Volkswagen Amarok 2023 Manuallines
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Volkswagen Amarok 2023 Manuallines

Volkswagen Amarok 2023 Manuallines

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Body builder guidelines
February 2023 edition
Body builder guidelines
The new Amarok
(from model year 2023)

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Summary of Contents for Volkswagen Amarok 2023

  • Page 1 Body builder guidelines February 2023 edition Body builder guidelines The new Amarok (from model year 2023)

  • Page 2: Table Of Contents

    1.2.1 Product and vehicle information for body builders ......................10 1.2.1.1 Contact in Germany ..............................10 1.2.1.2 International contact ............................... 10 1.2.1.3 Electronic repair and workshop information from Volkswagen AG (erWin*) ............11 1.2.1.4 Genuine Parts Online Ordering Portal*........................11 1.2.1.5 Online Owner’s Manual ............................11 1.2.1.6 European Type Approval (ETA) and EC Certificate of Conformity (CoC)..............
  • Page 3 3.3.1 Selective catalytic reduction system – diesel exhaust fluid ..................62 4 Electrics ....................................... 70 4.1 Installation and routing guidelines for electrical wiring ......................... 70 4.1.1 Wiring splicing method............................... 70 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 3 of 166...
  • Page 4 5.1.6 Tank and bulk container superstructure ........................131 5.1.7 Aerial cable routing ..............................131 5.1.8 Roof carriers ................................132 5.1.9 Load management on the vehicle tray........................133 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 4 of 166...
  • Page 5 5.5.6 Water tank on camping vehicles ..........................155 5.5.7 Conversions with an extended wheelbase ........................ 156 6 Listings ......................................161 6.1 List of changes..................................... 161 *Electronic Stability Control Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 5 of 166...

  • Page 6: General Information

    Therefore, 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 negative effect on the vehicle as a whole. As a result, Volkswagen AG only accepts liability for its own design, production and instruction services.

  • Page 7: Means Of Representation

    This note draws your attention to the risk of possible damage to the vehicle, as well as to regulations and provisions to be observed. Information This note indicates additional information. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 7 of 166...

  • Page 8: Vehicle Safety

    We recommend that you use parts, mechanical units, conversion parts or accessories that have been tested by Volkswagen AG for the corresponding vehicle type. Have the vehicle's safety checked immediately if non-recommended parts, mechanical units, conversion parts or accessories are used.

  • Page 9: Operational Safety

    The texts, pictures and data contained in these body builder guidelines are subject to copyright. This also applies to editions on CD-ROM, DVD or other media. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 9 of 166...

  • Page 10: General Notes

    1.2.1 Product and vehicle information for body builders 1.2.1.1 Contact in Germany If you have questions concerning vehicle models from Volkswagen Commercial Vehicles, you can contact us via the internet portals of Volkswagen AG (www.customized-solution.com) or via one of the following methods:...

  • Page 11: Electronic Repair And Workshop Information From Volkswagen Ag (Erwin*)

    *Information system, subject to payment 1.2.1.4 Genuine Parts Online Ordering Portal* For the purchase of spare parts and for the research of Volkswagen Genuine Parts, our latest parts catalogues are available on the Internet in the “Genuine Parts Online Ordering Portal”: http://www.partslink24.com...

  • Page 12: Worldwide Harmonised Light Vehicles Test Procedure (Wltp)

    The Volkswagen type approval can be used for the multi-stage type approval for vehicles with conversions or add-ons that remain within the ISC parameters / maximum technical specifications for add-on parts. If the add-on or conversion is outside the ISC parameters / maximum technical specifications defined by the manufacturer for add-on parts, the body builder must demonstrate compliance with the exhaust gas emissions requirements / electric range.

  • Page 13: Body Builder Guidelines, Consulting

    As a result, Volkswagen AG recommends that all work should be carried out on the base vehicle and the body in accordance with the current Volkswagen body builder guidelines applicabl e to the vehicle in question.
  • Page 14 Safety is only provided if the design, production and installation are carried out by the body builder performing the modifications in accordance with the state of the art and in accordance with the applicable body builder guidelines of Volkswagen AG – and assuming any deviations from these guidelines have been declared to be technically safe.

  • Page 15: Application For The Letter Of Non-Objection

     Details of the consumption of additional electrical equipment. Complete documentation avoids the need for clarification queries and accelerates the processing. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 15 of 166...

  • Page 16: Legal Entitlements

    Due to the multitude of modifications and diversity of operating conditions, the information provided by Volkswagen AG is subject to the reservation 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 must provide the following information in writing to their customers.

  • Page 17: Ensuring Traceability

    1.2.5 Trademarks VW badges and VW emblem are trademarks of Volkswagen AG. VW badges and VW emblems are not allowed to be removed without authorisation, or to be attached in a different location.
  • Page 18 Information You can find further information about vehicle storage in the following documents: − Operating manual − Vehicle care programme. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 18 of 166...

  • Page 19: Compliance With Environmental Rules And Regulations

    All plastic parts shall be identified according to the VDA material sheet 260 (“Components of motor vehicles; Identification of materials”), e.g. “PP-GF30R”. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 19 of 166...

  • Page 20: Recommendations For Inspection, Maintenance And Repair

    Please observe the Volkswagen AG owner's manual for the inspection, maintenance and repair of the base vehicle. Please only use brake fluids and engine oils approved by Volkswagen for your vehicle.

  • Page 21: Accident Prevention

    The requirements of a quality management system of this kind are described in DIN EN ISO 9001. For the reasons stated above, Volkswagen AG strongly recommends that all body builders should set up and maintain a quality management system with the following minimum requirements: Definition of responsibilities and authorisations including organisational plan.

  • Page 22: Planning Bodies

    On the Volkswagen AG homepage, you can put together your vehicle using the configurator and view the special equipment available: Volkswagen Commercial Vehicles (volkswagen- nutzfahrzeuge.de) Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 22 of 166...

  • Page 23: Vehicle Modifications

    The officially recognised appraiser or tester from the body builder must be informed about modifications to the chassis. Practical note Country-specific laws, directives and approval regulations shall be observed! Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 23 of 166...

  • Page 24: Special Equipment

    1.4 Special equipment We recommend using the special equipment from Volkswagen AG that can be obtained with a PR number for optimum adaptation of the body to the vehicle. You can obtain information on special equipment provided by Volkswagen under PR numbers from your Volkswagen dealership, your importer or in your contact options for product and vehicle information for body builders (see chapter 1.2.1 “Product and veh icle...

  • Page 25: Commercial Aspects

    (EBB) and driver assistance technologies are not permitted. 1.5.4 Road safety The respective instructions should be strictly followed to ensure operational and road safety of the vehicle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 25 of 166...

  • Page 26: Electromagnetic Compatibility (Emc)

    We do not stipulate any other special terms or conditions for installations or use. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 26 of 166...

  • Page 27: Pickup

    Maximum output power in watts (Peak RMS) Aerial position 1–30 50–54 2, 3 68–88 2, 3 142–176 2, 3 380–512 2, 3 806–870 2, 3 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 27 of 166...

  • Page 28: Raising The Vehicle With A Jack

    – The jack must be mounted and secured to the vehicle appropriately to ensure safety, durability, and accessibility. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 28 of 166...

  • Page 29: Vehicle Jacking Points And Axle Stand Positions

    When raising the vehicle with the jack, for your own safety, never get under the vehicle. 1.7.1 Vehicle jacking points and axle stand positions Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 29 of 166...

  • Page 30: Raising The Vehicle With A Lifting Platform

    If care is not taken when placing the lifting bags, the fuel system may be damaged. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 30 of 166...

  • Page 31: Noise, Vibration And Harshness (Nvh)

    The interior noise level should not be worsened by the conversion. Reinforce panels and structures as needed to prevent vibration. Consider the use of sound deadening material on panels. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 31 of 166...

  • Page 32: Vehicle Transport Aids And Vehicle Storage

    Claims arising from deterioration caused by improper storage, maintenance or handling will not be the responsibility of Volkswagen AG. Vehicle processors must establish their own procedures and precautions, especially when vehicles are stored outdoors, as they are exposed to any number of airborne contaminants.
  • Page 33 Run the engine until the coolant gauge reaches temperature (60°C) with the air conditioning system on, if applicable Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 33 of 166...

  • Page 34: Assemblies And Ergonomics

    For conversions that require a reversing camera, the return signal can be recorded as described in the section on reversing lights. For more information, see chapter 4.6.8. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 34 of 166...

  • Page 35: Aids For Entering And Exiting Vehicles

    The overall width of the Amarok with the exterior rear view mirrors extended is 2,208 mm. – The maximum vehicle width (X) is 1,910 mm. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 35 of 166...

  • Page 36: Worldwide Harmonised Light Vehicles Test Procedure (Wltp) Calculation Inputs

    Modifications to the tyres installed on the finished vehicle must be accounted for. The efficiency class and tyre class are needed to determine the correct calculation. This can be found on the tyre label according to the following example: Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 36 of 166...

  • Page 37: Key To Vehicle Dimensions

    All dimensions are subject to manufacturing tolerances and refer to minimum specification models and do not include additional equipment. Height dimensions show the range for minimum to maximum weight range and are for reference only. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 37 of 166...

  • Page 38: Recommended Main Load Range Dimensions

    Volkswagen Commercial Vehicles WLTP calculator. See chapter “1.2.1.7 Worldwide Harmonised Light Vehicles Test Procedure”. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 38 of 166...
  • Page 39 Dimension of the end face of the vehicle Measurement 1,820 (measured from the road surface to the roof surface) 1,860 1,839 1,945 2,214 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 39 of 166...

  • Page 40: Number Plate

    The number plate shall be mounted on the rear of the vehicle so that no part of the number plate is more than 1,300 mm above the ground. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 40 of 166...

  • Page 41: Assemblies And Ergonomics - Specifications

    Load-bearing structures should not be mounted on an existing cargo box. Mounting points for the body are provided on the frame. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 41 of 166...
  • Page 42 Distance between the top of the cab and the vehicle body 30 mm Maximum exterior vehicle width (without side step) 1,910 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 42 of 166...

  • Page 43: Chassis Cab Body - Basic Dimensions And Weights

    The illustrations are for orientation purposes only. 1.12.2 Chassis cab body – basic dimensions and weights Chassis cab body – double cab illustrated Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 43 of 166...

  • Page 44: Unladen Mass And Payload

    Warning note Check local regulations for legal requirements. Details on the axle loads for your vehicle can be provided by your Volkswagen Commercial Vehicles partner or importer . Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 44 of 166...

  • Page 45: Front, Rear And Side Skid Plate

    For a specific vehicle torque specification, refer to the corresponding VW Commercial Vehicles workshop manual or contact your local Volkswagen Commercial Vehicles partner or importer. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 45 of 166...

  • Page 46: Load Distribution - Specifications

    – Avoid one-sided load distribution. – For further information, please contact your local Volkswagen Commercial Vehicles partner or importer. DoubleCab Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 46 of 166...

  • Page 47: Centre Of Gravity

    For double cab vehicles, there is a limit to the additional mass that must be considered, in addition to not exceeding the gross axle and towing weights. DoubleCab Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 47 of 166...
  • Page 48 3,615 4x2* 2,435 3,615 2,435 3,615 * 4x2 vehicles with increased ride height. **Dimension ‘C’ is taken from the body fasteners. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 48 of 166...

  • Page 49: Towing

    1.15 Towing 1.15.1 Towing requirements If a towing device is required, the vehicle converter should use a Volkswagen-approved tow-bar. 1.15.2 Towing Warning note – Do not exceed the total mass or maximum trailer weight specified for your vehicle. Refer to your vehicle operating manual for maximum trailer weight specifications.

  • Page 50: Chassis

    Do not damage the surface or corrosion protection of the spring during removal and assembly. – Do not add any additional axles. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 50 of 166...

  • Page 51: Brake System

    Brake lines shall not be used to support or secure other components. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 51 of 166...

  • Page 52: Overrun Brake Connection

    Volkswagen Commercial Vehicles partner or importer. A pre-installed cable is located behind the tread surface of the A-pillar and is marked TRAILER BRAKE CONTROLLER. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 52 of 166...

  • Page 53: Drive Train

    As a guideline, if the reference mass used for type approval of the completed vehicle does not exceed 2,840 kg, a light commercial vehicle engine may be specified for N1 and N2 vehicles. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 53 of 166...

  • Page 54: Fuel System

    The fuel filler neck is secured to the frame bracket with a cable tie on vehicles with a chassis cab, but only for transporting the vehicle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 54 of 166...

  • Page 55: Securing The Fuel Filling System

    Contact your Volkswagen Commercial Vehicles partner or importer to obtain a suitable component. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 55 of 166...
  • Page 56 Fuel filler neck – overview Item Description Fuel tank breather hose Rear axle breather pipe Fuel tank cap Fuel filler pipe Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 56 of 166...
  • Page 57 The width of the bracket at the point where it is connected to the body must be at least 180 mm. All three mounting points on the filler neck must be used. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 57 of 166...
  • Page 58 2 mm minimum bracket thickness The angle of 30° should be maintained to ensure a good flow of fuel during refuelling and to prevent backflow. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 58 of 166...
  • Page 59 At least 9 mm distance between the tank cap and the vehicle body, if necessary at the most unfavourable opening angle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 59 of 166...

  • Page 60: Breather Hose For Fuel Filling System (Diesel)

    800 mm (4x4 or 4x2) above the ground. We recommend measuring this height when the vehicle is fully loaded. *Only rear-wheel drive 110 kW EU4 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 60 of 166...
  • Page 61 Schematic diagram of mounting position for fuel tank breather hose Item Description Front lower partition of a loading bed (loading bed rotated for clarity). Fuel tank breather hose securely fastened. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 61 of 166...

  • Page 62: Breather Hose For Axle Venting

    (AdBlue®) are maintained. – For more information on the diesel exhaust fluid system (AdBlue®), refer to the owner's manual for the vehicle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 62 of 166...
  • Page 63 (AdBlue®-compatible) caps may damage the system. Information Immediately wash off any spilled diesel exhaust fluid (AdBlue®) on a painted surface with mild soapy water. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 63 of 166...
  • Page 64 Injector for diesel exhaust fluid (AdBlue) Injector for diesel exhaust fluid (AdBlue) Exhaust system with selective catalytic reduction catalytic converter Tank for diesel exhaust fluid (AdBlue) Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 64 of 166...
  • Page 65 Injector for diesel exhaust fluid (AdBlue) Injector for diesel exhaust fluid (AdBlue) Exhaust system with selective catalytic reduction catalytic converter Tank for diesel exhaust fluid (AdBlue) Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 65 of 166...
  • Page 66 If the vehicle body and mounting bracket do not provide an earthing path for the filler neck, an earth strap must be added to connect the filler neck to the chassis frame. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 66 of 166...
  • Page 67 The entire filler and breather hose from the filler neck to the diesel exhaust container must be at an angle of at least 2°. This is necessary for ensuring proper filling process. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 67 of 166...
  • Page 68 – Between the diesel exhaust fluid filler assembly and the vehicle body, a minimum of 9 mm clearance must be maintained. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 68 of 166...
  • Page 69 A kit approved by Volkswagen Commercial Vehicles for routing the diesel exhaust fluid filler neck is available. Contact your local Volkswagen Commercial Vehicles partner or importer. Diesel emission fluid filler neck routing kit The kit for routing the diesel exhaust fluid filler neck includes:...

  • Page 70: Electrics

    4.1 Installation and routing guidelines for electrical wiring 4.1.1 Wiring splicing method Volkswagen Commercial Vehicles strongly discourages the use of cable splices because the resulting connection is variable and unpredictable. However, if a cable splice is unavoidable, it must be made with heat-shrinking DuraSeal to be environmentally sealed and with a suitable nylon insulated crimp splice.
  • Page 71 Adhesive and tape are not acceptable. – The grommet feed-through must be adequately sealed to prevent corrosion and water ingress. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 71 of 166...

  • Page 72: Battery And Cables

    Do not overcharge a battery as this can cause acid leaks resulting in damage to the vehicle and possible personal injury Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 72 of 166...
  • Page 73 Batteries should be recharged before they are put into storage. Batteries should not be left in a discharged state as this will result in the formation of sulphate Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 73 of 166...
  • Page 74 Excessively fast charging can damage a battery. For this reason, charging times must be carefully controlled. Fast battery chargers Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 74 of 166...
  • Page 75 Follow the instructions provided with the battery charger to charge the rechargeable battery. To disconnect the battery charger, reverse the connection procedure. 40 mm Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 75 of 166...
  • Page 76 Battery cable fixing torque The correct fixing torque for battery clamps can be found in the Workshop Manual. Please contact your Volkswagen Commercial Vehicles partner or importer. Battery specifications Warning note – For vehicles equipped with non-sealed (maintenance- free) batteries, regular controls must be carried out to determine whether the electrolyte level is correct.
  • Page 77 Battery part numbers and usage If a vehicle’s battery type is changed to other compatible derivatives, the dealership must reconfigure the vehicle to the new battery types. The central vehicle configuration can be updated by a Volkswagen Commercial Vehicles partner or importer. Production plant...
  • Page 78 2.0 mm. – If present, ensure that the existing nut is reused. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 78 of 166...
  • Page 79 There is one empty position available on the positive battery fuse block. This empty position can be used to connect the auxiliary battery system and for all aftermarket installations that require a 12-V battery supply. Battery connections should be properly tightened. Contact your authorised Volkswagen Commercial Vehicles partner or importer for the correct torque specifications.
  • Page 80 Earth point on upper material of rear right fender Earth point connections must be properly tightened. Contact your authorised Volkswagen Commercial Vehicles partner or importer for the correct torque specifications. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition...

  • Page 81: Connecting Auxiliary Loads / Accessories - Vehicles With Factory-Fitted Auxiliary Switches, Wiring And Fuse Box

    ON position, or in the OFF position if the accessory delay is active, whether the engine is running or not. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 81 of 166...
  • Page 82 Wiring circuit near the auxiliary fuse box – POSITION A Wiring circuit near the radiator support panel Engine compartment fuse box Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 82 of 166...
  • Page 83 AUX 3 – FLOOR Black/grey 1.5 mm² AUX 4 – FLOOR Black/green 1.5 mm² AUX 6 – FLOOR Black/yellow 2.5 mm² Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 83 of 166...

  • Page 84: Alternator

    4.2.3 Alternator Power output of the alternators Contact your local Volkswagen Commercial Vehicles dealership for alternator output current specifications for your vehicle. Drive train Current output Amps @ 80.6°F (27°C) Pulley type Voltage regulator type 2.0 l Diesel Single 100 A at 750 rpm (min) to 155 A at...

  • Page 85: Parking Aid

    Failure to follow this instruction may result in loss of control of your vehicle and personal injury. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 85 of 166...
  • Page 86 X, Y, and Z plane positions. Maintaining the sensor position on these planes is important for proper operation of the system. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 86 of 166...
  • Page 87 Position planes of the vehicle Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 87 of 166...

  • Page 88: Sensor Positions

    Position of the front parking aid sensors Sensor Number Front right outside Front right inside Front left inside Front left outside Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 88 of 166...
  • Page 89 Position of the rear parking aid sensors Sensor Number Rear left outside Rear left inside Rear right inside Rear right outside Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 89 of 166...
  • Page 90 For more information, refer to the operating manual for the vehicle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 90 of 166...

  • Page 91: Engine Management System

    There is no option available for outputting the vehicle speed. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 91 of 166...

  • Page 92: Information And Infotainment System

    In these cases, the function should not be used. Incorrect reversing brake assist events may occur. – Do not cover the reversing camera. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 92 of 166...
  • Page 93 Any object mounted within the field of view cone of the front camera and exterior mirror cameras will obstruct the visibility of the 360 degree camera. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 93 of 166...
  • Page 94 1 – Field of view of the front camera 2 – 360° camera field of view 3 – Field of view of the reversing camera Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 94 of 166...
  • Page 95 – Any change to the track will cause the dynamic guide values to be unrepresentative of the vehicle’s turning circle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 95 of 166...
  • Page 96 1 – Field of view of the reversing camera Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 96 of 166...

  • Page 97: Exterior Lighting

    See also chapter 4.13 “Fuses and relays”. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 97 of 166...

  • Page 98: Rear Combination Lights

    Minimum angle of the obstacle-free zone towards the centre of the vehicle 45° Maximum distance from the outer edge of the vehicle to the inner edge of the light 400 mm Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 98 of 166...

  • Page 99: Rear Fog Light

    If there is only one rear fog light, it must be positioned on the centre line of the vehicle or on the driver side of the vehicle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 99 of 166...
  • Page 100 Minimum angle of the obstacle-free zone upwards from the light 25° Minimum angle of the obstacle-free zone towards the centre of the vehicle 25° Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 100 of 166...

  • Page 101: Rear Number Plate Lights

    Distance between the centre line of the number plate and the centre of the light One quarter of number plate width (min. 90 mm, max. 175 mm) Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 101 of 166...

  • Page 102: Additional Exterior Lights

    Volkswagen Commercial Vehicles recommends that when additional tail light clusters are installed, power should be supplied through the trailer towing module and associated circuits. For all other additional exterior lights, power must be supplied through an ad ditional fuse box with a suitable switch and/or relay, as required.
  • Page 103 Connecting additional electrical equipment – vehicles with level 2 LED headlights Level 2 – LED headlights – dipped beam Item Description Dipped beam = connector C1, PIN 1 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 103 of 166...
  • Page 104 Doing so may result in damage to the headlight control system. Information Right-hand drive vehicle shown, left-hand drive vehicle similar. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 104 of 166...

  • Page 105: Brake Lights

    The existing elevated side light circuit wiring can handle a current load of 3.1 A at steady state (at 13.5 V). Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 105 of 166...

  • Page 106: Reversing Lights, Reversing Camera, Reversing Alarm (Manual Gearbox)

    Volkswagen Commercial Vehicles recommends using the Genuine Accessories trailer kit for all trailer electrical connections. Connecting the trailer coupling lights – system recommendations. Information Not all functions and outputs are supported in all markets.
  • Page 107 B(+) fuse 87 (40 A) BJB B(+) fuse 73 (30 A) BJB Connection C Earth CAN L CAN H Not used Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 107 of 166...

  • Page 108: Lights - Hazard Warning Lights / Turn Signals

    Rear right front turn signal output = onboard supply control unit connector C6 pin 38 Rear left front turn signal output = onboard supply control unit connector C6 pin 39 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 108 of 166...

  • Page 109: Electrically Operated Exterior Mirrors

    When a centre brake light is installed, it may be powered by the onboard supply control unit (connector 5 pin 13). Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 109 of 166...

  • Page 110: Automatic Main Beam

    Auto position of the headlight switch is not available (or Auto is not selected on the original switch). Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 110 of 166...

  • Page 111: Cruise Control System

    Removing the cover opens the radar to environmental factors such as rain, snow and mud. Radar performance and long-term durability cannot be guaranteed. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 111 of 166...
  • Page 112 Vehicles partner or importer. For more information, refer to the operating manual for your vehicle. 1 Adaptive cruise control module 2 Adaptive cruise control radar clearance zone Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 112 of 166...

  • Page 113: Driver Assist Systems

    The radar and camera monitoring zones must not be impaired by add-ons/modifications. Radar monitoring zone – side view Radar monitoring zone – top view Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 113 of 166...
  • Page 114 Camera monitoring zone – top view Camera monitoring zone – side view For more information on the driver assist systems, refer to the operating manual. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 114 of 166...

  • Page 115: Information System Area View Overhead View Camera

    Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 115 of 166...
  • Page 116 Area View overhead view camera radar housed in the left tail light Area View overhead view camera radar housed in the right tail light Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 116 of 166...

  • Page 117: Side View Camera

    1 Position of the side view camera Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 117 of 166...
  • Page 118 Side view camera viewing areas Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 118 of 166...

  • Page 119: Lane Departure Warning System

    Field of view of the camera For more information, see the section on adaptive cruise control in chapter 4.7.1. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 119 of 166...

  • Page 120: Lane Centring Assistant

    – Lane centring assist will not work, or performance may be adversely affected, if the vehicle’s track width is changed. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 120 of 166...

  • Page 121: Handles, Locks, Catches And Access Systems

    Onboard supply control Function unit connector CTRL MOD. - DOOR LOCK # ALL LOCKED CTRL MOD. - DOOR LOCK # UNLOCK ALL Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 121 of 166...

  • Page 122: Fuses And Relays

    4.13 Fuses and relays 4.13.1 Fuses Information For information on the position and ratings of the fuses, refer to the operating manual. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 122 of 166...

  • Page 123: Body And Paint

    All fasteners through the vehicle floor, sides or roof must be sealed. Ensure that fasteners in the B-pillar area do not interfere with seat belts or seat belt reels. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 123 of 166...

  • Page 124: Integrated Bodies And Conversions

    For further information, please contact your Volkswagen Commercial Vehicles partner or importer. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 124 of 166...
  • Page 125 275 mm 275 mm 110° 110° 110° 110° 50 mm (max.) Centre line of the vehicle Section through centre of wheel guard Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 125 of 166...

  • Page 126: Chassis Cab

    Bonded joints are recommended but they should be supplemented by mechanical fasteners to prevent initial separation and long- term failure. Ensure even distribution of bolt load to avoid point loading. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 126 of 166...
  • Page 127 Body mounting holes in chassis frame – double cab Dimensions (mm) for body mounting holes in chassis frame – double cab Dimensions 1,244 1,244 1,248 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 127 of 166...
  • Page 128 D – spare wheel winch guide cone E – spare wheel winch F – mounting support G – stop damper H – mounting support Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 128 of 166...
  • Page 129 MRO = mass in running order (tank 90% full / SCR tank 90% full + 75 kg driver ) Distance between frame and centre line – all cab versions Dimensions Measurement *Standard running gear **Raised running gear / 4x4 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 129 of 166...

  • Page 130: Integrity Of The Front Section For Cooling, Collision, Aerodynamics And Lighting

    Static and dynamic sealing and finishing After cutting or drilling the body, ensure proper sealing against the ingress of water, salt, dust etc. Use sealing and surface material approved by Volkswagen Commercial Vehicles as well as underbody corrosion protection See also chapter 5.4 “Corrosion protection”.

  • Page 131: Tank And Bulk Container Superstructure

    There is a maintenance tip on the grommet. – For information on the main beam headlight cable routing, see Exterior lighting – additional exterior lighting. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 131 of 166...

  • Page 132: Roof Carriers

    A- pillar, which should not exceed 60 kg total additional load. Ensure that the loaded vehicle is operated within its intended centre of gravity. For more information, contact your Volkswagen Commercial Vehicles partner or importer.

  • Page 133: Load Management On The Vehicle Tray

    Cargo box reinforcement brackets must be installed for accessories that extend beyond the cargo box side rail and weigh more than 45 kg. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 133 of 166...
  • Page 134 Volkswagen Commercial Vehicles also provides these load compartment reinforcement brackets as a Genuine Accessories part via the ETKA replacement parts system. Please contact your Volkswagen Commercial Vehicles partner or importer.
  • Page 135 It is the responsibility of the vehicle converter to ensure that the conversion is performed in a manner that will ensure the durability of the cargo box. Contact your Volkswagen Commercial Vehicles partner or importer for information on supplying and installing the reinforcement brackets. Sun roof, ladder rack, canoe rack...
  • Page 136 Structural mounting points – double cab Item Description Front M8 structural mounting points Central M8 structural mounting points Rear M8 structural mounting points Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 136 of 166...
  • Page 137 Some vehicles are equipped with side mounting rails that have multiple pre-threaded mounting points. Additional load carrying capacities and fastening devices are described in the owner's manual for the vehicle. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 137 of 166...
  • Page 138 The maximum force between directly opposite mounting points is The maximum force between diagonally opposite mounting points is 125 kg 272 kg Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 138 of 166...
  • Page 139 Item Description Front M8 structural mounting points Rear M8 structural mounting points Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 139 of 166...

  • Page 140: Front Wing Trim

    The wheel housing trims can be removed after the wing trim is removed by accessing and releasing the wheel housing trim brackets from the inside of the wing panel. Refer to the workshop manual or contact your Volkswagen Commercial Vehicles partner or importer for information on the correct removal and installation procedure to assist in the removal of the wheel housing trim.

  • Page 141: Airbag Systems

    Note that this does not apply to vehicles that are only equipped with front airbags and not side airbags. Drilling or grinding work in this area is only permitted if the battery cables are disconnected. Deployment zones of the driver and front passenger front airbags Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 141 of 166...
  • Page 142 *120 l single-stage passenger airbag (Australia, Europe, New Zealand) **90 l single-stage passenger airbag (except Australia, Europe, New Zealand) Driver and front passenger knee airbags Dimensions (mm) Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 142 of 166...
  • Page 143 Central airbag Dimensions (mm) Information Left shown here, right is similar Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 143 of 166...
  • Page 144 Side airbag Dimensions (mm) Information Left shown here, right is similar Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 144 of 166...

  • Page 145: Additional Impact Sensors (Front)

    Do not make any modifications to the front section of your vehicle or add any additional parts. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 145 of 166...
  • Page 146 Item Description SRS front impact sensors Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 146 of 166...

  • Page 147: Seat Belt Systems

    Removal and reinstallation of the seat belt, automatic belt retractor, or any component of the seat belt system should be avoided. If, however, it is necessary to remove and reinstall the system during the conversion, follow the seat belt system removal and installation guidelines as described in the Workshop Manual. Contact your Volkswagen Commercial Vehicles partner or importer for further information.
  • Page 148 50 mm to the left of the belt webbing 525 mm above the hole for the automatic belt retractor Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 148 of 166...

  • Page 149: Corrosion Protection

    5.4.2 Touching up damaged paintwork After cutting or reworking sheet metal on the vehicle, the damaged paint must be touched up/repaired. Ensure that all materials are compatible with the relevant Volkswagen specifications , and try to maintain the original condition as far as possible.

  • Page 150: Frame And Body Mounting

    Drilling and welding of frames Dimensions (mm) for body mounting holes in the upper flange of the chassis frame (see table below) Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 150 of 166...
  • Page 151 DO NOT DRILL or MODIFY extruded holes/slots. Do not drill new or modified holes larger than 16.5 mm. Refer to chapter 5.1. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 151 of 166...

  • Page 152: Self-Supporting Body Structure

    Floor plates should essentially be attached to cross members and supporting booms, but not to the top of the chassis frame. Heat shields on the bottom of the exhaust system. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 152 of 166...
  • Page 153 L-section longitudinal member Frame longitudinal member of the base vehicle Vehicle centre line of the base vehicle See also chapter 5.1 “Body”. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 153 of 166...

  • Page 154: Frame Drilling And Tube Reinforcement

    A diameter of 16.5 mm is the maximum hole size allowed in the chassis frame side panel, regardless of use. Avoid drilling into enclosed frame members to prevent the risk of corrosion from chips. Refer to chapter 5.4 Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 154 of 166...

  • Page 155: Additional Equipment - Subframe Attachment

    We recommend attaching a sticker or label near the filler opening indicating the fluid to be used, e.g.: “Water only” for water tanks. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 155 of 166...

  • Page 156: Conversions With An Extended Wheelbase

    Practical note All emission control systems must remain operational and fully functional after wheelbase extension. Contact your local Volkswagen Commercial Vehicles partner or importer for further information. Modification to the fuel system for conversions with an extended wheelbase Warning note –...
  • Page 157 Exhaust modifications to support retrofits with an extended wheelbase are limited to the section of the exhaust system downstream of the point indicated in the figures below: Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 157 of 166...
  • Page 158 Modification zone “DO NOT MODIFY” zone 2.0 l Single Turbo Diesel Engine EU6.2 Item Description Modification zone “DO NOT MODIFY” zone Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 158 of 166...
  • Page 159 2.0 l Bi-Turbo Diesel EU6.2 Item Description Modification zone “DO NOT MODIFY” zone Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 159 of 166...
  • Page 160 Contact your local Volkswagen Commercial Vehicles partner or importer for further information. Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 160 of 166...

  • Page 161: Listings

    Recommendations for vehicle storage 1.2.7 Compliance with environmental rules and regulations 1.2.8 Recommendations for inspection, maintenance and repair 1.2.9 Accident prevention 1.2.10 Quality system Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 161 of 166...
  • Page 162 Gross vehicle mass and axle load 1.12.5 Front, rear and side underbody protection 1.12.6 Rear skid plate – chassis with cab Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 162 of 166...
  • Page 163 Connecting auxiliary loads / accessories – vehicles with factory- fitted auxiliary switches, wiring and fuse box 4.2.3 Alternator 4.2.4 Ignition signal Parking aid 4.3.1 Sensor positions Engine management system Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 163 of 166...
  • Page 164 Integrated vehicle and conversions 5.1.3 Chassis - cab 5.1.4 Front end integrity for cooling, collision, aerodynamics and lighting 5.1.5 Tipper bodies Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 164 of 166...
  • Page 165 Water tank on camping vehicles 5.5.7 Conversions with an extended wheelbase Listings List of changes Last page Title, post box, issue date Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 165 of 166...
  • Page 166 Consulting for body builders in Germany is available from the listed address. Volkswagen Commercial Vehicles Brieffach 2949 Postfach 21 05 80 D-30405 Hannover Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition The new Amarok – Page 166 of 166...

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