2022-2025 Volkswagen Amarok Truck Body and paint User Manual
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Body and paint for Your Volkswagen Amarok Truck Second Generation (2022-2025)

5 Body and paint  
5.1 Body  
5.1.1 Body structures general information  
Warning note  
All external or internal projections must comply with  
local regulations  
Do not cut, drill or weld any parts that will affect the  
load path in the event of an accident.  
Vehicle converters must ensure that all modifications  
comply with general product safety requirements,  
legal provisions or type approvals.  
Practical note  
Load-bearing bodies should not be mounted on an existing  
load area or cargo box.  
See also chapter 1.11 “Assemblies and ergonomics”.  
When performing vehicle conversions/modifications, observe the following points:  
-
-
-
Make sure that the structural body strength of the vehicle is maintained.  
Do not drill into enclosed frame structures.  
Make sure the design of the body modifications or additional bodywork distributes the load evenly.  
Practical note  
Uneven load distribution may result in unacceptable driving  
and braking characteristics.  
Repaint metal edges after cutting and drilling. All metal edges must meet local regulatory standards for exterior and interior protection.  
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  
5.1.2 Integrated bodies and conversions  
Warning note  
The entire wheelhouse cover must comply with local legal  
vehicle standards.  
For integrated bodies such as ambulances or motor homes with raised rear overhangs built on the chassis, the following applies:  
-
Reduced exit angles, e.g. rear entry step, should be discussed with the end user/customer. Consider removable components to  
avoid damage on ferries or flat-bed trailers.  
-
-
A special spare wheel storage may be required if it is obscured by the rear step, check for accessibility.  
Recommended minimum tyre to wing panel clearances for conversions are shown in the following figure and table:  
Wheel housing dimensions  
Practical note  
Wheel housing dimensions are for reference only.  
Wheel housing covers are only intended to show and  
“open” the wheel housing.  
Changes to the wheel size and tyre size may affect  
driving behaviour and vehicle handling, and certain  
functions and vehicle characteristics. Any modification  
must be made in accordance with local legal  
requirements. 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  
Information  
All dimensions are given in millimetres.  
Dimensions Y and Z are only applicable when  
dimension J reaches a value.  
Dimension J is specified from ground level with the  
vehicle at kerb weight on level ground.  
Dimensions of the wheel guard  
255/70R16 255/70R17 / 255/65R18 /  
Tyre  
215/70R16  
LT265/70R17  
specification  
255/ 255/  
55R20  
474  
A
B
C
D
E
F
474  
458  
474  
458  
474  
458  
458  
305 mm  
275 mm  
110°  
420  
305 mm  
275 mm  
110°  
420  
305 mm  
275 mm  
110°  
420  
305 mm  
275 mm  
110°  
420  
G
H
J
217  
185  
185  
192  
-
-
-
968  
665  
774  
774  
801  
K
L
635  
635  
635  
635  
-
30  
30  
30  
r
50 mm (max.)  
Centre line of the vehicle  
Section through centre of wheel guard  
1
X
Y
Z
566  
525  
566  
525  
566  
525  
566  
525  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 125 of 166  
5.1.3 Chassis cab  
Warning note  
Do not cut, drill or weld any parts that are relevant to  
the load path in the event of an accident situation.  
The vehicle converter must confirm that all  
modifications comply with general product safety  
requirements, legal provisions or type approvals.  
Excessive heat may be generated by the exhaust  
system, especially the catalytic converter. Ensure that  
adequate heat protection devices are in place.  
Practical note  
Uneven load distribution may result in unacceptable driving  
and braking characteristics.  
When performing vehicle conversions/modifications, observe the following points:  
-
Ensure that all the reinforced holes provided in the top of the chassis frame are used to their full length for vehicle frames or  
subframes (see illustrations).  
-
-
-
-
Make sure that the structural integrity of the vehicle is maintained.  
Do not drill into enclosed frame structures.  
Make sure that the design of vehicle modifications or the additional structure distributes load evenly.  
Repaint metal edges after cutting and drilling. All metal edges must meet local regulatory standards for exterior and interior  
protection.  
-
-
-
-
All fasteners through the vehicle floor, sides or roof must be sealed. See also chapter 5.4 “Corrosion protection”.  
Ensure that additional equipment near the fuel tank will not damage the tank in the event of an accident.  
The following applies to all bodies that are attached to, or mounted on, the cab structure of the base vehicle:  
Care should be taken to ensure that neither the conversion body nor the existing vehicle structure is pre-stressed by the assembly  
process.  
-
-
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  
Body mounting holes in chassis frame double cab  
Dimensions (mm) for body mounting holes in chassis frame double cab  
Dimensions  
A
B
C
D
E
20  
26  
20  
1,244  
1,244  
1,248  
890  
F
G
H
506  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 127 of 166  
Vertical dimensions of body mounting holes double cab  
Measuring point  
GVM @ RGAWR  
MRO  
WLTP  
Height from A  
A
540 * / 659 **  
656 * / 776 **  
637 * / 761 **  
-
B retaining bolt of the  
tow-bar  
-
-
-
37  
C mounting support  
-
-
-
-
-
-
6
D spare wheel winch  
33  
guide cone  
E spare wheel winch  
-
-
-
44  
F mounting support  
G stop damper  
-
-
-
-
-
-
-
-
-
12  
22  
12  
H mounting support  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 128 of 166  
*Only rear-wheel drive 110 kW EU4  
** 4x4 or 4x2  
GVM = gross vehicle mass: total permitted weight  
RGAWR = rear gross axle weight rating  
MRO = mass in running order (tank 90% full / SCR tank 90% full + 75 kg driver )  
Distance between frame and centre line all cab versions  
A
Dimensions  
Measurement  
A
B
446  
23  
*Standard running gear  
**Raised running gear / 4x4  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 129 of 166  
5.1.4 Integrity of the front section for cooling, collision, aerodynamics and lighting  
Cooling  
Continuous airflow through the front section and engine compartment must not be impeded by the installation of additional equipment. If  
in doubt, contact your Volkswagen Commercial Vehicles partner or importer.  
Lighting  
The lighting system must not be modified.  
Collision  
Do not cut, drill or weld any parts that are relevant to the load path in the event of a collision. Do not add any material in the collision zone.  
This could adversely affect the calibration of the collision sensor.  
The side airbag system is not permitted if:  
-
-
A swivel mechanism is attached to the front seats  
A side panel or other attachment is anchored to the inner or outer area of the B-pillar  
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”.  
5.1.5 Tipper bodies  
Double cab versions can be used for tipper conversions with the exception of the extended rear chassis frame.  
All versions allow one-way and three-way tipping.  
We recommend that the tipping system only be in operation when the engine is running. We also recommend that the main switch be  
located in the safety area of the cab. Refer to the section on hydraulic lifting equipment for information on how to route wires and  
hydraulic lines. Ensure that the gross axle weight rating, including the minimum load on the front axle, is not exceeded or fallen below.  
For tipper subframes, follow these guidelines:  
-
-
-
Design a full length continuous frame with fasteners for engine, pump unit, tank, pivot points and cylinders.  
Use all the mounting points on the chassis frame to fit the subframe.  
Very rigid subframes can damage the chassis frame by preventing its natural flex. Flexible mounts should therefore be used with a  
flexibility of up to +/- 12 mm when the vehicle is loaded or unladen (whichever is the worst case). Compliant mounts should have a  
minimum deflection of 2 mm per 200 kg mass at each front chassis frame mount. Compliant mounts must have captive bolts. Use a  
minimum of two M10 grade 8.8 bolts, washers and self-locking nuts at each fixed and compliant chassis frame location.  
The subframe must extend to the rear of the cab and be secured at all mounting points, with the front end designed to minimise  
localised frame loading. However, it is preferable to fit the subframe on the mounting brackets at a distance from the top of the  
chassis frame.  
-
-
Lateral tipping loads/forces must be absorbed by the subframe. We do not recommend applying loads to the chassis frame.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 130 of 166  
5.1.6 Tank and bulk container superstructure  
Due to the high rigidity of tanks, it is necessary to isolate the tank and its subframe from the chassis frame to allow for the chassis frame’s  
natural flexibility. Please observe the following guidelines:  
-
-
-
-
Secure the tank to the full length of the subframe.  
Secure the subframe to all mounting points on the housing frame.  
The front mounting points must be designed so that they allow relative movement between the chassis frame and subframe.  
The subframe must extend to the rear of the cab and must not come into contact with the chassis frame at the front end under  
worst case deflection.  
-
-
Flexible mounts should be used with a flexibility of up to +/- 12 mm when the vehicle is loaded or unladen (whichever is the worst  
case). Compliant mounts should have a minimum deflection of 2 mm per 200 kg mass at each front chassis frame mount. Compliant  
mounts must be provided with captive bolts.  
Use M10 property class 8.8 bolts, washers and self-locking nuts for each chassis frame bracket at each fixed and compliant location.  
Warning note  
Ensure that the aerial cables have adequate clearance  
from hot and moving parts.  
Do not secure the aerial cables to the original vehicle  
wiring, fuel lines, and brake lines.  
Keep the aerial and power cables at least 100 mm  
away from electronic modules and airbags and  
associated wiring.  
5.1.7 Aerial cable routing  
Information  
Make sure that air-tightness is maintained to prevent  
water from entering the vehicle interior while routing  
the cables through the grommet.  
Aerial cables should be routed from the engine  
compartment through the existing grommet and into  
the vehicle interior. 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  
5.1.8 Roof carriers  
Roof carriers can be fitted to all double cab versions provided that the following conditions are met:  
-
-
-
-
-
The load carried must not exceed 85 kg (the body builder must ensure that this limit is stated in the  
owner's manual).  
The height of the load must not exceed 300 mm (the body builder must check whether this limitation is noted in the owner's  
manual).  
The load must be evenly distributed (the body builder must check whether this limitation is noted in the  
owner’s manual).  
The carriers and the load carried on them, regardless of the type of carrier attachment, are supported according to the  
specifications of your local Volkswagen Commercial Vehicles partner or importer.  
Removing or covering the radio aerial mast (especially with metal objects) will adversely affect radio performance, and fitting  
anything directly over the mast base will affect GPS performance.  
Double cab  
The above limitations are based on the integrity of the body structure, vehicle handling, brakes, and axle loads. These considerations must  
also apply to double cab applications, especially the steering, brakes and front axle, as well as the additional permanent loads on the 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.  
Roof carrier special installation for vehicle conversion  
Item  
Description  
1
2
3
4
Rear edge of front mounting point  
85 kg (dynamic) (maximum) / 350 kg (static) (maximum)  
Maximum roof carrier length: within the length of the drain gutter  
Maximum loading height 300 mm  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 132 of 166  
5.1.9 Load management on the vehicle tray  
Warning note  
Use only the recommended mounting points, otherwise the  
cargo box may be damaged.  
Practical note  
The weight and cargo should be routed through the  
recommended structural mounting points.  
A minimum clearance of 28 mm must be maintained  
between the cab and any mounted bodywork, load  
bearing raised accessories, the roof, tray or load  
management structure to prevent damage to the cab  
structure during operation  
Vehicles built with a cargo tray are equipped with mounting locations in the tray side rail that allow for the installation of body solutions  
such as protective roofs, sport bars, luggage racks etc.  
Information  
Side rail mounting points with M8 threaded fasteners  
must not be tightened to a torque greater than  
25 Nm.  
For information on the factory load securing, refer to  
the operating manual for the vehicle.  
Refer to chapter 1.11.  
Cargo box reinforcement brackets  
Practical note  
Make sure all loads are properly balanced and  
secured.  
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  
Practical note  
To support the structural strength of the cargo box  
when accessories are fitted, Volkswagen Commercial  
Vehicles recommends installing cargo box reinforcing  
brackets.  
Examples include canopies, ladder racks, livestock  
cages, luggage rack cross members, load-bearing  
raised accessories etc. Cargo box reinforcement  
brackets are available through the *ETKA system as  
Volkswagen Genuine Accessories.  
* ETKA: electronic parts catalogue for after sales  
Position of the reinforcing brackets for the cargo box  
Element Description  
1
Cargo box reinforcement brackets  
These reinforcing brackets are designed to provide additional reinforcement between the floor and the wall of the cargo box to ensure  
that the off-road capability of the cargo box is maintained when load bearing raised accessories are installed.  
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.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 134 of 166  
Practical note  
These reinforcement brackets have been specially  
developed for licensed Genuine Accessories. Their suitability  
for use with accessories from other manufacturers (which  
are not licensed by Volkswagen Commercial Vehicles) must  
be checked by the manufacturer or the supplier of the  
accessories.  
Said party bears responsibility for the proper use of these reinforcement brackets in a vehicle modified by a body builder or modified using  
products from another accessory manufacturer.  
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  
Practical note  
If a sunroof, ladder rack, canoe rack or similar accessory  
mounted on the cargo box is attached, a combination of the  
mounting points indicated on the top of the cargo box must  
be used to ensure proper attachment to the vehicle. Load-  
bearing and heavy vehicle accessories must also be secured  
in the transverse plane to ensure a secure fit.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 135 of 166  
Structural mounting points double cab  
Item  
Description  
1
2
3
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  
Mounting points for side rails  
Element  
Description  
1
2
Load carrier rail on left  
Load carrier rail on left  
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  
Load-carrying capacity of the mounting points  
A
B
The maximum force between directly opposite mounting points is  
125 kg  
The maximum force between diagonally opposite mounting points is  
272 kg  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 138 of 166  
Sport bar  
Information  
When fitting a sport bar, a combination of the specified  
mounting points must be used to ensure suitable  
attachment to the vehicle.  
Item  
Description  
1
2
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  
5.1.10 Front wing trim  
Information  
View of right wing trim, similar on left.  
2
3
1
Item  
Description  
Wing trim  
1
2
3
Front wing mud guard  
Wheel housing trim  
To allow access to the engine compartment and certain accessory attachments, the front right and left wing trims can be removed without  
removing the wheel housing trim and front wing mud guard.  
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.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 140 of 166  
5.2 Airbag systems  
5.2.1 Airbags  
Front seats  
-
-
Side airbags are not compatible with swivelling front seats.  
If you wish to retrofit a pivoting device on the front seats and/or an armrest on the outside of the front seats, please note the  
function and/or deployment range of the side airbag.  
-
-
-
Pressure-based airbag sensors for the side airbags are located near the top centre of the inner door panel on the front doors.  
Acceleration-based airbag sensors for side airbags are located near the bottom of the C-pillar inner panel for all cab versions.  
For double cab vehicles, additional airbag sensors for acceleration-based airbags are located on the lower B-pillar directly above the  
seat belt retractor.  
Warning note  
Modifications or reinforcements in the area of the sensors  
can affect the firing point of the side airbags and lead to  
uncontrolled deployment of the side airbags.  
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  
Dimensions (mm)  
A
B
268  
530  
525  
630  
592  
E*  
E**  
F*  
550  
521  
600  
527  
-
C
D*  
D**  
F**  
-
*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)  
A
B
C
540  
D
E
F
540  
400  
170  
400  
170  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 142 of 166  
Central airbag  
Dimensions (mm)  
A
B
C
350  
750  
450  
Information  
Left shown here, right is similar  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 143 of 166  
Side airbag  
Dimensions (mm)  
A
B
C
550  
350  
250  
Information  
Left shown here, right is similar  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 144 of 166  
Side and curtain airbag double cab  
Dimensions (mm)  
A
B
140  
40  
C
250  
100  
D
Information  
Left shown here, right is similar  
5.2.2 Additional impact sensors (front)  
Warning note  
Modifications or reinforcements in the area of the  
front additional impact sensors may adversely affect  
their function.  
Modifications or additions to the front section of your  
vehicle (including the bonnet, bumper carrier system,  
frame, front section body structure, towing brackets  
and bonnet pins) may affect the performance of the  
airbag system and increase the risk of injury. 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  
Item  
Description  
1
SRS front impact sensors  
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The new Amarok Page 146 of 166  
5.3 Seat belt systems  
Warning note  
Follow the seat belt system removal and installation  
procedures approved by Volkswagen Commercial Vehicles  
in order to ensure proper operation of the restraint system.  
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.  
When removing the seat belt system, a belt fork retainer should be applied to the belt webbing 200 mm below the tongue stop. This will  
prevent a situation where all the belt webbing runs back into the automatic belt retractor and the retractor is locked.  
When reinstalling the automatic belt retractor, first attach the retractor to the vehicle and carefully pull the belt webbing out of the  
retractor to allow the D-loop to be fitted. Then remove the fork retainer. Once the automatic belt retractor is locked in place, allow a small  
amount of belt webbing to roll back into the retractor so that the belt webbing lock can release. Do not attempt to release the automatic  
belt retractor by pulling on the webbing with significant force or by manually disturbing the locking mechanism.  
5.3.1 Seat belts no drilling zones  
DoubleCab first row seat belt  
Warning note  
Do not drill in the area of the automatic belt retractors  
on the right/left side.  
Drilling is only permitted in the area marked in red.  
Damage to automatic belt retractor: when drilling  
holes near or above the retractor and anchorage  
pretensioner, the mechanisms must be covered to  
prevent swarf/debris from falling into the assembly  
group and causing functional problems.  
Damage to the belt webbing: all installed parts must  
not cut, pinch, or interfere with the belt webbing  
along its entire path (from the automatic belt  
retractor to the D-ring). Avoid sharp supports near the  
belt webbing; all edges must have a minimum radius  
of 0.5 mm. Avoid installing parts that can change the  
course of the belt to the occupant.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 147 of 166  
Fig.: Seat belt on the right (schematic diagram)  
-
Dimension  
A
30 mm below the D-ring  
B
C
15 mm to the right of the belt webbing  
30 mm above the hole for the  
automatic belt retractor  
D
E
25 mm to the left of the belt webbing  
220 mm above the hole for the  
automatic belt retractor  
F
35 mm to the left of the belt webbing  
G
380 mm above the hole for the  
automatic belt retractor  
H
I
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  
5.4 Corrosion protection  
5.4.1 General information  
Avoid drilling into enclosed frame vehicle parts to avoid the risk of corrosion from chips.  
However, if drilling is required:  
-
-
-
-
-
After cutting or drilling, deburr before repainting to protect against corrosion.  
Repaint metal edges and protect from corrosion after cutting or drilling operations.  
Attempt to remove and treat all chips from inside the side support to prevent corrosion.  
Apply corrosion protection inside and outside the chassis frame if the coating has been damaged by drilling or welding.  
In regions where salt is used to de-ice road surfaces, it may be necessary to reapply cavity wax to the inner frame section that was  
damaged by drilling or welding.  
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.  
Warning note  
Surfaces of components such as brakes or catalytic converters  
must not be painted over or contaminated.  
5.4.3 Underseal and materials  
Make sure that all materials used comply with Volkswagen specifications and try to maintain the original condition as far as possible. Some  
manufacturer-specific products will affect the original finish. The specifications for corrosion protection materials can be obtained from  
your Volkswagen Commercial Vehicles partner or importer.  
5.4.4 Painting road wheels  
Warning note  
Do not paint any surfaces that are in contact with wheels,  
brake drums or brake discs, hubs and holes or surfaces under  
wheel nuts. Any further treatment in these areas may  
adversely affect the performance of the wheel clamp and the  
safety of the vehicle. Cover the wheel when changing the  
paint or touching up paint.  
5.4.5 Galvanic (bi-metallic) corrosion / contact corrosion  
If materials with different electrochemical potential come into contact with each other, take appropriate measures to isolate the electrical  
contact by using an insulating material.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 149 of 166  
5.5 Frame and body mounting  
5.5.1 Mounting points and pipes  
Warning note  
Drilling into reinforcements and load paths may adversely  
affect collision performance. The vehicle converter must  
ensure that all modifications comply with general product  
safety requirements, regulatory provisions or type  
approvals.  
Unused holes on the frame may be a result of the manufacturing process and may not necessarily be designed for mounting additional  
equipment/materials. Always use housing mounts as shown in the subframe for low-floor or other equipment. If additional fasteners are  
required, please follow the recommendation in the figure shown. This does not apply to areas of load applications such as spring mounts or  
damper mounts.  
Information  
After drilling, deburr and countersink all holes and remove  
chips from the frame. Follow corrosion protection  
procedures.  
See also chapter 5.4 “Corrosion protection”.  
Drilling and welding of frames  
D
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  
Item  
A
Description  
45 mm FRONT / 15 mm REAR  
B
45 mm FRONT / 15 mm REAR  
C
45 mm FRONT / 15 mm REAR  
D
45 mm FRONT / 15 mm REAR  
E
Do NOT enlarge the holes in the chassis rails and do not drill in the surrounding areas.  
Do not drill more than two vertical holes in the chassis rail.  
F
-
No welding allowed except as described below:  
-
-
-
Do not use a gas flame to make holes in frames. Drill holes with sharp drill bits.  
Use cold riveting only when attaching brackets with rivets.  
Use high-strength bolts and appropriate nuts for bolted attachments.  
Bolt specifications:  
• Metric – property class 8.8 or 10.9  
• Japanese – 7T or 9T  
• SAE – class 5 or 8  
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Deburr holes after drilling to fit screws or rivets. On the screw head side of the hole, make a chamfer  
of 1.0 mm x 45 degrees to improve the screw fit.  
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Do not drill holes near changes to the longitudinal member profile.  
Do NOT drill out existing holes in top and bottom flanges.  
No more than two holes may be drilled in a vertical line from the frame stay down.  
Corrosion protection shall be applied after drilling work on the vehicle. Corrosion protection and protective coatings for all  
modifications must conform to all local design regulations.  
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Reinforcements shall be added to the vehicle structure to prevent excessive load concentrations.  
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  
5.5.2 Self-supporting body structure  
Bodies and structures can be evaluated as follows:  
Self-supporting if they comply with the following rules:  
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Cross members are used at each mounting point on the chassis (see figure below).  
Each cross member has an appropriately designed connection to the body side panel (3) or continuous floor frame (5), see  
illustration.  
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The body side panel or continuous floor frame supports any overhang beyond the chassis frame, whether it is a standard frame or  
an extended frame.  
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-
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Alternatively, the self-supporting body structure can be designed as shown in the figure.  
This concept is based on a self-supporting body with the floor mounted directly on top of the chassis frame.  
The figure shows a general vehicle cross-section in which the cross members and opposite booms are flush with the surface of the  
chassis frame longitudinal members.  
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It is important to the overall function of the vehicle structure that the booms are each connected to a continuous longitudinal floor  
side frame or structural body side structure assembly.  
Low-floor rework for guidance only:  
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Design individual cross members and booms to be spaced no more than 600 mm apart.  
The boom moment must be absorbed by a cross member between the chassis frame with shared through bolts where possible.  
Drill the frame and add spacer tubes.  
Refer to chapter 5.5  
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The outer ends of the boom should be attached to the supporting body side/floor edge frame or body side structure (including the  
wheel housing).  
The wheel housing should be continuous in the longitudinal direction by means of a rigid attachment to the floor edge frame or  
body side structure.  
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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  
Typical design principles for a self-supporting body structure  
Item Description  
1
2
3
4
5
6
7
8
Secure with 2 x M10 bolts at all standard positions  
Floor panel  
Body side frame  
Floor cross member  
Continuous U-section floor frame  
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  
5.5.3 Frame drilling and tube reinforcement  
The chassis frame can be drilled and reinforcement spacer tubes can be welded on, provided the following is observed:  
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All details shown in the illustration (see figure in chapter 5.5.2) must be observed.  
Drill and weld only the side panels of the chassis frame.  
Drill the holes precisely and use a drilling template to ensure the holes are perpendicular to the vertical centre line of the frame  
(note: consider the angle of the longitudinal member).  
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Drill undersize and ream the holes to the correct size.  
Remove all chips from the inside of the longitudinal member and treat it to prevent corrosion.  
Fully weld each end of the tube and grind flat and square, in groups if necessary. Pay attention to the demoulding angle of the side  
member.  
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Apply corrosion protection to the inside and outside of the chassis frame.  
Refer to chapter 5.4  
Holes should be placed in groups of two (2) either vertically at a distance of 30 to 35 mm from the top and/or bottom of the chassis  
frame or horizontally at a minimum distance of 50 mm, 30 to 35 mm from the top and/or bottom of the chassis frame.  
Always use M10 bolts with a minimum grade of 8.8.  
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Do not position the tubes at mid chassis frame height as this may cause “corrugation” on the deep side panels.  
If possible, the boom moments should be resolved by matching internal cross members between the chassis sill panels in line with  
the booms.  
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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  
5.5.4 Additional equipment subframe attachment  
Typical subframes and longitudinal members for platform and low-loader bodies or semi-trailer bodies that exceed the standard length or  
the length of the frame for regular production should comply with the following guidelines:  
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Platform and low bodies mounted on integral longitudinal members (metal conduits or box sections not wood) must use both  
sides of all frame mounting brackets.  
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Longitudinal members must be relieved at the front end if they are to come into contact with the top of the chassis frame, in order  
to minimise stress concentrations. However, it is preferable to fit the longitudinal members on the mounting brackets at a distance  
to the top of the chassis frame.  
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A grade 8.8 (MINIMUM M12) retaining bolt must be used for each mounting point.  
For minimum floor height, wheel housings are required to keep the rear tyres clear, see vehicle data sheets for appropriate tyre  
impacts.  
5.5.5 Area for fitting additional body attachments to the rear of the bumper  
Practical note  
When the vehicle is on level ground and all measurements  
are taken behind the bumper edge:  
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The area intended for fitting add-on parts is defined as  
220 mm horizontally and 95 mm vertically downward  
to the road surface, with a maximum width of  
1,390 mm around the vehicle centre line.  
The manufacturer does not recommend attaching  
additional add-on parts (tow bars, steps, bicycle  
carriers and luggage carriers) outside the designated  
area.  
5.5.6 Water tank on camping vehicles  
Information  
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  
5.5.7 Conversions with an extended wheelbase  
Warning note  
All extended wheelbase conversions must comply with  
the frame and assembly guidelines referenced in this  
publication.  
All vehicles with frame extensions must comply with  
local regulations for emissions, durability and  
conformity.  
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  
All modifications to the fuel system must comply with  
local regulations.  
All modifications to fuel system components, such as  
extending or re-routing fuel lines and relocating fuel  
system components, must be approved by a local  
supervisory authority  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 156 of 166  
Exhaust system modifications for conversions with an extended wheelbase  
Warning note  
All modifications to the exhaust system must comply  
with the regulations in force in the country of  
registration.  
Bodies and load carriers intended to accommodate or  
transport humans or live animals must be  
manufactured and installed so that the exhaust outlet  
is positioned to discharge exhaust gases to the outside  
and away from the sealed passenger/animal  
compartment.  
Any modification or additional body structure that  
affects the exhaust system and exhaust pipe must not  
block or obstruct the exhaust gas stream.  
Practical note  
Acoustic/silencing devices located in the permitted  
modification zone may be relocated, but not removed,  
and may require approval testing by regulatory  
agencies to ensure compliance with applicable noise  
regulations.  
Use existing mounts for the modified exhaust system  
whenever possible.  
Information  
Modifications to the emission control system as part  
of the exhaust gas treatment (selective catalytic  
reduction system) are not permitted except in the  
areas specified below.  
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  
2.3 l Petrol EU5  
1
2
Item  
Description  
1
2
Modification zone  
“DO NOT MODIFY” zone  
2.0 l Single Turbo Diesel Engine EU6.2  
1
2
Item  
Description  
1
2
Modification zone  
“DO NOT MODIFY” zone  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 158 of 166  
2.0 l Bi-Turbo Diesel EU6.2  
1
2
Item  
Description  
1
2
Modification zone  
“DO NOT MODIFY” zone  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 159 of 166  
3.0 l Turbo Diesel EU 6.2  
1
2
Item  
Description  
1
2
Modification zone  
“DO NOT MODIFY” zone  
Selective catalytic reduction systems for conversions with a long wheelbase  
Warning note  
All modifications to the selective catalytic reduction  
system must comply with local regulations.  
All modifications to components of the selective  
catalytic reduction system, such as extending or re-  
routing pressure lines and relocating system  
components, must be approved by a local supervisory  
authority.  
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  

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