2022-2025 Volkswagen Amarok Truck Drive train User Manual
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Drive train for Your Volkswagen Amarok Truck Second Generation (2022-2025)

3 Drive train  
3.1 Engine  
3.1.1 Air flow areas of the engine cooling system  
Engine cooling output must be maintained by preventing accessories and vehicle attachments from interfering with cooling air flow areas.  
Item  
Description  
Interference with cooling air flow in this area can result in impaired engine and gearbox cooling output.  
A
Impairment of cooling air flow in this area poses a low risk of impaired drive train cooling output.  
B
C
Impairment of cooling air flow in this area may result in impaired engine performance due to obstruction of charge air flow.  
3.1.2 Engine selection for conversions  
The vehicle converter is responsible for selecting the correct exhaust engine in accordance with the latest EEC/EU regulations or the  
applicable local legislation, depending on the vehicle category and weight.  
Please note the additional weight due to the vehicle conversion.  
The weight is based on the reference mass, which is defined as the mass in running order, minus 75 kg for the driver, plus 100 kg uniform  
mass.  
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  
3.2 Fuel system  
Warning note  
–
Make sure the modified vehicle complies with all  
relevant legal requirements.  
–
Do not remove the fuel cooler(if fitted) or relocate it  
when the vehicle is converted.  
Practical note  
–
–
–
–
Ensure that modifications to the vehicle do not  
obstruct air flow to the fuel cooler.  
Ensure adequate clearance is maintained from all hot  
and moving components in all driving conditions.  
Ensure that no sharp edges, including fasteners, are  
pointed at any component of the fuel system.  
The fuel filler neck must be supported in accordance  
with the guidelines in this section.  
3.2.1 Securing the fuel filler neck during transport  
Practical note  
The vehicle must not be operated while the fuel filler neck is  
in transport condition.  
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  
3.2.2 Securing the fuel filling system  
Practical note  
–
Ensure that the mounting bracket for the filler neck is  
made of a conductive material and provides an  
earthing path for the fuel filler neck.  
The completed fuel filler pipe system must have a  
continuous slope of at least 2.1 degrees from the filler  
neck to the fuel tank and should have an entrance  
angle of at least 30 degrees.  
–
When routing the fuel filler pipe, make sure it does  
not make contact with exhaust components or sharp  
edges.  
–
–
The fuel filler pipe must not kink.  
The midpoint of the filler neck must be at least  
250 mm from the midpoint of the fuel tank and have  
an entrance angle of at least 30 degrees  
Information  
–
Fasteners for securing the fuel filler pipe to the vehicle  
body are not supplied by VW Commercial Vehicles.  
The routing of the filler and breather hose must not  
contain any dips. Additional support may be required  
to prevent the hose from sagging, which could create  
a dip. A dip in the line may cause splashing or back  
splashing during normal filling operations.  
–
–
If the vehicle body and support do not provide an  
earthing path for the fuel filler neck, an earth strap  
must be installed to connect the filler neck to the  
chassis frame.  
–
–
Do not extend the fuel filling system beyond the  
vehicle dimensions or the service body dimensions.  
If the vehicle is equipped with a capless filler neck and  
the capless system is not to be located in a filler shaft  
of the converted vehicle, it must be replaced with a  
threaded cap filler neck system because the capless  
filler neck must be protected from dust and dirt.  
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  
Fuel filler neck – overview  
2
1
3
4
Item  
Description  
1
2
3
4
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  
Mounting bracket for fuel filler neck  
A
1
Mounting instructions for the fuel filling system  
Item  
Description  
A
1
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  
Angle of the filler neck  
A
B
Installation dimensions for filler neck  
Item  
Description  
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.  
A
B
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 58 of 166  
Distance to vehicle body  
A
Item  
Description  
At least 9 mm distance between the tank cap and the vehicle body, if necessary at the most unfavourable opening angle.  
A
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 59 of 166  
Height of fuel filler neck – chassis with chassis cab  
A
Item  
Description  
A
The filler neck opening height should be at least 250 mm, measured from the midpoint of the ICV opening of the fuel tank to the  
midpoint of the filler neck opening.  
3.2.3 Breather hose for fuel filling system (diesel)  
The fuel tank breather hose must have a shepherd’s crook on the end and the opening must be at least at the height described in this  
document to meet water permeability specifications and prevent water from entering the fuel system.  
A section of the flexible fuel hose should be attached to the vehicle body with the open end at least 600 mm (4x2)* or 800 mm (4x4 or 4x2)  
above the ground. We recommend measuring this height when the vehicle is fully loaded.  
The fuel tank breather hose must be routed so that it is protected and away from direct splash water, wheel splash, mud splash, and any  
water drainage holes that may be present.  
The fuel tank breather hose must be routed upright with a shepherd’s crook on the end, as shown in the illustration. The shepherd’s crook  
must be located behind the filler neck as shown in the illustration.  
A section of the flexible fuel hose should be attached to the vehicle body with the opening of the shepherd’s crook at least 600 mm (4x2)*  
or 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  
Hose routing for the fuel tank breather system  
Information  
Contact your Volkswagen Commercial Vehicles dealership to  
confirm the correct part number for your vehicle.  
Schematic diagram of mounting position for fuel tank breather hose  
2
1
Item  
Description  
1
2
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  
3.2.4 Breather hose for axle venting  
The breather hose for the rear differential should be fitted to the filler neck or the vehicle body. If required due to the assembly of an  
auxiliary body, retrofits, or relocation of the fuel filler neck, the axle breather hose must be routed along the activated charcoal filter  
system. A section of the flexible fuel hose should be attached to the vehicle body with the open end at least 600 mm (4x2)* or 800 mm  
(4x4 or 4x2) above the ground. We recommend measuring this height when the vehicle is fully loaded. A breather cap can be used on the  
axle breather hose.  
*Only rear-wheel drive 110 kW EU4  
3.3 Selective catalytic reduction system  
3.3.1 Selective catalytic reduction system – diesel exhaust fluid  
Warning note  
–
–
–
The engine may not start if you tamper with or disable  
the selective catalytic reduction system.  
The engine may not start if the diesel exhaust fluid  
(AdBlue®) level is low. Make sure it is topped up.  
The engine may not start if the diesel exhaust fluid  
(AdBlue®) is contaminated. Renew the contaminated  
fluid immediately.  
–
The use and refilling of diesel exhaust fluid (AdBlue®)  
is mandatory for the vehicle for meeting the legal  
emission requirements.  
The selective catalytic reduction system helps to reduce exhaust emissions by injecting diesel exhaust fluid (AdBlue®) into the exhaust  
system. For proper operation of this system, ensure that the diesel exhaust fluid (AdBlue®) is topped up regularly.  
Information  
–
–
When removing or renewing the cargo box, make sure  
that the angle of the filler hose and the distances  
between the fuel filler neck and the filler neck for  
diesel exhaust fluid (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  
Filling the diesel exhaust fluid tank  
Warning note  
Diesel exhaust fluid (AdBlue®) must not come into contact  
with eyes, skin or clothing. If the fluid comes into contact  
with the eyes, rinse them with plenty of water and seek  
medical attention. Clean affected skin with soap and water.  
If swallowed, drink plenty of water and seek medical  
attention immediately.  
Practical note  
Use only the vehicle-specific vented filler cap for diesel  
exhaust fluid (AdBlue®). Use of other diesel exhaust fluid  
(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  
2.0 l Turbo Diesel EU6.2  
E
B
A
C
D
Item  
Description  
A
B
C
D
E
Pressure line for diesel exhaust fluid (AdBlue)  
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  
3.0 l Turbo Diesel EU 6.2  
A
E
C
D
B
Item  
Description  
A
Pressure line for diesel exhaust fluid (AdBlue)  
Injector for diesel exhaust fluid (AdBlue)  
Injector for diesel exhaust fluid (AdBlue)  
B
C
D
E
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  
Tank and filler neck for diesel exhaust fluid (AdBlue)  
Item  
Description  
A
Filler neck for diesel exhaust fluid (AdBlue)  
Tank for diesel exhaust fluid (AdBlue)  
Filler hose for diesel exhaust fluid (AdBlue)  
B
C
Fitting the filler neck for diesel exhaust fluid – vehicles with chassis cab  
Practical note  
Make sure that the bracket for the filler neck is made of a  
conductive material and provides an earthing path for the  
filler neck.  
Appropriate assembly tools and alignment of the diesel exhaust fluid filler neck and filler pipes are required if the vehicle modification will  
affect the diesel exhaust fluid (AdBlue®) system.  
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  
Filler neck bracket for diesel exhaust fluid  
1
x3 2  
Item Description  
1
2
Mounting points for the diesel exhaust fluid filler neck bracket  
All three mounting points on the diesel exhaust fluid filler neck must be used and tightened to 5.4 Nm.  
Angle of the diesel exhaust fluid filler neck  
1
2
Item Description  
1
When refilling, an angle of 30° to the filler neck must be maintained to ensure a sufficient flow of the diesel exhaust fluid and to  
prevent backflow.  
2
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  
Practical note  
Care must be taken when fitting U-bolts or other fasteners  
on the frame rail, as the diesel exhaust line can be pinched  
and crushed. To avoid damaging/crushing the diesel exhaust  
line, body builders/installers should inspect the underside of  
the frame carriers and check the routing of the diesel  
exhaust hose before fitting any parts. Make sure the diesel  
exhaust line does not have an adverse effect on the  
clamping surface. If additional clearance is needed for the  
diesel exhaust line, the diesel exhaust line can be moved  
within the existing positioning clips by rotating the diesel  
exhaust line back and forth while gently pulling on the  
diesel exhaust line. This will create the necessary clearance  
for inserting the U-strap between the frame rail and the  
diesel exhaust line.  
Information  
–
–
–
The finished diesel exhaust fluid filler set must have a  
continuous slope of at least 2° from the filler neck to  
the tank.  
The diesel exhaust fluid filler hose must be routed to  
ensure there is no contact with exhaust components  
or sharp edges.  
The routing of the diesel exhaust fluid filler hose and  
the breather hose must not contain any dips.  
Additional support may be required to prevent the  
diesel exhaust fluid filler hose from sagging, which  
could cause backing-up in a dip. A dip in the line can  
cause splashing or backsplash during normal filling  
operations and can also cause the collected diesel  
exhaust fluid to freeze in the line and damage the  
component.  
–
–
–
No kinking is allowed in the diesel exhaust fluid filler  
hose.  
Do not extend the diesel exhaust fluid filler hose  
outside the vehicle body.  
If the diesel exhaust fluid filler housing supplied with  
the kit is not used, the technician must ensure that the  
filler neck is at an angle of at least 30° to the  
horizontal.  
–
–
If the diesel exhaust fluid filler housing supplied with  
the kit is used, the three fasteners included in the kit  
must be used to secure the container to the housing.  
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  
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:  
Item  
Description  
1
Filler housing  
2
3
4
Main filler pipe (large diameter EPDM pipe)  
Breather pipe (smaller diameter EPDM pipe)  
Screws for fastening the filler neck to the housing  
If necessary, the hoses and pipes of the diesel emission control kit can be shortened to the desired length.  
Use cable ties or similar fasteners to keep the hoses and pipes within the desired routing path while the vehicle is in operation.  
Information  
The kit does not include cable ties, hose clips, or the  
rivets/screws to secure the housing to the vehicle body.  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 69 of 166  

Related Topics

3.1 Engine 3.2 Fuel system 3.3 Selective catalytic reduction system

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