Get Body and paint -> 5.5 Frame and body mounting Guide for Volkswagen Amarok Truck Second Generation (2022-2025)

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

-

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.

-

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.

-

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.

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5.5.2 Self-supporting body structure

Bodies and structures can be evaluated as follows:

Self-supporting if they comply with the following rules:

-

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.

-

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.

-

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.

-

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:

-

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

-

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.

-

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

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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:

-

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).

-

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.

-

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.

-

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.

-

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

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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:

-

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.

-

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.

-

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:

-

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.

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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

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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

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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.

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Body and paint -> 5.5 Frame and body mounting for Your Volkswagen Amarok Truck Second Generation (2022-2025)

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