Get General information -> 1.11 Assemblies and ergonomics Guide for Volkswagen Amarok Truck Second Generation (2022-2025)

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.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

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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.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 35 of 166

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:

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 36 of 166

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

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.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 37 of 166

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”.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 38 of 166

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

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 39 of 166

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.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 40 of 166

General information -> 1.11 Assemblies and ergonomics for Your Volkswagen Amarok Truck Second Generation (2022-2025)

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