Get General information -> 1.2 General notes Guide for Volkswagen Amarok Truck Second Generation (2022-2025)

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.

−

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:

−

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:

−

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

−

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

−

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:

−

Classified as “safe”

If the overall vehicle is classified as “safe”, the Sales department can subsequently issue the LONO certificate.

−

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:

−

Documents preferably in standardised digital formats (e.g. PDF, DXF, STEP)

Technical data and documentation should be complete

The following details must be included:

−



−

Vehicle type

Vehicle equipment (chassis, panel van, window van, etc.)

Wheelbase

Frame overhang

Vehicle identification number (if already available)

−

Any deviations from these body builder guidelines must be indicated on all documentation

−

Axle load calculation

−

All data about dimensions, weight and centre of gravity (weighing certificate)

−

Special operating conditions (e.g. poor road conditions, extreme dust, high altitude, or ambient temperature extremes)

−

Certificates (e-registration, seat tensile test)

−

Attachment of the body on the vehicle

−

Subframe:



−

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)



−

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

−

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

−

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:

−



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:

−

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:

−

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):

−

Practical note

When connecting a battery charger, the following

connection specification must be observed under all

circumstances:

−

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:

−

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:

−

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.

−

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.

−

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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General information -> 1.2 General notes for Your Volkswagen Amarok Truck Second Generation (2022-2025)

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