Get Body and paint -> 5.1 Body Guide for 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

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

192

-

968

665

774

801

K

L

635

-

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

1,248

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

B

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

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

Body and paint -> 5.1 Body for Your Volkswagen Amarok Truck Second Generation (2022-2025)

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