2022-2025 Volkswagen Amarok Truck Drive train -> 3.2 Fuel system User Manual
MyCarUserManual.com
USER MANUALS FOR EVERY MAKE & MODEL

Drive train -> 3.2 Fuel system for Your Volkswagen Amarok Truck Second Generation (2022-2025)

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  

Related Topics

Drive train
3.1 Engine 3.3 Selective catalytic reduction system

Popular Owner Manuals

Audi
Audi
BMW
BMW
Citroen
Citroen
Ford
Ford
Honda
Honda
Peugeot
Peugeot