vehicle electri cal system is only allowed to be done at potentials expressly provided for this purpose (see

description) and shall be fused extern ally in accordance w ith VDE.
– For additional information, refer to Amarok customer service documents.
– All electric al cables connected to the vehi cle electrical system shall be reli ably and durably protected against overload to

battery "+" and the bo dy earth
– Earth potential: T he specified potentials always refer to the vehicle body earth

2.5.3.1 Position of the interface

Fig. 1: Electrical interface for special vehicles

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 62 of 130

Fig. 2: Position of the electrical interface in the vehicle

* 1 => UF1 interface for special vehicles

** "Arrow" => Direction of travel

2 Technical data for planning

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 63 of 130

2 Technical data for planning

Cross­[mm²]

Max.
draw [A]

Max. current
supply [A]

Fusing

Mating plug
contact

Restrictions

hite

Not
permissible

F37 (15 A)

1J0.937.733.K

BCM std: 4.0

BCM std: 0.21
BCM max:
Not
permissible

F30 (5 A)

1J0.937.733.K

With BCM max:
PWM signal, signal
output even when
left corneri ng lighting
is activated

Not
permissible

No
independent

1J0.937.733.K

With automatic
gearbox or BCM
max:
PWM signal

black

Not
permissible

F26 (10 A)

1J0.937.733.K

A4 and A5 are phys.
connected

ed

Not
permissible

F28

1J0.937.733.K

reen

Not
permissible

F52 (5 A)

1J0.937.733.K

yellow

Not
permissible

No
independent

1J0.937.733.K

When dimmer
installed:
PWM signal

black

5.0

F27 (10 A)

1J0.937.733.K

Pin A8 and plug 2
pin A1 are phys.
connected

ue

Not
permissible

F50 (5 A)

1J0.937.733.K

Not
permissible

No
independent

1J0.937.733.K

With BCM max:
PWM signal; pick
at left side light
With BCM std.: pi ck
off from rotary l ight
switch

2.5.3.2 Assignment of the terminal strip (UF1)

Selected vehicle electrical sys tem potentials are assigned to the 3 plugs. The interface assignment and the possibility of
drawing or supplying current depend on the equipment.

Plug 1 (violet)

1J00.937.743.K

potenti

Pin

al

Colour

section

current

Use

75 A

55

RFL

56bL

56bR

86S

58d

56aL

Black/w

Grey/ye
llow

Black/bl
ue

Yellow/

Yellow/r

Black/g

Green/

White/

1 12.0

1.5

1.0 1.0

0.5 1.0

0.5 1.0

0.5 1.0

0.5 2.0

0.5 1.0

A1

A2

A3

A4

A5

A6

A7

A8

BCM max:

0.5

X-contact

Fog light

Reversing light

Dipped beam (left)

(10 A)

1

Dipped beam (right)

S contact

Terminal 58d

High beam (left)

A9

A10

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 64 of 130

15 A

58LA

Black/bl

Green/
black

0.5 2.0

1 0.5

Terminal 15

-off

Side lights

-

Cross­section
[mm²]

Max.
draw [A]

Max. current
supply [A]

Fusing

Mating plug
contact

black

5.0

F27 (10 A)

1J0.937.733.
C

Pin A1 and plug 1
connected

violet

Not
permissible

No
independent

1J0.937.733.
C

Not
permissible

No
independent

1J0.937.733.
C

Earth signal

signal

ed

-

No
independent

1J0.937.733.
C

1J0.937.733.
C

Not
permissible

No
independent

1J0.937.733.
C

Earth signal

signal

violet

Not
permissible

No
independent

1J0.937.733.
C

-

No
independent

1J0.937.733.
C

Pin A8 is only fit ted

signal as with pi n A 4

1J0.937.733.
C

ellow

Not
permissible

No
independent

1J0.937.733.
C

contact

Plug 2 (yellow)
1J00.937.743.C

potenti

Pin

al

Colour

current

2 Technical data for planning

Use Restrictions

A1

A2

A3

A4

A5

A6

A7

A8

White/

56aR

White/

V

Black/w

L

hite

Black/r

50

n.c.

Black/g

R

reen

Brown/

HB Sig

Black/r

50

ed

0.5 1.0

0.5 0.022

0.5 0.2

0.5 0.23

0.5 0.2

0.35 0.014

0.5 0.2

1

High beam (right)

Speed signal

Turn signal left

Starter

n.c.

Turn signal right

Handbrake.C

Starter

pin A8 are phys.

Stat. Turn signal
status no timing

Stat. Turn signal
status no timing

Earth signal

with manual
gearboxes: same

A9

n.c.

71b

Black/y

1.5 0.5

A10

n.c.

Horn momentary

Signal pick-off at
vehicle horn

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 65 of 130

Plug 3 (grey)

Cross­section
[mm²]

Max.
draw [A]

Max. current
supply [A]

Fusing

Mating plug
contact

ed

Not
permissible

No
independent

1J0.937.731.G

ed

Not
permissible

No
independent

1J0.937.731.G

rey

permissible

25 F31 (30 A)

1J0.937.731.G
running tl 15

wn

Not
permissible

HSB_FUSE_S
6 (40 A)

1J0.937.731.G

ellow

permissible

2.5 F47 (5 A)

1J0.937.731.G
running tl 75

A6

n.c. 1J0.937.731.G

Not assigned

1J0.937.741.G

potenti

Pin

al

Colour

current

2 Technical data for planning

Use Restrictions

54

Black/r

0.5 0.25

Brake light

A1

Pin A1 and pin A2
are phys. connected

Connection to starter
battery

A2

A3

A4

A5

54

15

30 A

75

Black/r

Black/g

Red/bro

Black/y

0.5 0.2

2.5

Not

4 306

0.5

Not

Brake light

Continued engine

Terminal 30

Continued engine

1. An external fuse is required in case of external power supply. It is essential to take account of the effects on the vehicle electrical system

2. Note the specification of the instrument cluster interface

3. If the cable between pin 4 and pin 8 is disconnected (plug 2) then the ends of the cable must be insulated correctly. Note the necessary continuous current for the relay coil of ≥
200 mA

4. Note the influence / feedback on the instrument cluster

5. If the cable between pin 1 and pin 2 is disconnected (plug 3) then the ends of the cable must be insulated correctly.

6. Note parallel operation of additional loads (load balance)

7. An external fuse is required directly before the interface

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 66 of 130

2 Technical data for planning

2.5.3.3 Connector pin assignment and circuit diagrams for interface for special vehicles

Detailed information about the special interface c an be found in the workshop manuals and circuit diagrams (no. 21/1) of
Volkswagen AG.

Information

Volkswagen AG workshop manuals and circuit
diagrams can be downl oaded from the Internet at
erWin* (Electronic Repai r and Workshop Information
from Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 67 of 130

2 Technical data for planning

2.5.4 Vehicle battery

If a vehicle is not operated for a long time, its battery gradually loses charge due t o the electrical loads (clock, tachograph,
cigarette lighter or radio) and can suffer permanent damage.

To avoid this damage, the wiring harnes s is disconnected in the production faci lity using a connector and shall be reconnected
during transfer s or vehicle delivery services.
The connector s hall be disconnected again if the vehicles are to be left unused at the body manufactur er for some time.

2.5.3.1 Installation of additional battery

When installing additional batteries, please note that this may only be done in conjunction with a battery isolation relay. The
additional battery is only allowed to be used for its specified additional loads. Additional loa ds could be, for example:
refrigeration systems, auxiliary heating etc.
If an additional battery is accommodated in the passenger compartment, ensure that there is suf ficient ventilation.

Warning note

When work is performed on the vehicle electrical
system, the earth cables should always be
disconnected from the battery and the additional
battery. Only then should you disconnect the positive
cables.
Short-circuits could occur if this is not observed.

2.5.5. Digital tachograph (EC monitoring device)

The tachograph rec ords distance and spe ed data from two dri vers and gives an automati c warning before driving times are
exceeded. The st ored data can be printed out on the integrated printer or downloaded vi a the download interface.

Information

Please note when ord ering your base vehicle:
The preparation for the digital tachograph (PR no.

9ND) and the digital tachograph (PR no. YA J) can be
ordered ex-works as optional equipment.

If the vehicle is used for commercial purposes and has a max. permitted combination weight of more than 3.5 t, it is a legal
requirement of EU Regulation 3820/85 f or a tachograph to be fitted.
The requirement to fit an EC/AETR monitoring device is waived acc. to Art. 3 (1) of Directive (EEC) no. 3821/85 for means of
transport specified in Art. 3 of Directive (EC) no. 561/2006 and Art. 2 AETR.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 68 of 130

2 Technical data for planning

2.6 Engine peripherals/powertrain

In the event of modifications to nois e-relevant components such as the engine, e xhaust system, tyr es, air intake system, etc.,
noise measurements shall be carried out acc. to EC directives. The permitted val ues are not allowed to be exceeded.
The national regulat ions and directives apply.
Components for sound insulation that are installed as standard are not allowed to be modified or removed
(see also chap. 2.4.4 "Acoustic insulation").

2.6.1 Engine/powertrain components

– No modifications to the engine air i ntake system are permitted.
– Subsequent solutions regarding engine speed control are not possible.
– Modifications to the cooling system (radiator, radiator grille, air ducts, etc.) are not permitted.
– Keep cooling air i ntake areas clear.

2.6.2 Drive shafts

The correct configuration and implem entation of a modified powertrain prevents noise and vibration, and should only be
performed by a company which is qualified to build drive shafts.

Only genuine Volkswagen parts should be used.

2.6.3 Fuel system

Modifications to the fuel system are not permitted.

Modifications to the body in the area of t he fuel tank require t he fuel tank to be removed f irst.
Comply with the work shop manuals of Volkswagen AG.

Information

Volkswagen AG workshop manuals and work shop

information can be downloaded from the Internet at
erWin* (Electronic Repai r and Workshop Information
from Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

Note the following when working on the fuel system:
– Vehicles with a petrol engine have their activated charcoal container located at the rear end of the f uel tank. The position and

attachment of the activated charcoal container are not al lowed to be modified.
– Do not attach heat-c onducting components or components t hat restrict the ins tallation space.
– Modifications to the fuel pump, fuel line length and fuel line routing are not permitted. Modifications to these mutually

configured compo nents can impair t he function of the engine.

Please also compl y with chapter 4.1.4 "R em oval of the fill er neck".

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 69 of 130

2 Technical data for planning

2.6.4 Exhaust system

Modifications to the exhaust system up to the main silencer and in the area of the com ponents for exhaust post-treatment
(diesel parti culate filter, catalytic converter, lambda probe, etc. ) are never permitted.

If modificati ons are required to the exhaust system for the add-on/removal/conversion nevertheless, this can have effects which
are relevant to registration. Please contact us in advance regarding the sc ope of your conversi on so that we can advise you.

We recommend that yo u use VW genuine parts and comply with the workshop manuals of V olkswagen AG.

Information

You will find fur ther information on ins tallation and
removal of the exhaust system on the Int ernet at
erWin* (Electronic Repair and Workshop Information
from Volkswagen AG ):

http://erwin.volkswagen.de/erwin/showHome.do

* Information system from Volkswagen AG, subject to payment

Information

Country-related regulations and guidelines shall be
complied with

Exceptions require the approval of Volkswagen AG before the conversion, and shall be documented i n a registration report
detailing the modi fications and adjustments made.

Please use the online contact form for this:

http://umbauportal.de/kontaktformular or
http://umbauportal.de/ihr-kontakt-zu-uns

Warning note

Attention! Danger of fire!
The lengths and routings of the exhaust system have

been configured optimally with regard t o their
temperature properties. Modifications may result in
relatively high to extreme heating of the exhaust
system and the sur rounding components (drive shafts,
tank, floor pan, etc.).

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 70 of 130

2 Technical data for planning

2.0 l 132 kW TDI

2.7 Ancillary drives, engine/gearbox

When planning the s pecial vehicle, select the equipment of the base vehicle according to the requir em ents of the future
application. (S ee also chap. 1.5.1 "Sel ecting the base vehicle")
You can optimise your base vehicle i n advance for the convers ion by selecting the f ollowing optional equipment items:

For correct operation of the ancillary drive, we recommend that you use the additional units (e. g. refrigerant compressor)
provided ex-works for the base vehicle.

For further inf ormation, see:
– Chap.1.5.1 "Selec ting the base vehicle"
– Chap. 2.5.4 "Vehic le battery"

2.7.1. Retrofitting air-conditioning system

All installed electrical devices must be checked acc. to EC D irective 72/245/EEC and shall bear the "e" mark.
To retrofit air-conditioning sys tems, we recommend the "regulated air-conditioning system" PR no. 9AD/9AP
("Climatic/C limatronic air-c onditioning system") that you can buy ex works as optional equipment.

We recommend using the original refrigerant compressor:

Engine designation Climate contr ol Refrigerant

compressor
Type

2.0 l 118 kW

Petrol

TFSI

2.0 l 90 kW TDI

2.0 l 103 kW TDI

Diesel

Cab

Cab

DENSO-6SEU14
(140 cc)

DENSO-6SEU14
(140 cc)

If other air-condi tioning systems are to be retrofitted, the guidelines from the equipment manufacturer and for the system
components shoul d be observed. The body builder is then solely responsible for operating and road safety.

Retrofitti ng or replacing ancill aries, for example, the r efrigerant compr essor, is possible in place of the original refrigerant
compressor or wi th the aid of an additional belt pulley via the second belt track. (See chap. 2.7.3 "Specification of genui ne
refrigerant c ompressor" and chap. 2.7.2 "Driving an anci llary via the 2nd belt track")

The following point s should be observed f or the compatibility with the base vehicle:
– Vehicle parts and their function should not be impaired by the installation of an air-conditioning system.
– The capacity of the battery and power supplied by the alternator must be dimensi oned sufficiently.
– Additional fuse pr otection of the air-conditioning system circuit (see chap. 2.5.2.1 "Electrical cables/fuses").
– The refrigerant compressors should be mounted on the provided assembly carriers.
– The weight of the anc illary is not allow ed to exceed the weight of the original ref rigerant compress or (see table 2).
– The diameter and pos ition of the drive pul ley for the ancillary must correspond with that of the original refrigerant compressor.

(see Fig. 1-5)
– There shall be adequate space for operating the ancillary.
– The track position of the poly V-belt mus t be identical to t he original and the poly V-b elt specifications must be observed (see

table 4).

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 71 of 130

2 Technical data for planning

– If the standard ref rigerant compres sor is used, it is necessary to optimise the fill volume and conduct oil circulation and oil

return measurement s. Measurements for ensuring the oil circulation in the r efrigeration circuit shall be carried out by the body

builder at its ow n cost, and be conducted at the corresponding com pressor manufacturers.
– Ensure that lines (brake hoses/cables and wires) are routed correctly.
– The accessibility of the ancillaries installed and si m ple maintenance possibilities may not be impaired.
– The Owner's Manual and the maintenance manual for the anci llaries should be handed over when the vehic le is delivered.
– The necessary ai r supply and the engine cooling may not be impai red.
– When compact s ystems (evaporator, condenser and fan) are mounted on the cab roof, the permitted roof loads may not be

exceeded (see chap. 2.3.1 "Maximum roof loads").
– Attachments t o the roof require a safet y certificate fr om the responsible department (see chap. 1. 2.2.1 "Safety cert ificate").

Practical note

In vehicles without air conditioning, it is necessary to
recode the engine control unit when an ancillary is
retrofitted.

2.7.2. Driving an ancillary via the 2nd belt track*

Further ancill aries (e.g. generators, compressors or pumps) can be driven via t he second belt track with the aid of an additional
pulley. You can obtai n the correspondin g conversion kit separately from Volkswagen Genuine Par ts.
The conversion k it comprises:
– Hub (part no. 03L.105.215)
– Belt pulley, diamet er: 160 mm 6PK (03L.10 5.255.C)
– Fastening material (N.106.517.01 + N .100.051.10)

For information on the conversion kit, please ask your VW partner or contact the superstructure manufacturer support via the
contact form:

http://umbauportal.de/kontaktformular or
http://umbauportal.de/ihr-kontakt-zu-uns

Information

For detailed inst ructions about the installation and
removal, for example, of the poly V-belt, refer to the
workshop manuals of Volkswagen AG on the Int ernet
under erWin (Electronic Repair and Workshop
Information of Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

The max. consumable power with 4-cylinder TDI engines is: 8.0 kW.

* Delivery date had not yet been defined as at the copy deadline.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 72 of 130

2.7.3. Specifications of standard refrigerant compressor

[kW]

2.0 l 132 kW TDI

type

[kg]

2.0 l 132 kW TDI

compressor)

2.0 l 132 kW TDI

type

2.0 l 132 kW TDI

Table 1: Maximum output of refrigeran t compressor

Engine designation Refrigerant compres sor

type

Power L
[kW]

2 Technical data for planning

Cooling power
Q

2.0 l 118 kW

Petrol

TFSI

DENSO-6SEU14 (140 cc) 5.71

1)

8.32

1)

2.0 l 90 kW TDI

2.0 l 103 kW TDI

Diesel

1) Figures on refrigerant compressor with high pressure Pd=1.47MPaG, suction pressure Ps = 0.196MPaG and speed N =4000rpm

DENSO-6SEU14 (140 cc) 5.71 1) 8.32 1)

Table 2: Weight of refrigerant compressor

Engine designation

2.0 l 118 kW

Petrol

TFSI

Refrigerant compressor

Max. weight

DENSO-6SEU14 (140 cc) 4.62 kg

2.0 l 90 kW TDI

2.0 l 103 kW TDI

Diesel

DENSO-6SEU14 (140 cc) 4.62 kg

Table 3: Belt pul ley diameter of refri gerant compressor

Engine designation Refrigerant

compressor
type

Pulley
diameter

Transmission
ratio "i"
(crankshaft/refri
gerant

2.0 l 118 kW
TFSI

Petrol

2.0 l 90 kW TDI

2.0 l 103 kW TDI

Diesel

Table 4: Specifi cations of poly V-belt

Engine designation

2.0 l 118 kW

Petrol

TFSI

2.0 l 90 kW TDI

2.0 l 103 kW TDI

Diesel

2) Figures were not available at the copy deadline.

DENSO-6SEU14

100 mm

DENSO-6SEU14 100 mm

Refrigerant compressor

Belt specific ation/part no.

DENSO-6SEU14 (140 cc) 6 PKD 1577

DENSO-6SEU14 (140 cc)

6PK1555, SILENT GRI P /
03L.903.137.H

2)

---

1.38

/ 06H.903.137.H

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 73 of 130

2.7.3.1 Connection measurements of standard refrigerant compressor

2 Technical data for planning

Fig. 1 Poly V-belt drive (here only TDI engine depicted, the original engine position differs from the picture)

1 - Alternator
2 - Poly-V-belt pulley
3 - Reversing pulley
4 - Air-conditioning compressor assembly

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 74 of 130

2 Technical data for planning

Fig. 2: Dimensions of air-conditioning compressor, pulley diameter 100 mm (side view)

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 75 of 130

2 Technical data for planning

Fig. 3: Dimensions of air-conditioning compressor Denso 6SU14 (front view)

Fig. 4: Dimensions of air-conditioning compressor Denso 6SU14 (view from above)

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 76 of 130

2 Technical data for planning

5.3±0.2

Fig. 5: Detail U - Denso 6SU14 air-conditioning compressor drive pulley, pulley diameter d = 100 mm

Please also compl y with the following chapt ers during the con version:

– 2.7.1 Ancillar ies
– 2.5.4 Vehicle batt ery
– 2.5.2.2 Addition al electrical ci rcuits
– 3 Modifications to closed bodies
– 5.2 Refrigerated vehicles

Please observe the installation and r em oval regulations of Volkswagen AG when per forming convers ions.

Information

For detailed inst ructions about the installation and
removal, for example, of the poly V-belt, refer to the
workshop manuals of Volkswagen AG on the Int ernet
under erWin (Electronic Repair and Workshop
Information of Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 77 of 130

2.7.4 Installation and removal of the poly V-belt

2 Technical data for planning

Fig. 7 Belt ten sioner

1 - Belt tensioner
2 - Locking pin
3 - Moveable eye
4 - Fixed eye
5 - Spring

Z - Midpoint of the central bolt

2.7.4.1 Removal of the belt

In order to remove the belt, it is necess ary to turn the belt t ensioner clockwis e using a suitable tool until the moveable eye " 3"
overlaps with the f ixed eye "4", and sec ure it with a locking pin " 2" (d = 5 mm). This means the spring of the belt tensioner is
tensioned, the tens ion of the belt is removed and the belt can be removed. This posit ion of the belt tensi oner is referred to below
as the locking position.

2.7.4.2 Installation of the belt

For installat ion, the belt must be guided over all units and reversing pulleys, and then finally placed over the belt tensioner. After
the locking pin has been removed (which is only permitted wi th the belt installed), the belt tensi oner turns anticlockwise and
transfers the clamping force to the belt. Only poly V-belts with the approved length are al lowed to be used, so that the belt
tensioner can operated within its def ined operating range. This applies in particular to belt drives that no longer c orrespond to
the initial equipment status. The pos ition of the tensi oner in the install ed position with the engi ne stopped is ref erred to below as
the nominal position. From this posi tion, the belt tens ioner is capable of compensating for tolerances and belt stretching due to
temperature, etc.
At the lower limit stop, the spring is slackened and cannot exer t tension on the belt any longer.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 78 of 130

Angle [°]

Distance A [mm]

Position of the bel t tensioner

0 0 Locking position (overlap) – A

28

14.5

Start of working range –B

34

17.5

Nominal position (NOM) – C

57

50.3

End of working range – D

Volkswagen Technical Site: http://vwts.ru http://vwts.info

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

2.7.4.3 Working range of the belt tensioner:

The following displ ay shows various points of the working range of the belt tens ioner and should make i t easier to check that the
belt tensioner is in the correct position. This diagram does not provide any statement relating to the safety of a belt dr ive that is
different from the series production status.

2 Technical data for planning

Fig. 8 Working range of the belt tensioner

A - Locking position 0° (overlap)
B - Start of working range 28°

C - Nominal position 34°

D - End of working range 57°
E - Bottom stop 80°

The angle is measur ed between the fixed eye a nd the movable eye. I n the nominal posit ion, it is 34°. It is not allowed to go
beyond the working range from 28°-57°. For distance A, it is necessary to specify the actual dimension between the fixed eye
and the moveable eye, assuming the moveable eye is in the working range. The distance A in the nominal position is 17.5 mm.

Information

You will find fur ther information in t he Volkswagen AG
workshop manuals on the Internet at erWin (Electronic
Repair and Workshop Information from Volkswagen
AG): http://erwin.volkswagen.de/erwin/showHome.do

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 79 of 130

2 Technical data for planning

2.7.4.4 Belt routing

The function of the bel t tensioner can be significantly i m paired if the belt routing is changed from that of series production and
passed over the idler roller of the belt tensioner. The bisector (1) between the arriving and departing sides of the bel t should be
almost at right angl es ( ≈  to the lever arm of the belt tensioner in the working area. (Fig. 9)

Fig.9: Belt routing around the belt tensioner
1-Bisector of the arriving and departing sides of the belt around the belt tensioner

α – Angle of the belt routing around the belt tensioner
ß – Angle between the bisectors of the arriving and departing sides of the belt in relation to the lever arm of the belt tensioner.

Information

You will find fur ther information in t he V olkswagen AG
workshop manuals on the Internet at erWin* (Electronic
Repair and Workshop Information from Volkswagen
AG): http://erwin.volkswagen.de/erwin/showHome.do

* Information system from Volkswagen AG, subject to payment

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 80 of 130

2 Technical data for planning

2.8 Add-ons/units

2.8.1 Roof rack

Roof loads raise the centre of gravity of the vehicle and lead to a high dynamic axle load shift. Also, t here is greater body lean
when driving on rough roads and when corneri ng. The driving characteristics are significantl y impaired. For this reason, roof
loads should be avoided if at all possible.

Where possibl e, the fixed points on the r oof should be used for attaching racks (see the manufacturer's installation instructions).

The Amarok DC (Doubl e C ab) has 2 contact points on each side of the roof and the Amarok SC (Single Cab) has 1 contact
point on each side (see Fig. 2.8.1.1).

Fig. 1: Roof rack contact points on Amarok DC (marked in red)

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 81 of 130

2 Technical data for planning

[kg]

[kg]

[kg]

Petrol

2.0 l 118 kW TFSI

2.0 l 120 kW TDI

2.0 l 132 kW BiTDI

8-speed automatic

2.8.2 Towing bracket

We recommend using hitches approved by Volkswagen as towing br ackets.
The "Preparation for towing bracket " (PR no: 1D7) is part of the standard equipment on v ehicles from model ye ar

2012.
The cross member (bumper) required f or the towing bracket on Amarok chassis m ust be
sourced subsequent ly as a Volkswagen genuine part (see chapter 1.2.1.4 "Genuine parts online") .

You can obtain the ball head towing bracket incl. electrical set as a genuine accessory (PR no. YAK) directly from Volkswagen
AG.

Fig. 1: 1 = Bumper 2 = Ball head

Maximum trailer loads:

Engine

Total towing

weight

Max. trailer

1

load

Drawbar

load

2.0 l 90 kW TDI
5550

Diesel

2.0 l 132 kW BiTDI

* End of variant calendar week 26/2012

1

Unbraked trailer load: 750 kg

2

Does not apply to hot country (8Z6) and super hot country (8Z9)

3

Only applies to 4x2 / leaf spring 2+1 (comfort)

5950² 3200² 130²

The maximum permit ted gross combination weight and maxim um permitted tr ailer load specifi ed in the documents are not
allowed to be exceeded.

For retrofitting a towing bracket :
– Comply with the regulations of the country in question, in this regard see also ECE -R55 and RREG 94/20/EC ( in the valid

version).
– The necessary cl earance for the towing bracket shall be guaranteed (clearance acc. to DIN 74058).
– The vehicle shall be presented to a motor vehicle test centre with responsibil ity for this matter .

3000

2800³

120

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 82 of 130

Practical note

There are mounting p oints in the vehicl e's chassis rails,
or if the towing brac ket preparation and step have been
ordered, then they are below the step.

Operation with the factory-fitted hitch may be excluded
at a very low ride height or if there is a long body
overhang, as well as after an extension of the
overhang.

Information

The towing brackets listed here are only valid for EU
countries. There are different var iants for countries
outside the EU. You can obtain more infor m ation on
this from your Volkswagen dealer.

2 Technical data for planning

2.8.3 Other accessories

Please note our extensive range of ac cessories when ordering your base vehicl e.
The available opti onal equipment i ncludes a winch (max. 3.6 t ) with mounting on the front of the vehicle and on the load surf ace
as an additional of froad package (PR no. YAJ).

Information

For further inf ormation, see: http://www.volkswagen-

zubehoer.de/

2.9 Lifting the vehicle

– With lifting platforms

The vehicle is only allowed to be raised at the lifting point s provided (see owner' s manual).

– With a jack:

See the owner's manual for the procedure and jacking points on all vehicle variants (in all chassis w ithout standard add-ons).

The body maker is responsible for making sure that the jack corresponds to the weight of the body. The hard points for li fting

platforms on the ladder frame can be used ( w ith large pads) and shall remain accessible even after the conversion.

Alternative hard p oints should be cr eated if this is not possible.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 83 of 130

3 Modifications to closed bodies

3 Modifications to closed bodies

3.1 Body-in-white/bodywork

Comply with the following instructions with regard to mounting bodies and maki ng conversions on t he vehicle:
– Changes to the body ar e not allowed to impair the function and strength of units and operating devices of the vehicle, neither

may they reduce the s trength of weight-bearing parts.
– During vehicle conversions and installation of bodies , it is not permitt ed to make any modificat ions which impair the function

and freedom of movement of the suspension (e.g. for maintenance and inspection wor k) or the accessibility to the same.
– Interventions i n the cross-member structure from the f ront end to the rear of the B-pillar are not allow ed.
– Modifications in the roof area and on the r ear gate are not allowed.
– The clearance for the fuel filler neck as well as for the tank and fuel lines shall be m aintained.
– Avoid corners with sharp edges.
– Neither drilling nor welding is perm itted on the A and B-pillars.
– If cutting is performed on the C and D-pillars (rear gate), i ncluding the corresponding roof bows, then rigidity shall be restored

by means of additional components.
– The permitted a xle l oads are not allowed to be exceeded.
– Holes in the frame longitudinal member are the result of t he production proces s and are not suitable for attaching add-ons,

bodies, instal lations and conversions; otherwise, the frame may be damaged.
– The standard tank cap is not allowed to be rem oved or covered wit h a part which creates a block.

Please also refer to chapter 4.1 "Cargo b ox removal".

3.1.1 Side wall and rear wall cut-outs

The body and underbody form a self-supporting unit. Weight-bearing parts of this self-supporting unit are not al lowed to be
removed without replacement.
Windows, roof hat ches and air inlets and outlets shall be s urrounded by a stable fram e. This frame shall be connected to other
body elements by means of a force-locking connection.

Information

You will find fur ther information on body assembly work
on the Internet at erWin (Electronic Repair and
Workshop Informat ion from Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

3.1.2 Installation of windows

Information

For detailed inst ructions about the installation and
removal of windows , refer to the workshop manuals of
Volkswagen AG on the Internet under erWin (Electronic
Repair and Workshop Information from Volkswagen
AG): http://erwin.volkswagen.de/erwin/showHome.do

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 84 of 130

3 Modifications to closed bodies

3.1.3 Roof cut-outs

The roof cut-out s hall be provided with an al l-round frame having a force-locking connection with the adjacent, weight-bearing
parts (bows and roof frame).

Information

You will find fur ther information on body assembly work
on the Internet at erWin (Electronic Repair and
Workshop Information from Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

3.1.4 Modifications to the roof

The following point s shall be observed if modifications are made to the roof structure:
– The all-round concept shall be retained, and adequate replacement rigidity shall be guaranteed.
– Impairments t o the function of the rai n/light sensor shal l be avoided.
– The vehicle constraints (strength, overall vehicle dimensions, registration, etc.) shall be considered with regard to attachments

on the roof panel. ( T his does not apply to area illumination and s potlights.)
– The replacement rigidity of the new roof structure shall correspond to that of the standard roof.
– Following all conver sion and installation work on the vehicle, surface and corrosion protection shall be applied to the affected

points.

Information

You will find further informati on on body assembly work
on the Internet at erWin (Electronic Repair and
Workshop Information from Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 85 of 130

3 Modifications to closed bodies

3.2 Interior

The following point s shall be observed wi thout fail for conver sions:
– The driver and front passenger airbag units, the airbags and belt tensioners are pyrotechnical objects.
– Their handling, t ransport and storage are subject to legislation on potentially explosive substances, and the responsible public

authority or gover nment agency shall therefore be notif ied. Purchase, transport, storage, installation and rem oval as well as

disposal are only al lowed to be performed by t rained personnel in accordance wi th the corresponding safety regulations.
– Modifications in the cockpit area and above the shoulder line shall be conduct ed in accordance wit h the criteria of the hea d

impact tests acc. to ECE-R21 or 74/60/EEC as amended by 2000/4/EC. This applies in particular to the deployment areas of

airbags (wood décor, additional installations, m obile phone holders, bottle holders, etc.).
– Painting or surf ace treatment of the instrument panel, s teering wheel impact absorber and the tear seams of the airbags i s not

permitted.
– The permitted c entre of gravity posi tion and axle loads are not allowed to be exceeded.
– The interior fitting-out shall be configured with soft edges and surfaces .
– Installations shall be manufactur ed from flame-retardant materials, and be firmly installed.
– Unhindered acces s to the seats shall be guaranteed.
– No projecting parts, corners or edges that could cause injur ies are allowed to be located in the area of t he seats.

3.2.1 Safety equipment

Warning note

In case of interventions by the body buil der in the
structure of t he vehicle, such as

– modifications to the seats and consequently altered

kinematics of the occupants in case of a crash
– modifications to the front body
– installations of parts in the vici nity of the exit openings

and the deployment range of the airbags (see owner's

manual of the vehicle)
– installation of third-party seats
– modifications to the doors

the safe functi on of the front airbag, side airbag and
belt tensioners is no longer guaranteed. This could
result in personal injuries.

No vehicle component s that give rise to vibration are allow ed to be attached in the vicinity of the airbag control unit or t he sensor
installation locations.
Modifications to the floor struc ture in the area of the airbag control unit or the satellite sensors are not allowed.
(See also chapter 2.4.1 "Modifications in the area of airbags")
For information about the deployment zones of the airbags, refer to the owner's manual of the vehicle.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 86 of 130

4 Modifications to open bodies

4.1 Removal of the cargo box

4 Modifications to open bodies

Fig. 4: Cargo box removal

The following work is required in order to remove the cargo box (1):
– Removal of the tail lights (3).
– Disconnecting of the cable routing for the number plate light and the earth cable.
– Releasing the parking brake cable from underneath (4).
– Removing the left wheel housing liner (5).
– Unscrewing the filler neck (6).
– Removing the electrical cables from the load bed.
– Unscrewing the bolts (2) on the left and right.
– Removing the complete rear bumper (7) or at least the cover and the plastic tri m (only applies to vehicl es with rear bumpers).

– Lifting the car go box, e.g. with a crane (attaching the cargo box at the 4 standard load securing points).

To do this, the vehicle should be lifted on a lifting platform so its suspension is fully extended.
To avoid damage to the metal panels during r em oval, carefully pull the cargo box towards the rear out of t he overlapping area
with the driver' s cab prior to lifting.

You will find fur ther information on removal of the rear bumper (7) and the cargo box in the Volkswagen AG work shop manuals.

Information

Volkswagen AG workshop manuals and circuit
diagrams can be downl oaded from the Inter net at
erWin* (Electronic Repai r and Workshop Information
from Volkswagen AG):

http://erwin.volkswagen.de/erwin/showHome.do

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 87 of 130

4 Modifications to open bodies

Important notes:
– The spare wheel is secured to the cargo box us ing a support bracket. A replacement attachment of the spare wheel shall be

provided if the c argo box is dispensed with/removed.
– A suitable holder shall be created for the filler neck of the fuel tank (a new type approval may be required) .
– Provide suitable t ail lights wit h the sam e performance figures as the standard ones.

Furthermore, c om ply with the data for special bodies li sted in chapter 3.2 "Interior".

4.1.1 Removal of tail lights

The following work is required to remove the tail light:
– Switch off the igni tion and all elect rical loads, and pull out the ignition key.
– Open the tailgate.
– Unscrew and remove the fastening screws (arrows) from the tail light (Fig. 1) .
– Guide the tail light sideways out of the ball head in the direction of the arrow. (Fig. 2)
– Disconnect the plug connection -arrow- at the tail light. (Fig. 3)

Fig. 4.1.1.1: Removal of the tai l light (Figs. 1, 2 and 3)

4.1.2 Releasing the parking brake cable at the rear

The following steps are required to release the parking br ake cable:

– Lift the vehicle (see also chap. 2.9 "Li fting the vehicle")
– Remove rear wheels.
– Following this, pull the parking br ake cable (A) out of the holders on the body (bottom arrow).

Fig. 4.1.2.1: Releasing the parking brake cable

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 88 of 130

4.1.3 Removal of the wheel housing liner

The following work shall be performed in order to remove the wheel housing liner:
– Remove the wheel.
– Unscrew and remove the bolts (3).
– Unscrew the hexagon nut (2).
– Pull the rear wheel housing liner (1) out of the wheel housing.

4 Modifications to open bodies

Fig. 4.1.3.1: Removal of the wheel housing liner

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 89 of 130

4.1.4 Removal of the filler neck

Important safety note:
Work on the filler neck is only allowed to b e performed when the tank is empty or has been r em oved!

The following work shall be performed in order to remove the filler neck:

Unscrew the bolt (2) for the filler neck (1) on the underbody.
– Open the tank flap and clean the inside of the tank flap unit thoroughly.
– Unscrew the cover.

4 Modifications to open bodies

– Unscrew and remove the bolt (2) on the tank flap unit.
– Unclip the tank flap unit and remove it completely.

– Unscrew and remove nuts (2) from the filler neck (1) on the top of the cut-out

for the tank fl ap unit.
– Remove the filler neck (1) from below; this requires turning the filler neck.
– In vehicles with central locking, the plug for the filling station element shall be

disconnected.

Fig. 4.1.4.1: Detaching the filler neck on floor

Fig. 4.1.4.2: Releasing the tank flap unit

Fig. 4.1.4.1: Releasing the filler neck

Please also compl y with the following chapt ers for your conver sion:
– Recommendations for attaching the filler neck (chap. 4.1.7)
– Standard mountin g points for special bodies (chap. 4.3)

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 90 of 130

4.1.5 Unscrewing securing bolts

The following work shall be performed:
– Remove bolts (2) on left and right.

4 Modifications to open bodies

Fig. 4.4.5.1: Unscrewing securing bolts

4.1.6 Removal of the bumper

You will find fur ther information on removal of the rear bumper (7) and the cover on th e plastic trim in t he Volkswagen AG
workshop manuals.

Information

Volkswagen AG workshop manuals and circuit

diagrams can be downl oaded from the Inter net at
erWin* (Electronic Repai r and Workshop Information
from Volkswagen AG ):

http://erwin.volkswagen.de/erwin/showHome.do

You can order the Amarok (Single Cab or Double Cab) without rear bum per and with 180° folding tailgate as optional equipment
(PR no. 0S0) directly ex-works.

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 91 of 130

4 Modifications to open bodies

4.1.7 Recommendations for attaching the filler neck

Warning note

Please note that work on the filler neck may only be
performed when the t ank is empty or has been
removed!

If the cargo box is r em oved for a body modifi cation or is modified in the corresponding area, a suitable new f astening must be
created for the f iller neck. The fastening must meet the r equirements of regulation ECE-R 34 "Prevention of fire ris ks".

Comply with the following points during the work:
– The filler pipe s hall be fixed to the ladder frame if possible, or else to components attached to that.
– The whole system with fuel filler pipe, filler neck and fi ller cap may not be damaged.
– The whole system must be permanently l eak-proof in all oper ating conditions.
– The hose clamp must have the same retenti on force and durability as the producti on solution.
– All parts of the fuel filler system must be routed at a sufficient distance fr om m oving parts and sharp edg es to avoid damage.

Sufficient di stance from the rear wheel should be ensured in particular.
– Components of the fuel filler system m ay not be attached to safety-related parts, for example, brak e lines.
– All materials used must be petrol- or diesel-resistant.
– A sufficient angl e of the filler pipe to the tank should be ensured. Pipe routing that could cause a siphon effect must be

avoided.
– If the standard tank cap is not used, it m ust be ensured that the overpressure and vacuum protection functions integrated into

the standard tank cap are retained.
– The accessibility of the pump nozzle to the filler neck s hould be guaranteed as wi th the production solut ion.

In addition, and dep ending on the fuel, the following requirements and recommendations shall be complied with when routing
the filler neck for diesel and petrol "filler pipes".

Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 92 of 130

4.1.7.1 Diesel filler pipe

4 Modifications to open bodies

Fig. 1: Filler pipe assembly (ASSY)

1 Ventilation valve

2 Fastening lug for closure neck
2 Closure cap (tank cap):

- Opening pressure at 0.025 to 0.045 bar negative pressure (rel.)

- Opening pressure at 0.150 to 0.250 bar positive pressure (rel.)

Requirements on t he Amarok diesel fi ller pipe:
– An earthing path from the filler pipe via the closure neck and fastening lug to the vehi cle body work (screw connection) shall

be guaranteed.
– A ventilation func tion for the fuel t ank via the filler pipe shall be provided.
– The connecting hos e and vent line are not all owed to be kinked.
– The filler pipe, connecting hose and vent line are not allowed t o be in contact with adjacent components, in order to prevent

any chafing or leaks.

Recommendations for the convers ion:
– The positive pressure and negative pressure protect ion functions integr ated in the closure cap (tank cap) shall be retained if

at all possibl e.
– The filler pipe s hall be fixed to the ladder frame if possi ble, or else to components attached to that.

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4.1.7.2 Petrol filler pipe

Component

Amarok DC

Amarok SC

Cargo box*

121 kg

151 kg

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Fig. 2: Petrol filler pipe

1 Ventilation line
2 Activated charcoal container

Requirements on t he Amarok petrol filler pipe:
– An earthing path from the filler pipe via the closure pipe and fastening lug to the vehicle body work (screw connection) s hall

be guaranteed (sam e as diesel).
– The positive pressure protection function for the f uel tank shall be ensured in t he filler pipe (Amarok petrol standard solution:

protection valve in the tank cap).

– The connecting hos e and vent line are not all owed to be kinked.
– The filler pipe, connecting hose and vent line are not allowed t o be in contact with adjacent components, in order to prevent

any chafing or leaks.
– The air intake for the activated charcoal canister (ACC) shall be routed in an area where no water can be sucked in even

when driving through water.

(Amarok petrol standard solution: ACC ventilation line for air intake routed i n the area of the fuel f iller pipe in the wheel

housing).

4.1.8 Weight of cargo box

* incl. the add-on parts for the tailgate, hinges, tail light cluster, wheel housing liner and tailgate lock

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4.2 Chassis frame

4.2.1 Ladder frame Amarok DC (Double Cab)

Fig. 4.2.1.1: Plan view of Amarok DC without cargo box

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Fig. 4.2.1.2: Plan view of ladder frame Amarok DC

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4.2.2 Ladder frame Amarok SC (Single Cab)

Fig. 4.2.2.1: Plan view of Amarok SC (Single Cab) without cargo box

4 Modifications to open bodies

Fig. 4.2.2.2: Plan view of ladder frame Amarok SC

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4.2.3 Sections, Amarok SC (Single Cab)/Amarok DC (Double Cab)

~169

~ 162

4 Modifications to open bodies

Fig. 4.2.2.1: Section Q-Q (Amarok SC) Fig. 4.2.2.2 Section R-R (Amarok SC/DC)

Fig. 4.2.2.3: Section S-S (Amarok SC/DC) Fig. 4.2.2.4: Section T-T (Amarok SC/DC)

Please refer to the Amarok DoubleCab and SingleCab build dim ension drawings f or further connection sizes
(see chapter 6.1 "T echnical data").

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4 Modifications to open bodies

4.3 Standard mounting points for special bodies

Special bodies are possible after the cargo box has been removed (see chap. 4.1).

Comply with the following points when mounting special bodies:
– Use standard mounti ng points.
– If the cargo box is r eplaced by other bodies, the new body shall hav e a m aximum static torsional rigidity of C

(see Fig. 4.3.3).
– The wheel clearanc e on the rear axle shall be maintained.
– A suitable holder shall be created for the filler neck of the fuel tank (a new type approval may be required) .
– Suitable tail lights with the same performance data as the standard ones shal l be used.

The frame is a hollow section construction consisting of pressed sheet metal parts.

Brackets are welded onto the longitudinal members for at tachment of the cargo bo x. Holes or slots
with the dimension 21 m m , 23 mm or 21x30 mm are pr ovided for attachment of the cargo bo x (Fig. 4.3.1/4.3.2) .
For more informat ion, refer to chap. 4. 2 " C hassis frame".

The attachment bet ween the body and vehicle frame shall al w ays use all brackets.
The screw connections onto the brackets shall be force-locking.

=1400 Nm/°

T

Fig. 4.3.1: Amarok Double Cab – mounting brackets for cargo box (see red mark)

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4 Modifications to open bodies

Fig. 4.3.2: Amarok Single Cab – mounting brackets for cargo box (see red mark!)

Fig. 4.3.3: Static rigidity of cargo box between the bolting points at the front (1) and rear (2) of body-in-white, CT = 1,400 Nm/°

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4 Modifications to open bodies

4.4 Subframe (mounting frame)

The subframe shall be designed to be sel f-supporting according to the load.

The preferred material is steel. I f alternative materi als are used, the strength of the subfram e shall at least corr espond to that of
a steel frame.

Cross members shall be provided at leas t in the front and rear ar eas to ensure the st ructure is torsional ly rigid.

The subframe is r equired for bodies in w hich point loads are appl ied to the chassis, e.g. for tippers and s emitrailer tractors.

The purpose of the subframe is to distribute the applied point loads evenly over t he vehicle frame. F or this purpose, it should lie
on top of the longitu dinal members, be continued up to the cab and be tapering in the front area.

The various air gaps between the cab and subf rame shall not be f illed in. Self-supporting bodies can be attached directly to the
standard brackets on the frame by means of a base frame.
The subframe and sel f-supporting bodies shall be attached t o the chassis using all available brackets.

Bolts with strength class 10.9 shall be used for securing.

Information

For further inf ormation, see:

– Chap. 4.1 "Removal of the cargo box"
– Chap. 4.3 "Standar d mounting points

for special bodi es"

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