2022-2025 Volkswagen Amarok Truck General information User Manual
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General information for Your Volkswagen Amarok Truck Second Generation (2022-2025)

1 General information  
1.1 Introduction  
These body builder guidelines provide body builders with important technical information which must be complied with when planning and  
manufacturing a body for road safety and operational reliability. The add-on, body, installation or conversion work required for this is  
referred to below as “body activities”.  
Due to the vast number of body builders and types of conversion, it is not possible for Volkswagen AG to predict all possible changes which  
may can occur due to the body activities, e.g. with regard to driving properties, stability, weight distribution, centre of gravity of the vehicle  
and its handling characteristics. Therefore, Volkswagen AG does not accept any liability for accidents or injuries arising from changes of this  
kind made to its vehicles, especially if the changes have a negative effect on the vehicle as a whole. As a result, Volkswagen AG only accepts  
liability for its own design, production and instruction services. The body builder itself is obliged to ensure that its body activities are not  
faulty in themselves, and also that they cannot result in defects or dangers on the vehicle as a whole. The body builder must also ensure  
the conformity of the body activities with the respective and applicable laws (in particular approval and registration processes). The body  
builder itself is liable in the event that this obligation is violated.  
These body builder guidelines are intended for professional body builders. As a result, these body builder guidelines assume corresponding  
background knowledge. Note that some work (e.g. welding on load-bearing parts) is only allowed to be performed by appropriately  
qualified personnel. This requirement exists in order to avoid risks of injury and to achieve the quality needed in the body activities.  
1.1.1 Concept of these guidelines  
The following body builder guidelines are divided into 6 chapters so that you can find information rapidly:  
1. General information  
2. Chassis  
3. Drive train  
4. Electrical  
5. Body and paint  
6. Listings  
Information  
For more information, see 1.2.1.1 “Contact”, 1.2.2 “Body  
builder guidelines, consulting”.  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
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1.1.2 Means of representation  
The following means of representation are used in these body builder guidelines:  
Warning note  
A danger note draws your attention to possible accident or  
injury risks to which you or other persons might be exposed.  
Environmental note  
An environmental note provides you with information about  
environmental protection.  
Practical note  
This note draws your attention to the risk of possible  
damage to the vehicle, as well as to regulations and  
provisions to be observed.  
Information  
This note indicates additional information.  
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1.1.3 Vehicle safety  
Warning note  
Before installing external add-ons or mechanical units, it is  
essential that you read the chapters in these body builder  
guidelines that are related to installation, as well as  
corresponding chapters in the instructions and information  
for the suppliers' mechanical units and in the detailed  
owner's manual for the base vehicle. Otherwise you will not  
be able to recognise dangers, and might expose yourself or  
others to danger.  
We recommend that you use parts, mechanical units, conversion parts or accessories that have been tested by Volkswagen AG for the  
corresponding vehicle type.  
Have the vehicle's safety checked immediately if non-recommended parts, mechanical units, conversion parts or accessories are used.  
Practical note  
It is essential that you comply with European vehicle  
approval or UN ECE R regulations, as well as national  
registration regulations and also technical vehicle  
regulations. This is because body activities on the vehicle  
can alter the vehicle type under registration regulations and  
the operating permit may be invalidated.  
This applies in particular to:  
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modifications which change the vehicle type approved  
in the operating permit,  
modifications which might be expected to endanger  
road users or  
modifications which impair the exhaust or noise  
emissions characteristics.  
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1.1.4 Operational safety  
Warning note  
Incorrect interventions in electronic components and their  
software may result in these no longer functioning. Due to  
the networking of electronics, systems that were not  
modified can be affected.  
Malfunctions to the electronics can significantly impair the  
operational safety of the vehicle.  
Have work on or modifications to electronic components  
performed by a qualified specialist workshop which has the  
necessary specialist knowledge and tools for performing the  
necessary work.  
Volkswagen AG recommends a Volkswagen AG customer  
service workshop for this purpose.  
Service by a qualified specialist workshop is essential, in  
particular for safety-relevant work and work on safety-  
relevant systems.  
Some safety systems only operate when the engine is  
running. Therefore, do not switch the engine off when  
driving.  
1.1.5 Note on copyright  
The texts, pictures and data contained in these body builder guidelines are subject to copyright.  
This also applies to editions on CD-ROM, DVD or other media.  
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1.2 General notes  
The following pages contain technical guidelines for body builders and equipment fitters relating to the design and assembly of bodies. The  
body builder guidelines must be strictly adhered to when performing any modifications to the vehicle. The current version of the German  
edition of the body builder guidelines is the exclusive authority for the most up-to-date information.  
This also applies to legal claims. Should the body builder guidelines include references to legal regulations, then no guarantee can be  
provided for the completeness and correctness of this content, or that it is up-to-date. Country-specific features can vary.  
1.2.1 Product and vehicle information for body builders  
1.2.1.1 Contact in Germany  
If you have questions concerning vehicle models from Volkswagen Commercial Vehicles, you can contact us via the internet portals of  
Volkswagen AG () or via one of the following methods:  
00 800-2878 66 49 33 (00 800-CUSTOMIZED)  
Free hotline  
(from a German landline)  
 
 
 
Personal points of contact:  
1.2.1.2 International contact  
Please contact the body builder’s support personnel at the responsible importer for technical advice relating to Volkswagen Commercial  
Vehicles models and as a point of contact for conversions.  
To find the contact person assigned to you, please register on the Volkswagen AG CustomizedSolution portal (  
).  
Help is available for the registration option using the “Help” menu option.  
00-800-2878 66 49 33 (00-800-CUSTOMIZED)  
International hotline:  
Email  
 
 
Personal points of contact:  
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1.2.1.3 Electronic repair and workshop information from Volkswagen AG (erWin*)  
Body builders can access repair and workshop information, e.g.  
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Current flow diagrams  
Workshop manuals  
Maintenance  
Self-study programmes  
via the Electronic Repair and Workshop Information System from Volkswagen AG (erWin*).  
 
Body builders with Integrated Partner or Premium Partner status have access to discounted annual licenses, which  
can be applied for by going to My Customised Solution Portal/Requirements/Planning and Development.  
For exporting, body builders with Partner status receive information in this regard from their point of contact at the importer.  
*Information system, subject to payment  
1.2.1.4 Genuine Parts Online Ordering Portal*  
For the purchase of spare parts and for the research of Volkswagen Genuine Parts, our latest parts catalogues are available on the Internet  
in the “Genuine Parts Online Ordering Portal”:  
 
*Information system, subject to payment  
1.2.1.5 Online Owner’s Manual  
Detailed information about the functions and handling of your vehicle can be found in your Owner’s Manual which is enclosed with your  
vehicle ex-works. In addition to the hard copy of the Owner’s Manual, the following link and VIN number of the vehicle can be used to  
receive the Owner’s Manual in electronic form.  
 
1.2.1.6 European Type Approval (ETA) and EC Certificate of Conformity (CoC)  
Directive (EU) 2018/858 of the European Parliament establishes the standard for the approval of motor vehicles and their trailers, and of  
systems, components and separate technical units intended for such vehicles.  
Provisions were also adopted in these guidelines for the approval of vehicles produced in several stages: the multi-stage approval process.  
Accordingly, each manufacturer involved in the construction of a vehicle is itself responsible for the approval of modified or added scopes  
in its production stage.  
The manufacturer may choose one of the four following methods:  
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EU type approval (ETA)  
EU type approval for small series  
National small series type approval  
Individual approval  
CoC = Certificate of Conformity. A document that verifies the conformity of certain goods – and therefore also of vehicles and bodies – in  
accordance with the recognised (international) standards. The purpose of this EC Certificate of Conformity is to facilitate the approval of  
goods on international markets. As a result, the document is needed above all in import and export as part of the customs clearance  
procedure.  
The manufacturer, the owner of an EU type approval or EU small series type approval, is obliged to provide a Certificate of Conformity with  
every vehicle which corresponds to an approved type. If you are planning to apply multi-stage type approval, an agreement must be  
concluded in accordance with the 2018/858/EU regulation.  
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1.2.1.7 Worldwide Harmonised Light Vehicles Test Procedure (WLTP)  
New consumption values/ranges calculated in accordance with the new WLTP standards apply from September 2017 for new passenger  
cars entering the market and from September 2018 for new light commercial vehicles entering the market.  
As of 1 September 2018, certified WLTP measurements must be available for all newly registered passenger cars. For light commercial  
vehicles with exhaust emission standard EU6 under Regulation EC 715/2007, the regulation will come into force one year later on 1  
September 2019.  
28+6 markets in Europe are affected by the WLTP.  
WLTP stands for Worldwide Harmonised Light Vehicles Test Procedure. This is a worldwide standardised testing procedure for determining  
fuel consumption / electric range and exhaust emissions.  
It is replacing the NEDC (New European Driving Cycle) test procedure that has been in force since 1992.  
Unlike the NEDC, the WLTP takes into account individual special equipment and conversion solutions for weight, aerodynamics, electrical  
system requirements (no-load current) and rolling resistance which have an impact on the fuel consumption / electric range and exhaust  
emissions. This includes, in particular, changes that result in a larger end face, a different radiator inflow area, a higher kerb weight for the  
vehicle or changes to the tyre size or the rolling resistance. Special equipment that consumes power, such as the air conditioning system or  
seat heating, still remains switched off for the duration of the test procedure.  
Before initial approval, conversions or add-ons where WLTP is relevant can be made if they are approved by way of an individual approval  
or multi-stage type approval.  
The Volkswagen type approval can be used for the multi-stage type approval for vehicles with conversions or add-ons that remain within  
the ISC parameters / maximum technical specifications for add-on parts. If the add-on or conversion is outside the ISC parameters /  
maximum technical specifications defined by the manufacturer for add-on parts, the body builder must demonstrate compliance with the  
exhaust gas emissions requirements / electric range.  
Information about the ISC parameters / maximum technical specifications for add-on parts can be found on the Volkswagen  
CustomizedSolution portal. Please ask your technical service/test centre for advice if you have questions about alternatives.  
To determine the consumption values of converted new vehicles in compliance with the WLTP procedure and to obtain a WLTP  
certification, the “WLTP Conversion Calculator” is available to you.  
You can find more information as a Registered Converter on the CustomizedSolution portal / WLTP:  
Germany / International:  
1.2.1.8 Manufacturer’s declaration  
We issue a manufacturer's declaration for the base vehicle for the following scopes:  
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Electromagnetic compatibility (EMC)  
Dangerous goods transport ADR 2021 for vehicles EX/II (explosive substances)  
Please contact our customer support:  
 
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1.2.2 Body builder guidelines, consulting  
The body builder guidelines define the technical requirements for custom body builders and equipment fitters relating to the design and  
mounting of bodies for base vehicles of the Volkswagen Commercial Vehicles brand.  
The body builder guidelines must be strictly adhered to when performing any modifications to the vehicle.  
The statutory requirements, technical vehicle regulations and guidelines stated in the Directive are not comprehensive. When making  
modifications to vehicles, all applicable statutory requirements and all technical vehicle regulations and guidelines must be observed. The  
work safety regulations of the trade association and the Machinery Directive must be observed.  
Ensure that no modification adversely affects the functional reliability and safety of the running gear, the body or the electric system.  
Modifications must only be performed by qualified specialists and in accordance with the generally acknowledged rules of the automotive  
industry.  
Prerequisites for modifications to used vehicles:  
The vehicle shall be in a good overall condition, i.e. structural parts such as longitudinal and cross members, pillars etc. shall not be  
corroded to such an extent that structural stability might be adversely affected.  
Vehicles whose modifications might affect the validity of the general certificate of roadworthiness must be presented to an authorised  
testing centre for approval. It is recommended to clarify in advance with the relevant authority whether approval is required. Please  
contact us in case of inquiries for proposed modifications.  
When inquiring about planned modifications, please enclose two sets of design drawings of the complete scope of the modification,  
including weights, centre of gravity and dimensions, which also clearly show how the body is attached to the chassis. Please use the online  
contact form for this (see chapters 1.2.1.1 “Contact in Germany” and 1.2.1.2 “International contact”). Please also provide information  
about the intended operating conditions of the vehicle.  
If bodies comply with the present body builder guidelines, no additional approval by Volkswagen AG is required for the presentation of the  
vehicle at the relevant authority examining roadworthiness.  
1.2.2.1 Letter of non-objection  
Volkswagen AG does not issue body approvals for non-Volkswagen bodies. It merely provides body builders with important information  
and technical specifications for dealing with the product in these guidelines. As a result, Volkswagen AG recommends that all work should  
be carried out on the base vehicle and the body in accordance with the current Volkswagen body builder guidelines applicable to the  
vehicle in question.  
Volkswagen AG does not recommend body activities which  
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are not conducted according to these Volkswagen body builder guidelines  
exceed the gross vehicle weight rating  
exceed the gross axle weight rating.  
Volkswagen AG issues letters of non-objection on a voluntary basis, as follows:  
The assessment conducted by Volkswagen AG is exclusively based on the documents submitted by the body builder which is carrying out  
the modifications. The inspection and safety assessment only relate to the expressly designated scope of work, its basic compatibility with  
the designated chassis and its interfaces or, in the event of chassis modifications, the fundamental admissibility of the design for the  
designated chassis.  
The safety certificate relates to the presented overall vehicle, and not  
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to the design of the overall body,  
its functions or  
the planned use.  
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Safety is only provided if the design, production and installation are carried out by the body builder performing the modifications in  
accordance with the state of the art and in accordance with the applicable body builder guidelines of Volkswagen AG – and assuming any  
deviations from these guidelines have been declared to be technically safe. The letter of non-objection does not release the body builder  
who is performing the modifications from its responsibility for the product, or from its obligation to carry out its own calculations, tests and  
a trial of the entire vehicle in order to ensure that the operational safety, road safety and driving properties of the overall vehicle it has  
manufactured are acceptable. Accordingly, it is necessary to ensure that the body builder exclusively accepts its responsibility for ensuring  
that its body activities are compatible with the base vehicle as well as the operational and road safety of the vehicle. It is expressly stated  
that the letter of non-objection from Volkswagen AG does not represent a technical approval for the investigated changes.  
In the course of assessment of a presented vehicle, an assessment report is written as a means of obtaining a letter of non-objection (LONO  
report).  
The following assessment results are possible:  
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Classified as “safe”  
If the overall vehicle is classified as “safe”, the Sales department can subsequently issue the LONO certificate.  
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Classified as “not safe”  
Classification as “not safe” in the individual categories:  
base vehicle configuration  
impairment of the base vehicle and possibly  
sole body item  
leads to a corresponding classification of the overall vehicle. This means no LONO certificate can be issued initially.  
In order for a not-safe classification to be resolved, the safety certificate report states the necessary change for each item in question. In  
order for the letter of non-objection to be obtained, these points will have to be addressed by the body builder and documented in a  
clearly comprehensible manner in a report along the same lines as the LONO report. On the basis of this detailed report, it is possible for  
the desk-review assessment to be completed with a positive result.  
Depending on the defective points, it may be necessary not only to provide documentation of the defect resolution but also for the vehicle  
from the first inspection to be presented again. The first report indicates if it will be necessary for a new assessment to be carried out on  
the vehicle.  
The assessment report may also contain “notes/recommendations”.  
Notes/recommendations are technical remarks which do not have any effect on the letter of non-objection. They should be regarded as  
advice and suggestions for further consideration to support the continuous improvement of the final product for the customer.  
In addition, “notes/recommendations solely relating to the conversion” can also be formulated. The notes and recommendations stated as  
“solely relating to the body/conversion” must be dealt with and documented before the vehicle can be included in the body builder portal.  
Practical note  
Country-specific laws, directives and approval regulations  
shall be observed!  
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1.2.2.2 Application for the letter of non-objection  
Before starting any work on the vehicle, auditable technical documentation and drawings must be submitted to the responsible  
department as part of the letter of non-objection evaluation (see 1.2.1 “Product and vehicle information for body builders”).  
Speedy handling of the request requires:  
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Documents preferably in standardised digital formats (e.g. PDF, DXF, STEP)  
Technical data and documentation should be complete  
The following details must be included:  
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Vehicle type  
Vehicle equipment (chassis, panel van, window van, etc.)  
Wheelbase  
Frame overhang  
Vehicle identification number (if already available)  
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Any deviations from these body builder guidelines must be indicated on all documentation  
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Axle load calculation  
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All data about dimensions, weight and centre of gravity (weighing certificate)  
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Special operating conditions (e.g. poor road conditions, extreme dust, high altitude, or ambient temperature extremes)  
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Certificates (e-registration, seat tensile test)  
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Attachment of the body on the vehicle  
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Subframe:  
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Material and profiles  
Dimensions  
Type of profile  
Features of the subframe construction (profile modifications, additional reinforcements, offsets, etc.)  
Type of fixation for the body or add-ons to the vehicle frame (e.g. bolted connections)  
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Position (in relation to vehicle chassis)  
Type  
Size  
Number  
Property class  
All fixation brackets on the vehicle frame must be used for bolted connections to the subframe, or body.  
Type of fixation for the body or add-ons to the vehicle frame (bolting, bonding, welding)  
Photographic documentation of the conversion  
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All documents must clearly correlate with the conversion (e.g. drawings marked with allocated numbers).  
General (functional) description of deviations from the series vehicle, or added components.  
Electric wiring diagram  
Details of the consumption of additional electrical equipment.  
Complete documentation avoids the need for clarification queries and accelerates the processing.  
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1.2.2.3 Legal entitlements  
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There is no legal entitlement for a letter of non-objection to be issued.  
Due to ongoing technical development and the information derived from this, Volkswagen AG is entitled to refuse a letter of  
non-objection even if a comparable certificate had been issued formerly.  
The letter of non-objection can be restricted to individual vehicles.  
The subsequent issue of a letter of non-objection may be refused for vehicles that have already been completed or delivered.  
The body builder is solely responsible for:  
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the function and compatibility of its body activities with the base vehicle.  
road safety and operational reliability.  
all body activities and installed parts.  
1.2.3 Warranty and product liability of the body builder  
The body builder’s or equipment fitter’s warranty conditions apply to the body builder’s or equipment fitter’s scope of supply. Therefore,  
warranty claims associated with complaints to this scope of supply cannot be made under the warranty conditions applicable to  
Volkswagen Commercial Vehicles.  
Defects of bodies, installations and conversions provided by third parties as well as defects of the vehicle caused by the said bodies,  
installations or conversions are excluded from the Volkswagen warranty and also from the Volkswagen paint and body warranty. This also  
applies to accessories which were not installed and/or supplied by the vehicle manufacturer  
The body builder or equipment fitter is solely responsible for the design and assembly of bodies and the execution of conversions.  
All modifications must be documented by the body builder or equipment fitter.  
The body builder is responsible for ensuring that all modifications it performs comply with the technical vehicle regulations, specifications  
and standards that apply in the countries of registration.  
Due to the multitude of modifications and diversity of operating conditions, the information provided by Volkswagen AG is subject to the  
reservation that modified vehicles are not tested by Volkswagen AG. Modifications may affect the properties of the vehicle. For reasons of  
liability, the body builders or fitters must provide the following information in writing to their customers. In individual cases, Volkswagen  
AG reserves the right to demand evidence of the information being passed on to the customer.  
“Due to the modifications* to your Volkswagen Commercial Vehicles base vehicle, the properties of your base vehicle may have changed.  
Please understand that Volkswagen AG does not assume any liability for any negative effects resulting from the modifications* to the  
vehicle.”  
No general legal entitlement for the approval of a body modification exists, even if such approval was previously granted. If bodies comply  
with the present guidelines, no additional approval by Volkswagen AG is required for the presentation of the vehicle at the relevant  
authority examining roadworthiness.  
The body builder’s or equipment fitter’s warranty conditions apply to the body builder’s or equipment fitter’s scope of supply.  
Therefore, warranty claims associated with complaints to this scope of supply cannot be made under the warranty conditions applicable to  
Volkswagen Commercial Vehicles.  
UN ECE Regulation No. 155 for vehicle cyber security and UN ECE Regulation No. 156 for vehicle software updates apply to all new vehicle  
types from the middle of 2022 and to all new vehicle registrations from the middle of 2024; these contain new requirements for  
automotive cyber security and updates. Insofar as modifications are made to the vehicle, the body builder shall also ensure that these  
regulations are applied and complied with.  
* At this point, the term “modification” may be substituted by a more precise description of the work performed, e.g. by “camping equipment installation”, “wheelbase extension”, “box  
body”.  
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1.2.4 Ensuring traceability  
Body dangers only detected after delivery can mean that subsequent measures in the market will be necessary (customer information,  
warning, call-back). To make these measures as efficient as possible, it is necessary to be able to trace the product after delivery. For this  
purpose, and in order to be able to use the central vehicle register (CVR) operated by the Federal Motor Transport Authority or comparable  
registers abroad for tracing the affected vehicle keepers, we strongly recommend that body builders should store the serial number /  
identification number of their body linked to the vehicle identification number of the base vehicle in their databases. For this purpose, it is  
also recommended that customers’ addresses are stored and that subsequent owners are provided with a means of registration.  
1.2.5 Trademarks  
VW badges and VW emblem are trademarks of Volkswagen AG. VW badges and VW emblems are not allowed to be removed without  
authorisation, or to be attached in a different location.  
1.2.5.1 Positions on rear of the vehicle  
VW badges and VW emblems which are enclosed in the delivery must be fitted in the location intended by  
1.2.5.2 Appearance of overall vehicle  
If the vehicle does not correspond to the appearance and the quality requirements set by Volkswagen AG, then Volkswagen AG reserves  
the right to request removal of the Volkswagen AG trademarks.  
1.2.5.3 Non-Volkswagen trademarks  
Non-Volkswagen badges are not allowed to be attached next to Volkswagen badges.  
1.2.6 Recommendations for vehicle storage  
Extended storage times cannot always be avoided. The following measures are recommended to ensure that vehicle quality is not affected  
by long-term storage:  
At vehicle delivery:  
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Open all ventilation flaps, set blower to maximum speed.  
Put manual gearbox into 1st gear or lever of automatic gearbox into park position. Do not engage reverse gear. Do not apply the  
parking brake.  
If incomplete vehicles are stored outdoors (e.g. chassis), the fuel tank and its pipes, all components between the longitudinal members up  
to the rear bumper and the spare wheel must be protected (covered) against direct exposure to sunshine, snow and liquids.  
Check the battery open-circuit voltage for the first battery and second battery (depending on vehicle equipment):  
Battery open-circuit voltage  
Reading/measure  
<10% or Battery defective/totally discharged/  
<11.6 V fully charge battery immediately  
10% to 80% or Battery not able to start/  
11.6 to <12.5 V fully charge battery immediately  
≥80% or Battery voltage OK.  
≥12.5 V  
A maximum charging voltage of 14.8 volts must not be exceeded.  
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After delivery of vehicle:  
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Check weekly for aggressive deposits (e.g. bird droppings, industrial deposits) and clean if necessary.  
Brake clean the brake discs every three months.  
Check tyre pressure at least once a month. The tyre pressure sticker states the correct tyre pressure for tyres fitted at the  
factory. The information applies to summer tyres, all-season tyres and winter tyres. The tyre pressure sticker is located either on  
the driver seat console or on the inside of the tank flap (see chapter 1.2.1.5 “Online owner's manuals”).  
Check the battery open-circuit voltage in accordance with the maintenance cycle (in accordance with the information above):  
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Practical note  
When connecting a battery charger, the following  
connection specification must be observed under all  
circumstances:  
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Positive: always connect to jump-start terminal, if  
fitted, otherwise to battery positive terminal  
Negative: always connect to vehicle body ground  
terminal intended for battery charging  
Practical note  
Removal of the battery for charging as well as series or  
parallel charging are unauthorised.  
Practical note  
Directly connecting a battery charger to the starter battery  
can lead to incorrect battery status recording by the vehicle  
electronics in some vehicles.  
Information  
You can find further information about vehicle storage in  
the following documents:  
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Operating manual  
Vehicle care programme.  
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1.2.7 Compliance with environmental rules and regulations  
Environmental note  
The following principles of environmentally friendly design  
and material selection should be followed right from the  
planning stage of fitted components or bodies, and the  
statutory requirements in the EU Directive on End-of-Life  
Vehicles 2000/53/EC should also be taken into account.  
The body builder is responsible for ensuring that all modifications it performs comply with the environmental regulations, specifications  
and standards that apply in the countries of registration and sale. These may go beyond the existing prerequisites of the base vehicle and  
are the responsibility of the body builder.  
The body builder must ensure that add-ons and bodies (conversions) comply with all applicable environmental rules and regulations,  
especially, but not only, EU directive 2000/53/EC concerning end-of-life vehicles and the REACH Regulation (EC) 1907/2006 relating to  
restrictions on the marketing and use of certain dangerous substances and preparations (“low flammability” and certain flame-retardant  
agents).  
The registered keeper must keep all assembly documentation concerning the modification and hand it over together with the vehicle to the  
dismantler. This ensures that modified vehicles are processed in compliance with environmental rules and regulations at the end of their  
life cycle.  
Materials which represent a potential risk such as halogen additives, heavy metals, asbestos, CFCs and chlorinated hydrocarbons shall be  
avoided.  
Under environmental law, the body builder must also ensure the following aspects. Please note that the following list merely contains  
examples and is not exhaustive:  
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EU Directive 2000/53/EC must be adhered to.  
Preferably, materials which allow valuable substance recycling and closed material cycles shall be used.  
The material and production process shall be selected so that only low amounts of easily recyclable waste are generated.  
Plastics shall only be used where these offer advantages in terms of cost, function or weight.  
In the case of plastics, especially composite materials, only mutually compatible substances from one material family may be  
used.  
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With regard to components that are relevant for recycling, the number of plastic types used shall be kept as low as possible.  
It is necessary to check whether a component can be manufactured from recycled material or with recycled additives.  
Care shall be taken to ensure that recyclable components can be removed easily, e.g. by means of snap-lock connections,  
predetermined breaking points, good accessibility, use of standard tools.  
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Simple, environmentally friendly removal of the fluids shall be ensured by means of drain plugs etc.  
Wherever possible, the components shall not be painted or coated; instead, dyed plastic parts shall be used.  
Components in areas at risk of accident shall be designed to be tolerant of damage, repairable and easy to exchange.  
All plastic parts shall be identified according to the VDA material sheet 260 (“Components of motor vehicles; Identification of  
materials”), e.g. “PP-GF30R”.  
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1.2.8 Recommendations for inspection, maintenance and repair  
A service schedule outlining inspection and servicing work must be provided for the modifications performed by the body builder or  
accessories fitter. These instructions or schedules must include the maintenance and inspection intervals as well as the required operating  
fluids and materials and the spare parts. It is also important to specify parts and components with a limited service life which are to be  
checked at regular intervals in order to ensure service reliability and timely replacement where required.  
This should be supported by a repair manual including tightening torques, settings and tolerances as well as other relevant specifications.  
Special tools, including their source of supply, must also be stated.  
Body builders / fitters must also state which work may only be performed only by themselves or by their authorised workshops.  
If the body builder’s or accessory fitter’s scope of supply includes electric, electronic, mechatronic, hydraulic or pneumatic systems, then  
current flow diagrams and diagnosis routines or similar documentation facilitating a systematic search for faults should be provided.  
Please observe the Volkswagen AG owner's manual for the inspection, maintenance and repair of the base vehicle.  
Please only use brake fluids and engine oils approved by Volkswagen for your vehicle.  
More information about brake fluids and engine oils can be found in the operating manual for your vehicle:  
 
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1.2.9 Accident prevention  
Body builders shall ensure that the bodies comply with applicable legal rules and regulations as well as all regulations regarding work safety  
and accident prevention. All safety rules and the information material provided by accident insurance providers shall be observed.  
All technically feasible measures must be taken to prevent unsafe operation.  
Country-specific laws, directives and approval regulations must be observed.  
The body builder is responsible for the compliance with these laws, rules and regulations.  
For further information about commercial freight traffic in the Federal Republic of Germany please contact:  
Berufsgenossenschaft für Fahrzeughaltungen  
Fachausschuss “Verkehr”  
Sachgebiet “Fahrzeuge”  
Postal address:  
Ottenser Hauptstrasse 54  
D-22765 Hamburg  
+49 (0) 40 39 80 - 0  
+49 (0) 40 39 80-19 99  
 
Phone  
Fax  
 
Home page  
 
1.2.10 Quality system  
Worldwide competition, increased quality requirements placed on the overall product by customers, national and international product  
liability legislation, new forms of organisation and increasing pressure on costs are demanding effective quality assurance systems in all  
areas of the automotive industry.  
The requirements of a quality management system of this kind are described in DIN EN ISO 9001.  
For the reasons stated above, Volkswagen AG strongly recommends that all body builders should set up and maintain a quality  
management system with the following minimum requirements:  
Definition of responsibilities and authorisations including organisational plan.  
−
−
−
−
−
−
−
−
−
−
−
Description of the processes and procedures.  
Appointment of a quality management representative.  
Performing contract and build feasibility checks.  
Performing product checks based on specified instructions.  
Regulating the handling of faulty products.  
Documentation and archiving of test results.  
Ensuring the quality records of employees are up to date.  
Systematic monitoring of test equipment.  
Systematic material and parts identification.  
Performing quality assurance measures at the suppliers.  
Ensuring the availability of process, working and test instructions, and that they are up to date, in the departments and in the  
workplace.  
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1.3 Planning bodies  
Practical note  
In addition to a user and maintenance friendly design (see  
chapter 5.4 “Corrosion protection”), the right choice of  
materials and therefore observance of corrosion protection  
measures are important during the planning of bodies.  
1.3.1 Selecting the base vehicle  
The base vehicle needs to be selected carefully to ensure safe usage in the respective field.  
When planning, please consider the following for the use in question:  
−
−
−
−
−
−
Wheelbase  
Engine/gearbox  
Final drive ratio  
Gross vehicle weight rating  
Centre of gravity  
Electrics – scope  
Practical note  
Before carrying out body building or conversion measures,  
the supplied base vehicle should be checked with regard to  
the fulfilment of applicable requirements.  
You will find more information on the available body versions in the sales documentation.  
Please contact us (see chapters 1.2.1.1 “Contact in Germany” and 1.2.1.2 “International contact”).  
Information  
On the Volkswagen AG homepage, you can put together  
your vehicle using the configurator and view the special  
equipment available:  
Volkswagen Commercial Vehicles  
 
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1.3.2 Vehicle modifications  
Before starting work on the body, the body builder should check whether  
−
−
the vehicle is suitable for the planned body  
the chassis type and the equipment also correspond with the operating conditions after the conversion.  
Build dimension drawings, product information and technical data can be obtained from the relevant department or via the  
communication system for the planning of bodies (see chapter 1.2.1.1 “Contact in Germany”, 1.2.1.2 “International contact” and 1.2.2  
“Body builder guidelines, consulting”).  
Furthermore, the special equipment available from the factory should be noted (see chapter 1.4 “Special equipment”).  
Vehicles delivered from the factory comply with European directives and the national laws (except for some vehicles for countries outside  
Europe).  
The vehicles also need to meet the European directives and the national laws after the modifications have been made.  
Information  
Please note that a majority of the EC directives announced  
to date have been annulled by Regulation (EC) 661/2009  
“General Safety”. The EC directives have been replaced by  
new EU directives or UNECE regulations with the same  
corresponding content.  
Practical note  
Sufficient space must be provided in order to guarantee the  
function and operating safety of the components.  
Warning note  
Do not modify the steering or brake system! Modifications  
to the steering and brake system can result in these systems  
no longer working correctly and failing. This may result in  
the driver losing control of the vehicle and causing an  
accident.  
Practical note  
Modifications to the noise encapsulation can have effects  
which are relevant to registration.  
1.3.3 Vehicle acceptance  
The officially recognised appraiser or tester from the body builder must be informed about modifications to the chassis.  
Practical note  
Country-specific laws, directives and approval regulations  
shall be observed!  
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1.4 Special equipment  
We recommend using the special equipment from Volkswagen AG that can be obtained with a PR number for optimum adaptation of the  
body to the vehicle.  
You can obtain information on special equipment provided by Volkswagen under PR numbers from your Volkswagen dealership, your  
importer or in your contact options for product and vehicle information for body builders (see chapter 1.2.1 “Product and vehicle  
information for body builders”).  
Information  
You can also put together your vehicle using the  
configurator on the Volkswagen AG homepage and view the  
special equipment available:  
Volkswagen Commercial Vehicles  
 
Special equipment (e.g. frame reinforcements, anti-roll bars etc.) or equipment fitted later increase the kerb weight of the vehicle.  
The actual vehicle weight and the axle loads should be determined and documented by weighing before and after the conversion. Not all  
additional equipment can be installed into every vehicle without problems. This applies in particular if it is fitted later on.  
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1.5 Commercial aspects  
1.5.1 Restraint system  
Warning note  
–
–
Changes to the restraint system are not permissible.  
Airbags are explosive. Handling, transport and storage  
of airbags are subject to legislation on potentially  
explosive substances, and the responsible public  
authority or government agency shall therefore be  
notified. Purchase, transport, storage, installation and  
removal as well as disposal are only allowed to be  
performed by trained staff in accordance with the  
corresponding safety regulations.  
–
–
Do not alter, modify or relocate the airbag, the  
restraint system’s sensor and modules, or any of its  
components.  
Attachments or modifications to the front of the  
vehicle may have an adverse effect on the timing of  
airbag triggering and result in unsafe deployment of  
safety equipment.  
–
See also Section 5.2 “Airbag Supplemental Restraint  
System (SRS).”  
1.5.2 Drilling and welding  
Drilling and welding of the frame and body must be carried out in accordance with the guidelines in this document.  
1.5.3 Minimum requirements for the brake system  
Modifications to the anti-lock brake system (ABS), traction control system (TCS) and electronic stability control (ESC), electronic brake servo  
(EBB) and driver assistance technologies are not permitted.  
1.5.4 Road safety  
The respective instructions should be strictly followed to ensure operational and road safety of the vehicle.  
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1.6 Electromagnetic compatibility (EMC)  
Warning note  
-
Do not secure aerial cables to the vehicle’s original  
wiring, to fuel lines or to brake lines.  
-
Keep aerial and power cables at least 10 cm (4 inches)  
away from electronic modules and airbags.  
Information  
-
It is the responsibility of the body builder to ensure  
that all equipment installed in the vehicle complies  
with applicable local laws and other requirements.  
Installation of some aftermarket electronic devices  
could affect the performance of vehicle functions that  
use radio frequency signals such as broadcast  
receivers, tyre pressure monitoring system,  
pushbutton start, Bluetooth connectivity or satellite  
navigation.  
-
All radio frequency transmitters in your vehicle (e.g.  
mobile phones and amateur radio transmitters) must  
comply with the parameters in the following figures  
and tables. We do not stipulate any other special  
terms or conditions for installations or use.  
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1.6.1 Pickup  
MHz frequency band  
Maximum output power in watts (Peak RMS)  
Aerial position  
1–30  
50  
50  
50  
50  
50  
10  
1
50–54  
2, 3  
2, 3  
2, 3  
2, 3  
2, 3  
68–88  
142–176  
380–512  
806–870  
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1.7 Raising the vehicle with a jack  
Warning note  
–
–
–
Ensure that the jack’s screw thread is adequately  
lubricated before use.  
If possible, the socket should be used on level, solid  
ground.  
Turn off the ignition and fully apply the  
electromechanical parking brake before raising the  
vehicle.  
–
–
–
The jack supplied with this vehicle is for changing  
wheels only.  
Use the jack only when changing a wheel in an  
emergency.  
See the owner's manual for the procedure and jacking  
points on all vehicle versions.  
Practical note  
When converting the vehicle, make sure that access to the  
spare wheel is not blocked. Ensure that sufficient clearance  
remains for successful lowering and raising of the spare  
wheel. Failure to comply with this requirement may result in  
damage to the winch mechanism and unsafe position of the  
spare wheel.  
Information  
–
When using the vehicle jack, read the operating  
manual for information on proper use.  
The spare wheel winch is located above the spare  
wheel and is accessible from the rear of the chassis  
frame.  
–
–
The jack must be mounted and secured to the vehicle  
appropriately to ensure safety, durability, and  
accessibility.  
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Warning note  
-
When raising the vehicle with the jack, for your own  
safety, never get under the vehicle.  
1.7.1 Vehicle jacking points and axle stand positions  
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1.8 Raising the vehicle with a lifting platform  
Warning note  
When raising the vehicle with a two-pillar lifting platform to  
remove the engine/gearbox or rear axle, make sure the  
vehicle is secured to the hoist with vehicle restraint straps  
to prevent tipping. Failure to comply with these instructions  
could result in serious injuries.  
All vehicles  
Practical note  
–
When raising the vehicle with a two-pillar lifting  
platform, vehicle lift arm adapters must be used under  
the lifting points.  
–
–
When raising the vehicle with a two-pillar lifting  
platform, do not exceed the maximum kerb weight.  
It is important that only the correct lifting and support  
locations are used at all times.  
Warning note  
Ensure that the modified vehicle meets all relevant  
regulatory requirements.  
Practical note  
Ensure that the diesel fuel filter (if fitted) under the vehicle  
floor in front of the gearbox cross member is not damaged.  
If care is not taken when placing the lifting bags, the fuel  
system may be damaged.  
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1.9 Noise, vibration and harshness (NVH)  
Modifications to the drive train, engine, gearbox, exhaust gas, air intake system or tyres can affect exterior noise emissions. For this reason,  
the exterior noise level of the modified vehicle must be verified.  
The interior noise level should not be worsened by the conversion. Reinforce panels and structures as needed to prevent vibration.  
Consider the use of sound deadening material on panels.  
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1.10 Vehicle transport aids and vehicle storage  
Practical note  
–
–
–
–
Disconnect the battery if the vehicle will not be moved  
for more than 30 days.  
Ensure that protectors are not removed from an  
incomplete vehicle until the conversion has begun.  
Make sure that components removed during the  
conversion are kept clean and dry.  
Ensure that components removed during the  
conversion are reinstalled in the same vehicle.  
In addition:  
Raise the wipers and position them away from the windscreen.  
All air intakes should be closed.  
Increase the normal tyre pressure by 0.5 bar / 7.25 psi / 50 kPa.  
The handbrake system should not be used.  
Apply appropriate wheel chocks to prevent rolling.  
Deterioration of the vehicle body is a significant risk during storage, so proper storage procedures must be followed, including regular  
inspections and maintenance.  
Claims arising from deterioration caused by improper storage, maintenance or handling will not be the responsibility of Volkswagen AG.  
Vehicle processors must establish their own procedures and precautions, especially when vehicles are stored outdoors, as they are  
exposed to any number of airborne contaminants.  
The following may be considered a reasonable approach to storage:  
Short-term storage:  
Where possible, vehicles should be stored in an enclosed, dry, well-ventilated area based on firm, well-drained ground that is free of long  
grass or weeds and, where possible, protected from direct sunlight.  
Vehicles should not be parked near trees or near water, as additional protection may be required for certain areas.  
Long-term storage:  
The battery should be disconnected but not removed from the vehicle.  
The wiper blades should be removed and placed in the vehicle. Ensure that the wiper arms are suitably restrained from resting against the  
windscreen.  
Engage a gear and fully release the parking brake. Secure the wheels with wheel chocks if the vehicle is not parked on level ground.  
Set the climate control to the “open” position to provide ventilation where possible.  
If protective film was applied during manufacture, it must be left on the vehicle until it is made ready for delivery, but it must be removed  
after a storage period of six months at the most (the film is date stamped to indicate the required removal date).  
Ensure that all windows, doors, the bonnet, rear lid and luggage compartment lid are fully closed and the vehicle is locked.  
The handover inspection (PDI) is the final opportunity to ensure a battery is fit for purpose before the customer takes delivery of their new  
vehicle. Prior to handover of the vehicle to the customer, the battery must be inspected and appropriate action taken. The results of the  
inspection must be recorded on the PDI repair order.  
Batteries:  
To ensure that the battery is properly maintained and to prevent premature failure, it is  
necessary to periodically check and charge the battery while a vehicle is not in use.  
Leaving a battery below its optimum state of charge for an extended period of time can cause premature battery failure.  
To reduce the probability of premature battery failure, we recommend:  
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Keeping the battery connected – monthly controls should be carried out.  
Disconnecting the battery – a three-month check should be carried out.  
Action / time in storage  
Monthly  
Every 3 months  
Check that the vehicle is  
clean  
x
-
Remove external  
contaminants  
x
-
Check battery condition and  
recharge if necessary  
Connected  
Disconnected  
Visually inspect tyres  
Check for condensation in  
the vehicle interior  
x
-
-
x
Run the engine until the  
coolant gauge reaches  
temperature (60°C) with the  
air conditioning system on, if  
applicable  
-
x
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1.11 Assemblies and ergonomics  
1.11.1 General guidelines for assemblies  
The body builder must ensure that adequate clearance is maintained from moving components such as axles, fans, steering, brake system  
etc. under all drive conditions.  
The body builder is responsible for all installed components during the conversion. Durability must be confirmed by appropriate test  
procedures .  
Warning note  
Do not modify, drill, cut or weld any suspension  
components, especially the steering gear system, subframe  
or anti-roll bars, springs or shock absorbers including  
mounting brackets.  
1.11.2 Driver’s operating area  
Controls and/or equipment that must be used while driving, should be within reach of the driver so as not to impair the driver’s control.  
1.11.3 Driver’s field of vision  
Warning note  
Ensure that the modified vehicle meets all relevant  
regulatory requirements.  
1.11.4 Effects of conversions on parking aids  
Warning note  
Ensure that cab-mounted monitors comply with the interior  
package and safety requirements.  
For conversions that require a reversing camera, the return signal can be recorded as described in the section on reversing lights. For more  
information, see chapter 4.6.8.  
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1.11.5 Aids for entering and exiting vehicles  
Steps  
Practical note  
–
–
–
Ensure that reinforcements are installed so as to  
maintain the strength of the original body structure.  
Ensure that the modified vehicle meets all relevant  
regulatory requirements.  
If the conversion changes the type-approved  
dimensions, a new type approval must be obtained.  
On some derivatives of the Amarok, steps are part of the basic equipment or can be ordered as optional equipment. Please check for  
availability.  
If additional or alternative steps are installed, the required ground clearance must be observed.  
The body builder must ensure that a movable step automatically assumes the driving position as soon as the vehicle is moved. The tread  
surface of the step must be non-slip.  
Exterior mirror  
Information  
–
–
The overall width of the Amarok with the exterior rear  
view mirrors extended is 2,208 mm.  
The maximum vehicle width (X) is 1,910 mm.  
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1.11.6 Worldwide Harmonised Light Vehicles Test Procedure (WLTP) calculation inputs  
The following attributes are required as part of the WLTP calculation for finished vehicles:  
1.11.7 Mass of the finished vehicle  
All modifications and changes that affect the actual mass of the vehicle must be taken into account. The definition of actual mass is set out  
in the provisions of Regulation 2018/1832 Annex  
XXI. The actual mass of the finished vehicle must be specified for the front and rear axles. This weight distribution is important if the  
finished vehicle has mixed tyres between front and rear.  
1.11.8 Frontal surface  
All modifications and changes that affect the front surface of the finished vehicle must be taken into account. For more information, see  
later in this section.  
1.11.9 Rolling resistance of tyres  
Modifications to the tyres installed on the finished vehicle must be accounted for. The efficiency class and tyre class are needed to  
determine the correct calculation. This can be found on the tyre label according to the following example:  
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Exceeding attribute limits  
If the vehicle converter wishes to make use of the base vehicle approval, the vehicle converter must stay within the limits defined in the  
body builder guidelines and the emission type approval applicable to the vehicle. It is the responsibility of the vehicle converter to ensure  
compliance with these defined limits in order to maintain emissions performance. If vehicle converters wish to exceed the limits, they must  
seek clarification from the relevant technical service or type approval authority. In this case, the base approval may become invalid and the  
vehicle converter may have to recertify the vehicle against the exceeded limits.  
1.11.10 Key to vehicle dimensions  
General information  
Vehicles with increased ride height (4x2 / 4x4)  
Vehicles with low ride height  
(4x2)  
Dimensions (mm)  
Wheelbase length  
3,270  
3,270  
1,780  
1,707  
Total vehicle height at base kerb weight – measured at aerial base  
Double cab 1,875–1,886  
Total vehicle height – measured at aerial base with MAX rear axle load  
Double cab 1,810  
All dimensions are subject to manufacturing tolerances and refer to minimum specification models and do not include additional  
equipment. Height dimensions show the range for minimum to maximum weight range and are for reference only.  
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1.11.11 Recommended main load range dimensions  
Vehicle  
A (mm)  
B (mm)  
C (mm)  
Double cab  
2,104  
2,114  
755  
1.11.12 WLTP front area calculation  
Information  
All standard and optional equipment has already been  
taken into account. In other words, the vehicle frontal area  
of the base vehicle including the mirrors.  
In order to determine the WLTP values required for type  
approval, data must be entered into the Volkswagen  
Commercial Vehicles WLTP calculator. See chapter “1.2.1.7  
Worldwide Harmonised Light Vehicles Test Procedure”.  
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Calculating the frontal area  
Item  
Description  
1
2
3
4
Base vehicle  
Box in cab width and roof height of base vehicle  
Box surface 0.5 m² larger than frontal area of base vehicle  
Box surface 1 m² larger than frontal area of base vehicle  
Dimension of the end face of the vehicle  
Measurement  
mm  
A
1,820 (measured from the road surface to the roof surface)  
B
C
D
E
1,860  
1,839  
1,945  
2,214  
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Configuration of the front area of the vehicle  
Dimension of the frontal area  
Front area of the vehicle  
A ) Base vehicle + body [m²]  
A1) Additional surface due to body [m²]  
1 = base vehicle  
2.873  
3.175  
-
2 = box in cab width and roof height like basic vehicle  
0.302  
3 = area of box approx. 0.5 m² larger than front area of base vehicle 3.373  
0.500  
1.000  
4 = area of box approx.1 m² larger than front area of base vehicle  
3.873  
The body builder only has to calculate the front area of the assembled unit (AxB) in m².  
1.11.13 Number plate  
Front number plate:  
Warning note  
–
The attachment of a number plate to the front of the  
vehicle must comply with local regulations.  
No part of a motor vehicle registration number shall  
be obscured by standard equipment, regular  
production options, or equipment in accordance with  
local regulations.  
–
The number plate shall be mounted on the front of the vehicle forward of and parallel to the front “axle” so that no part of the number  
plate is more than 1,300 mm above the ground.  
Rear number plate:  
Warning note  
–
–
The attachment of a number plate to the rear of the  
vehicle must comply with local regulations.  
No part of a motor vehicle registration number shall  
be obscured by standard equipment, regular  
production options, or equipment in accordance with  
local regulations.  
The number plate shall be mounted on the rear of the vehicle so that no part of the number plate is more than 1,300 mm above the  
ground.  
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1.12 Assemblies and ergonomics – specifications  
1.12.1 Recommended body dimensions  
Warning note  
–
Vehicles equipped with Electronic Stability Control  
(ESC) must not have the wheelbase modified or any  
type of frame extension.  
–
Ensure that the mass added to the vehicle does not  
have an adverse effect on vehicle stability.  
Information  
–
Extreme rear overhang can result in unacceptable  
loading conditions, which can reduce the load on the  
front axle and result in unacceptable handling and  
braking characteristics. Ensure that the centre of  
gravity of the body and payload are not outside the  
recommended range.  
–
An excessively high centre of gravity could affect  
vehicle stability. Make sure that the centre of gravity  
of the body and the payload is not outside the  
recommended range.  
(See also chapter 5.1 “Body”)  
–
–
If there is a frame extension behind the rear axle, we  
recommend limiting the total rear overhang to a  
maximum of 50% of the vehicle wheelbase.  
If a ball coupling is attached to the vehicle, the body  
dimensions must include a clearance zone for ball  
couplings in accordance with local statutory  
requirements.  
–
–
If the conversion requires an overhang of more than  
50%, please contact your Volkswagen Commercial  
Vehicles partner or importer.  
Load-bearing structures should not be mounted on an  
existing cargo box. Mounting points for the body are  
provided on the frame.  
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Dimensions (mm)  
Double cab  
Description  
A
Frame length behind the rear of the cab (without tail light cross member) 1,517 mm  
B
C
Legislation on underbody bars and towing devices must be complied with  
Maximum recommended exterior vehicle size *  
2,400 above top of frame, provided load distribution  
requirements are met  
497 mm  
D
E
Centre line from front outside of body to rear axle  
Maximum recommended rear overhang  
(50% of vehicle wheelbase), provided load distribution  
requirements are met  
F
G
H
J
Distance between the rear of the cab and the vehicle body  
At least 25 mm  
Ensure that local lighting laws are complied with. See also: Exterior lighting (chapter 4.6).  
Distance between the top of the cab and the vehicle body  
Maximum exterior vehicle width (without side step)  
30 mm  
1,910  
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*For WLTP markets, these dimensions should be disregarded. Refer to the relevant WLTP dimensions. See also chapter 1.11 “Assemblies  
and ergonomics”.  
All dimensions (shown in mm) are subject to manufacturing tolerances and refer to minimum specification models that do not include  
additional equipment. The illustrations are for orientation purposes only.  
1.12.2 Chassis cab body – basic dimensions and weights  
Chassis cab body – double cab illustrated  
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Chassis cab body  
Description  
Double cab  
5,370/5,225  
1,910  
A
B
Overall length (mm) (with rear bumper) / (without rear bumper)  
Overall width – without exterior mirrors – without side step (mm)  
C
C
D
E
E
F
Overall height (mm)  
1,772–1,781  
1,877–1,886  
3,270  
Overall height * (mm) (brought to the base of the aerial mast)  
Wheelbase (mm)  
Toe (mm)  
1,650  
Toe * (mm)  
1,620  
Rear overhang (mm) (with rear bumper) / (without rear bumper) (without 1,215/1,070  
ball coupling)  
* Vehicles with raised ride height, 4x2 High Ride and 4x4  
1.12.3 Unladen mass and payload  
Warning note  
Check local regulations for legal requirements.  
Details on vehicle kerb mass and payload capacities can be provided by your Volkswagen Commercial Vehicles partner or importer.  
1.12.4 Gross vehicle mass and axle load  
Warning note  
Check local regulations for legal requirements.  
Details on the axle loads for your vehicle can be provided by your Volkswagen Commercial Vehicles partner or importer .  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 44 of 166  
1.12.5 Front, rear and side skid plate  
Warning note  
Check local regulations for legal requirements.  
Front skid plate, rear skid plate and side skid plate must meet the requirements of local design regulations.  
1.12.6 Rear skid plate – chassis with cab  
Warning note  
Warning note  
Check local regulations for legal requirements.  
Warning  
The rear skid plate must be designed in accordance with ECE 58 or applicable local legislation if required by local market regulations.  
1.13 Components – specifications  
Material specification, strength and torque  
Standard material and tightening torques (Nm) for screws/bolts: ISO 898-1, nuts: ISO 898-2  
Category 4.8  
Minimum  
Category 8.8  
Minimum  
Category 10.9  
Thread size  
M4  
Maximum  
1.4  
Maximum  
3.4  
Minimum  
Maximum  
1.1  
2.2  
3.7  
2.4  
4.9  
8.5  
20  
M5  
2.7  
6.7  
M6  
4.7  
11.5  
28  
11  
25  
15  
35  
M8  
M10  
M12  
M14  
M16  
M18  
M20  
M22  
M24  
41  
55  
50  
70  
68  
92  
95  
125  
200  
310  
400  
540  
745  
945  
113  
170  
250  
345  
470  
600  
153  
230  
315  
430  
590  
750  
150  
230  
315  
435  
590  
755  
This torque table is a recommendation and the body builder is responsible for ensuring the optimum torque on the assembled  
component. For a specific vehicle torque specification, refer to the corresponding VW Commercial Vehicles workshop manual or contact  
your local Volkswagen Commercial Vehicles partner or importer.  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 45 of 166  
1.14 Load distribution – specifications  
1.14.1 Load distribution calculations – weight distribution of driver and front passenger  
Practical note  
–
–
Do not exceed the gross axle weight ratings.  
Do not exceed the permissible total mass of the  
vehicle.  
–
The tyre manufacturer’s specifications must be  
complied with.  
Information  
–
–
–
Uneven load distribution may result in unacceptable  
handling and braking characteristics.  
Overloading the vehicle may result in unacceptable  
ground clearance.  
The centre of mass of the body and the payload it  
contains should be within the specified dimensions.  
Avoid one-sided load distribution.  
–
–
For further information, please contact your local  
Volkswagen Commercial Vehicles partner or importer.  
DoubleCab  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 46 of 166  
Weight distribution for driver and front passenger (vehicle with DoubleCab)  
Weight distribution per person (kg)  
“A” wheelbase (mm)  
“B” front seats and “C” second row seats  
driver (mm)  
(mm)  
3,270  
On the front axle  
On the rear axle  
Total  
75  
1,540  
-
-
40  
21  
35  
54  
2,360  
75  
1.14.2 Centre of gravity  
Information  
–
–
–
The calculations specified here do not include the ball  
coupling and other accessories fitted by the body  
builder.  
“Additional mass” includes all additional equipment  
and cargo, but excludes passengers seated in standard  
cabs.  
For double cab vehicles, there is a limit to the  
additional mass that must be considered, in addition  
to not exceeding the gross axle and towing weights.  
DoubleCab  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 47 of 166  
Critical centre of gravity of DoubleCab  
Model  
Recommended centre of gravity position for additional mass  
‘C’ max (mm)**  
‘A’ min (mm)  
‘B’ max (mm)  
4x2  
-
3,615  
3,615  
740  
590  
4x2*  
2,435  
4x4  
2,435  
3,615  
590  
* 4x2 vehicles with increased ride height.  
**Dimension ‘C’ is taken from the body fasteners.  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 48 of 166  
1.15 Towing  
1.15.1 Towing requirements  
If a towing device is required, the vehicle converter should use a Volkswagen-approved tow-bar.  
1.15.2 Towing  
Warning note  
–
Do not exceed the total mass or maximum trailer  
weight specified for your vehicle. Refer to your vehicle  
operating manual for maximum trailer weight  
specifications.  
–
–
Ensure that the drawbar load of the ball coupling is  
within the specified range.  
Towing trailers that exceed the maximum gross  
vehicle weight rating for the trailer will exceed the  
limits of your vehicle and may result in damage to the  
engine, gearbox and structure, loss of vehicle control,  
vehicle rollover, and personal injury.  
–
–
Do not cut, drill, weld or modify the ball coupling.  
Modification of the ball coupling could reduce the  
maximum trailer weight.  
Do not exceed the maximum vertical load of the  
towing bracket. Failure to follow this instruction may  
result in loss of control of your vehicle and personal  
injury.  
The following applies to towing devices installed by the vehicle converter:  
-
-
The maximum trailer weight must not exceed that of the unmodified vehicle.  
All modifications to the vehicle must be described in the vehicle owner's manual or a separate description  
that shall be enclosed with the vehicle documentation.  
-
-
Ball coupling installations must meet the requirements of local regulatory standards.  
Whenever frame drilling is necessary, use tube reinforcement.  
See also chapter 5.5 “Frame and body assembly”.  
1.15.3 Towing capacities and specifications  
Information  
Refer to your vehicle operating manual for maximum trailer  
weight specifications.  
Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition  
The new Amarok – Page 49 of 166  

Related Topics

1.1 Introduction 1.2 General notes 1.3 Planning bodies 1.4 Special equipment 1.5 Commercial aspects 1.6 Electromagnetic compatibility (EMC) 1.7 Raising the vehicle with a jack 1.8 Raising the vehicle with a lifting platform 1.9 Noise, vibration and harshness (NVH) 1.10 Vehicle transport aids and vehicle storage 1.11 Assemblies and ergonomics 1.12 Assemblies and ergonomics ? specifications 1.13 Components ? specifications 1.14 Load distribution ? specifications 1.15 Towing

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