Amarok Body Builder Guidelines 2013 PDF

Body builder guidelines 2013
Body builder guidelines

Amarok
Table of contents
Table of contents
Table of contents.............................................................................................................................................................................................. 2
1 General information .................................................................................................................................................................................... 6
1.1 Introduction ............................................................................................................................................................................................ 6
1.1.1 Concept of these guidelines........................................................................................................................................................ 7
1.1.2 Means of representation ............................................................................................................................................................. 8
1.1.3 Vehicle safety ............................................................................................................................................................................... 9
1.1.4 Operational safety..................................................................................................................................................................... 10
1.2 General notes ................................................................................................................................................................................ 11
1.2.1 Product and vehicle information for body builders............................................................................................................... 11
1.2.1.1 Contact ........................................................................................................................................................................... 11
1.2.1.2 Conversion Portal ......................................................................................................................................................... 12
1.2.1.3 Electronic Repair and Workshop Information from Volkswagen AG (erWin*) .................................................... 13
1.2.1.4 Genuine parts online ordering portal* ....................................................................................................................... 14
1.2.2 Body builder guidelines and consulting ................................................................................................................................. 14
1.2.2.1 Safety certificate ........................................................................................................................................................... 15
1.2.2.2 Application for the safety certificate .......................................................................................................................... 15
1.2.2.3 Legal entitlements ......................................................................................................................................................... 16
1.2.3 Warranty and product liability of the body builder .............................................................................................................. 16
1.2.4 Ensuring traceability .................................................................................................................................................................. 17
1.2.5 Trademarks ................................................................................................................................................................................. 17
1.2.5.1 Positions on rear of the vehicle ................................................................................................................................... 17
1.2.5.2 Appearance of overall vehicle .................................................................................................................................... 17
1.2.5.3 Non-Volkswagen trademarks .................................................................................................................................... 17
1.2.6 Recommendations for vehicle storage .................................................................................................................................... 18
1.2.7 Compliance with environmental rules and regulations ........................................................................................................ 19
1.2.8 Recommendations for inspection, maintenance and repair................................................................................................. 20
1.2.9 Accident prevention................................................................................................................................................................... 20
1.2.10 Quality system ......................................................................................................................................................................... 21
1.3 Delivery range...................................................................................................................................................................................... 22
1.4 Advantages of the concept ................................................................................................................................................................ 23
1.5 Planning bodies ................................................................................................................................................................................... 24
1.5.2 Vehicle modifications ................................................................................................................................................................ 25
1.5.3 Vehicle approval........................................................................................................................................................................ 25
2 Technical data for planning ...................................................................................................................................................................... 27
2.1 Base vehicle.......................................................................................................................................................................................... 27
2.1.1 Vehicle dimensions .................................................................................................................................................................... 27
2.1.1.1 Basic data Single Cab and Double Cab .................................................................................................................... 29
2.1.2 Overhang angle and ramp angle ............................................................................................................................................ 31
2.1.3 Vehicle centre of gravity ........................................................................................................................................................... 32
2.1.4 Bodies with a high centre of gravity ....................................................................................................................................... 32
2.1.4.1 Extremely high centres of gravity ( >800 mm) ......................................................................................................... 32
2.1.5 Determining centre of gravity .................................................................................................................................................. 33
2.1.6 Maximum dimensions ............................................................................................................................................................... 34
2.1.7 Steerability.................................................................................................................................................................................. 36
2.2 Running gear ........................................................................................................................................................................................ 37
2.2.1 Permitted weights and unladen weights ................................................................................................................................ 37
2.2.1.2 One-sided weight distribution .................................................................................................................................... 38
Volkswagen Commercial Vehicles – Body builder guidelines – Edition May 2013 The Amarok – Page 2 of 130
Table of contents
2.2.2 Turning circle............................................................................................................................................................................... 39

2.2.3 Authorised tyre sizes ................................................................................................................................................................. 39
2.2.4 Modifications to axles ............................................................................................................................................................... 39
2.2.5 Modifications to the steering system....................................................................................................................................... 39
2.2.6 Brake system and brake control system ESP* ........................................................................................................................ 40
2.2.6.1 General notes ................................................................................................................................................................ 40
2.2.6.2 Vehicle stability and ESP*............................................................................................................................................ 41
2.2.6.3 Influence of vehicle conversions on the function of the brake regulation system ESP* ....................................... 42
2.2.6.4 Downgrading ESP* ....................................................................................................................................................... 43
2.2.6.5 Activating the ESP* ....................................................................................................................................................... 43
2.2.7 Modification of springs, suspension mounting, dampers ..................................................................................................... 44
2.2.8 Wheel alignment settings ......................................................................................................................................................... 44
2.2.9 Wings and wheel houses .......................................................................................................................................................... 44
2.2.10 Overhang extension ................................................................................................................................................................ 45
2.2.10.1 Requirements for trailer operation with overhang extension ........................................................................................ 46
2.2.11 Wheelbase modification......................................................................................................................................................... 47
2.3 Body-in-white ...................................................................................................................................................................................... 48
2.3.1 Roof loads/vehicle roof ............................................................................................................................................................ 48
2.3.1.1 Dynamic roof loads ...................................................................................................................................................... 48
2.3.1.2 Static roof loads ............................................................................................................................................................ 48
2.3.2 Modifications to the body-in-white......................................................................................................................................... 49
2.3.2.1 Screw connections ........................................................................................................................................................ 49
2.3.2.2 Welding work ............................................................................................................................................................... 50
2.3.2.3 Welded connections ..................................................................................................................................................... 50
2.3.2.4 Selection of welding process....................................................................................................................................... 51
2.3.2.5 Spot welding ................................................................................................................................................................. 51
2.3.2.6 Shielding gas hole spot welding ................................................................................................................................ 52
2.3.2.7 Tacking ........................................................................................................................................................................... 53
2.3.2.8 Welding is not allowed................................................................................................................................................ 53
2.3.2.9 Corrosion protection after welding ............................................................................................................................ 53
2.3.2.10 Corrosion protection measures ................................................................................................................................. 53
2.3.2.11 Planning measures ..................................................................................................................................................... 53
2.3.2.12 Component design measures.................................................................................................................................... 55
2.3.2.13 Coating measures ....................................................................................................................................................... 55
2.3.2.14 Work on the vehicle ................................................................................................................................................... 55
2.3.3 Tailgate ....................................................................................................................................................................................... 56
2.4 Interior ................................................................................................................................................................................................... 57
2.4.1 Modifications in the area of airbags ....................................................................................................................................... 57
2.4.2 Modifications in the area of seats ........................................................................................................................................... 57
2.4.3 Forced ventilation ...................................................................................................................................................................... 57
2.4.4 Acoustic insulation ..................................................................................................................................................................... 57
2.5 Electrics/electronics ............................................................................................................................................................................. 58
2.5.1 Lighting ....................................................................................................................................................................................... 58
2.5.1.1 Vehicle lighting devices ............................................................................................................................................... 58
2.5.1.2 Mounting special lights ................................................................................................................................................ 58
2.5.1.3 Installing 3rd brake light ............................................................................................................................................. 58
2.5.1.4 Additional load compartment light ............................................................................................................................ 58
2.5.2 Vehicle electrical system ........................................................................................................................................................... 58
2.5.2.1 Electrical cables/fuses .................................................................................................................................................. 58
2.5.2.2 Additional circuits ......................................................................................................................................................... 59
Table of contents
2.5.2.3 Retrofitting electrical devices ...................................................................................................................................... 60

2.5.2.4 Electromagnetic compatibility..................................................................................................................................... 60
2.5.2.5 Mobile communication systems.................................................................................................................................. 61
2.5.2.6 CAN bus ......................................................................................................................................................................... 61
2.5.3 Electrical interface for special vehicles ................................................................................................................................... 62
2.5.3.1 Position of the interface ............................................................................................................................................... 62
2.5.3.2 Assignment of the terminal strip (UF1) ...................................................................................................................... 64
2.5.3.3 Connector pin assignment and circuit diagrams for interface for special vehicles .............................................. 67
2.5.4 Vehicle battery ........................................................................................................................................................................... 68
2.5.3.1 Installation of additional battery ................................................................................................................................ 68
2.5.5. Digital tachograph (EC monitoring device) ........................................................................................................................... 68
2.6 Engine peripherals/powertrain ......................................................................................................................................................... 69
2.6.1 Engine/powertrain components .............................................................................................................................................. 69
2.6.2 Drive shafts ................................................................................................................................................................................. 69
2.6.3 Fuel system ................................................................................................................................................................................. 69
2.6.4 Exhaust system........................................................................................................................................................................... 70
2.7 Ancillary drives, engine/gearbox...................................................................................................................................................... 71
2.7.2. Driving an ancillary via the 2nd belt track*........................................................................................................................... 72
2.7.3. Specifications of standard refrigerant compressor............................................................................................................... 73
2.7.3.1 Connection measurements of standard refrigerant compressor............................................................................. 74
2.7.4 Installation and removal of the poly V-belt ........................................................................................................................... 78
2.7.4.1 Removal of the belt ...................................................................................................................................................... 78
2.7.4.2 Installation of the belt .................................................................................................................................................. 78
2.7.4.3 Working range of the belt tensioner: ......................................................................................................................... 79
2.7.4.4 Belt routing .................................................................................................................................................................... 80
2.8 Add-ons/units ...................................................................................................................................................................................... 81
2.8.1 Roof rack ..................................................................................................................................................................................... 81
2.8.2 Towing bracket .......................................................................................................................................................................... 82
2.8.3 Other accessories ....................................................................................................................................................................... 83
2.9 Lifting the vehicle ................................................................................................................................................................................. 83
3 Modifications to closed bodies................................................................................................................................................................. 84
3.1 Body-in-white/bodywork .................................................................................................................................................................. 84
3.1.1 Side wall and rear wall cut-outs ............................................................................................................................................. 84
3.1.2 Installation of windows ............................................................................................................................................................ 84
3.1.3 Roof cut-outs .............................................................................................................................................................................. 85
3.1.4 Modifications to the roof .......................................................................................................................................................... 85
3.2 Interior ................................................................................................................................................................................................... 86
3.2.1 Safety equipment....................................................................................................................................................................... 86
4 Modifications to open bodies ................................................................................................................................................................... 87
4.1 Removal of the cargo box .................................................................................................................................................................. 87
4.1.1 Removal of tail lights ................................................................................................................................................................ 88
4.1.2 Releasing the parking brake cable at the rear ...................................................................................................................... 88
4.1.3 Removal of the wheel housing liner ........................................................................................................................................ 89
4.1.4 Removal of the filler neck ......................................................................................................................................................... 90
4.1.5 Unscrewing securing bolts ........................................................................................................................................................ 91
4.1.6 Removal of the bumper ............................................................................................................................................................ 91
4.1.7 Recommendations for attaching the filler neck ..................................................................................................................... 92
4.1.7.1 Diesel filler pipe ............................................................................................................................................................ 93
4.1.7.2 Petrol filler pipe............................................................................................................................................................. 94
4.1.8 Weight of cargo box ................................................................................................................................................................. 94
Table of contents
4.2 Chassis frame ....................................................................................................................................................................................... 95

4.2.1 Ladder frame Amarok DC (Double Cab) ................................................................................................................................ 95
4.2.2 Ladder frame Amarok SC (Single Cab) .................................................................................................................................. 96
4.2.3 Sections, Amarok SC (Single Cab)/Amarok DC (Double Cab) ............................................................................................ 97
4.3 Standard mounting points for special bodies .................................................................................................................................. 98
4.4 Subframe (mounting frame) ............................................................................................................................................................. 100
5 Implementations of special bodies ........................................................................................................................................................ 101
5.1 Conversions for people with disabilities ........................................................................................................................................ 101
5.2 Refrigerated vehicles ......................................................................................................................................................................... 102
5.3 Shelf installation/workshop vehicles .............................................................................................................................................. 103
5.4 Conversions for caravans ................................................................................................................................................................. 104
5.5 Conversions for municipal vehicles ................................................................................................................................................. 105
5.6 Articulated vehicles ........................................................................................................................................................................... 105
5.7 Elevated work platforms .................................................................................................................................................................. 106
5.8 Crane superstructures and lift systems ........................................................................................................................................... 107
6 Technical data........................................................................................................................................................................................... 108
6.1 Build dimension drawings................................................................................................................................................................ 108
6.1.1 Amarok Double Cab................................................................................................................................................................ 108
6.1.2 Amarok Single Cab ................................................................................................................................................................. 108
6.2 Diagrams (foil templates) ................................................................................................................................................................. 109
6.2.1 Amarok Double Cab (all views) ............................................................................................................................................ 109
6.2.2 Amarok Single Cab (all views) .............................................................................................................................................. 109
6.2.3 Side view all derivatives ........................................................................................................................................................ 110
6.3 Circuit diagrams ................................................................................................................................................................................. 111
6.4 CAD models........................................................................................................................................................................................ 111
6.5 Weight tables ..................................................................................................................................................................................... 112
6.5.1 Weight tables Amarok Double Cab ...................................................................................................................................... 112
6.5.1.2 Amarok Double Cab .................................................................................................................................................. 112
6.5.1.3 Amarok Double Cab chassis/CabChassis ............................................................................................................... 114
6.5.2 Weight tables Amarok Single Cab ........................................................................................................................................ 116
6.5.2.1 Amarok Single Cab: ................................................................................................................................................... 116
6.5.2.2 Amarok Single Cab - chassis/CabChassis .............................................................................................................. 117
7 Calculation ................................................................................................................................................................................................ 118
7.1 Determining the centre of gravity .................................................................................................................................................... 118
7.1.1 Determining the centre of gravity in x-direction .................................................................................................................. 118
7.1.2 Determining the centre of gravity in z-direction .................................................................................................................. 120
8 Listings ....................................................................................................................................................................................................... 125
8.1 List of changes ................................................................................................................................................................................... 125
* Electronic Stabilisation Program
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 body types, it is not possible for Volkswagen AG to predict all possible changes,
e.g. in driving properties, stability, weight distribution, centre of gravity of the vehicle and its handling characteristics which can
occur due to the body activities. 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 itself bears the product liability 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 7 chapters so that you can find information rapidly:
2 Technical data for planning
3 Modifications to closed bodies
4 Modifications to open bodies
5 Implementations of special bodies
6 Technical data
7 Listings
Information
For further information see 1.2.1.1 "Contact", 1.2.2

"Body builder guidelines, consulting" and 1.3 "Delivery
range".
The limit values selected in chapter 2 "Technical data

for planning" must be complied with without fail, and
must be used as the basis for planning.
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 a possible risk of

damage to the vehicle.
More information
This note indicates additional information.
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 to comply with national registration

regulations 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:
– 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.
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 in 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.
1.2 General notes
1.2.1 Product and vehicle information for body builders
1.2.1.1 Contact
If you have questions about vehicle models from Volkswagen Commercial Vehicles, you can contact us on the Internet on the
Conversion Portal of Volkswagen AG (www.umbauportal.de) using one of the following methods:
Per
Free hotline
0800-86228836.
(from a German landline)
Volkswagen Customer Support

Letter: Postfach 1998
38436 Wolfsburg
Contact form: http://www.volkswagen-nutzfahrzeuge.de/de/kontakt/ihr_kontakt_zu_uns.htx
Contact for questions about http://www.volkswagen-nutzfahrzeuge.de/de/kontakt/technische_frage.htx

payload increases/reductions:
For swift processing, we require a clearly legible copy of the vehicle documents, logbook or vehicle registration document
together with your question.
1.2.1.2 Conversion Portal
The Conversion Portal of Volkswagen Nutzfahrzeuge AG offers body builders not only a direct point of contact via the free
hotline, but also the opportunity to find out details about products, systems and topics relating to all aspects of Volkswagen
commercial vehicle bodies.
Information
The Conversion Portal of Volkswagen AG can be

reached at the following Internet address:
http://umbauportal.de/
In order to clarify your technical questions on the base vehicle, we offer you as a registered user the opportunity to use the
contact form on the Conversion Portal to make direct contact with support for commercial vehicle body builders.
Information
The contact form of Volkswagen AG can be reached at

the following Internet address:
http://umbauportal.de/kontaktformular
Volkswagen Nutzfahrzeuge AG has developed an innovative partner system with the objective of intensifying cooperation with
you, and to make it easier for the customers and dealers of Volkswagen commercial vehicles to search for a suitable body
builder as easily as possible. In the new Conversion Portal, you as a body builder have the opportunity to select between three
forms of cooperation:
– Registered user
– Integrated partner
– Premium partner
Registered user
As a registered member, you have access to a wide range of technical data and information, such as:
– CAD data
Here, you can order CAD data in Catia V5 and STEP formats for the corresponding vehicles for delivery by post.
Please only request the CAD data for current conversion projects because the data modules are subject to updates.
– Additional technical information

The "Additional technical information" section provides you with detailed information about various topics. The descriptions
help you in planning and carrying out your conversions.
– Marketing
In addition to the product catalogues, we offer you as a registered user access to the sales manuals incl. price information for
our model range in Germany and for export. Furthermore, you receive the current product information documents about
changes & new features on the vehicles in question, on a continuous basis. Using the Fleet Ordering Configurator, you can
access Group systems, and you have up-to-date information for your vehicle configurations.
– List of questions (technical FAQs)

This page contains a list of answers to the most frequently asked questions.
– Newsletter
Subscribe to the technical newsletter and receive regular e-mail notification about current topics. This includes current
technical modifications to Volkswagen commercial vehicles, information about exhibitions, training courses and events as well
as news of general interest relating to bodies and conversions.
Make use of these possibilities and register on the website: http://umbauportal.de/ using the link "Become a partner".
Integrated partner
– Your company will be presented to the users of the Conversion Portal as an integrated partner of Volkswagen Commercial
Vehicles. In this way, you can reach end users and dealers in a targeted way.
– We use your proposals and suggestions for model development.
– As an integrated partner, you have the opportunity to publish your company information and contacts for your customers and
the dealers of Volkswagen Commercial Vehicles.
– Benefit from access to additional information in the logon area for registered users:
Premium partner*
– Your company is presented as a selected specialist in the branch in question, and can present its products in the Conversion
Portal.
– The products you display in the Portal must undergo a safety assessment by Volkswagen Commercial Vehicles. In this way,
Volkswagen Commercial Vehicles confirms that the body or conversion is technically safe. You can also use the safety
assessment for commercial purposes.
– Following prior agreement, your products can be presented together with Volkswagen commercial vehicles at exhibitions.
Information
For more information about the partnership system and

registration, refer to:
http://umbauportal.de/
* Advantages for integrated partners automatically also apply to premium partners.
1.2.1.3 Electronic Repair and Workshop Information from Volkswagen AG (erWin*)
Body builders can access repair and workshop information, e.g.

– Circuit diagrams
– Repair manuals
– Maintenance
– Self-study programmes
via the Electronic Repair and Workshop Information from Volkswagen AG (erWin*).
Information
Volkswagen AG workshop manuals and workshop

information can be downloaded from the Internet at
erWin* (Electronic Repair and Workshop Information
from Volkswagen AG):
http://erwin.volkswagen.de/erwin/showHome.do
* Information system from Volkswagen AG, 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 on the "Genuine Parts Online Ordering Portal":
www.partslink24.com
1.2.2 Body builder guidelines and consulting
The body builder guidelines define the technical requirements for custom body builders and equipment fitters designing and
mounting 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.
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 if you have questions about proposed modifications.
Information
Please use the online contact form:
We require precise information from you in order to respond to your enquiry quickly and comprehensively.
When making enquiries, please enclose two sets of design drawings of the complete scope of the modifications, including all
weights, centre of gravity and dimensions, which also clearly show how the body is attached to the chassis. Please also provide
information about the intended operating conditions of the vehicle with your enquiry.
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.
The work safety regulations of the trade association and the EC Machinery Directive apply.
When making modifications to vehicles, all corresponding and applicable legal regulations, rules, laws and directives must be
observed.
1.2.2.1 Safety certificate
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 safety certificates 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 does not relate to the design of the body overall, its
functions or planned application. 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 safety certificate does not release the body builder who is performing the modifications from its responsibility or 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 safety certificate from
Volkswagen AG does not represent a technical approval for the investigated changes.
Practical note
Country-specific laws, directives and approval

regulations shall be observed!
1.2.2.2 Application for the safety certificate
In order for the evaluation to be carried out for the safety certificate, the following documents and drawings shall be submitted to
the responsible department before the start of work on the vehicle (see 1.2 General notes):
– All deviations from these Volkswagen body builder guidelines
– All data about dimensions, weight and centre of gravity (weighing certificates)
– Attachment of the body on the vehicle
– Application conditions of the vehicle, e.g.
 on rough roads
 in very dusty conditions
 at high altitudes
 at extreme outdoor temperatures
– Certificates (e-registration, seat tensile test)
Complete documentation avoids the need for clarification queries, and makes the processing faster.
1.2.2.3 Legal entitlements
– There is no legal entitlement for a safety certificate to be issued.

– Due to further technical developments and their findings, Volkswagen AG can refuse a safety certificate.
– The safety certificate can be restricted to individual vehicles.
– The subsequent issue of a safety certificate 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 fitter's warranty conditions apply to the body builder's or 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 fitter is solely responsible for the design and assembly of bodies and the execution of conversions.
All conversions must be documented by the body builder or fitter in the service schedule. This service schedule is provided with
every Volkswagen vehicle.
Due to the multitude of conversions 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 shall provide the following information in writing to their customers:
"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."
In individual cases, Volkswagen AG reserves the right to demand proof of the information being passed on to the customer.
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.
* 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".
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 in order to trace the affected vehicle owners, 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. Also, it is recommended for the customers' addresses to be stored and to provide a means for
subsequent owners to be registered.
1.2.5 Trademarks
VW badges and VW emblems 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 also supplied must be fitted in the location intended by Volkswagen.
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 trademarks 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:
– Fill tank.
– Do not park the vehicle under trees, poles, etc.
– Open all ventilation flaps, set blower to maximum speed.
– Disconnect battery(ies).
– Remove dirt, snow and moisture from vehicle (footwell).
– Close windows, doors, bonnet, rear lid and sunroof.
– On manual gearboxes select 1st gear and on automatic select P. Do not engage reverse gear. Do not apply the parking
brake.
– Pull off windscreen wiper bags and clamp polystyrene block under the wiper arm. Please remove any other loose film. ("Aero
wipers"*: remove and store in suitable location inside vehicle.)
– Check the tyre pressure.
Check vehicles weekly for contamination by aggressive media (e.g. bird droppings, industrial dusts) and clean, if required.
Check battery open-circuit voltage every three months. Open-circuit voltage means the voltage of the disconnected battery after
a minimum storage period of 12 hours. Recharge battery in due time before it reaches an open-circuit voltage of 12.4 V ('magic
eye' changes from green to black). Batteries with an open-circuit voltage of less than 11.6 V are in state of exhaustive discharge
and should be disposed of without delay.
Batteries shall be recharged only with current-controlled and voltage-limited chargers. A maximum charging voltage of 14.4 V
shall not be exceeded.
It is recommended to check the tyre inflation pressure every three months.
Reconnect battery negative lead(s) before recommissioning the vehicle.
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,
including with regard to the statutory requirements in
the EU Directive on End-of-Life Vehicles 2000/53/EC.
Fitters of accessories and body builders shall ensure that they comply with all applicable environmental rules and regulations,
especially EU Directive 2000/53/EC concerning end-of-life vehicles and EU Directive 2003/11/EC relating to restrictions on the
marketing and use of certain dangerous substances and preparations ("low flammability" and certain flame-retardant agents) for
closer definition of Directive 76/769/EEC).
The vehicle owner must keep all assembly documentation concerning the modification and hand them 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 lifecycle.
Materials which represent a potential risk such as halogen additives, heavy metals, asbestos, CFCs and chlorinated
hydrocarbons shall be avoided.
– 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 are
allowed to 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".
1.2.8 Recommendations for inspection, maintenance and repair
Maintenance instructions or service schedules outlining inspection and servicing work should 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. Parts and components with a
limited service life which must be checked at regular intervals to ensure service reliability and timely replacement must be
explicitly stated.
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.
The manual shall also state which type of work has to be performed only by the body builders and accessories fitters or their
authorised workshops.
If the body builder's or accessory fitter's scope of supply includes electric, electronic or mechatronic, hydraulic or pneumatic
systems, current flow diagrams and diagnosis routines or similar documentation facilitating a systematic search for faults shall
be provided.
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,
Postal address: Sachgebiet "Fahrzeuge"
Ottenser Hauptstraße 54
D-22765 Hamburg, Germany
Telephone: +49 (0) 40 39 80 - 0
Fax: +49 (0) 40 39 80-19 99
E-mail: [email protected]
Homepage: www.bgf.de
1.2.10 Quality system
Worldwide competition, increased quality requirements by customers on the overall product of the transporter, 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 on a quality management system of this kind are described in DIN EN ISO 9001.
A VDA working group has prepared the guideline entitled "Quality management in the automotive industry - Minimum
requirements on a management system for trailer and body manufacturers - System description and evaluation" for German
body builders, on the basis of DIN EN ISO 9000 ff. Appeared as VDA Vol. 8 [VDA 8] (incl. CD-ROM), order no. A 13DA00080.
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 organisation plan.
– Description of the processes and procedures.
– Appointment of 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.
1.3 Delivery range
The vehicle drawings shown here are symbolic representations. The vehicle drawings are not to scale.
Wheelbase Gross vehicle Amarok Single Cab Amarok Double Cab

weight rating
[mm] [kg] 2-seater 5-seater
3095 2820
3,095 3040
Wheelbase Gross vehicle Amarok Single Cab Amarok Double Cab

weight rating Chassis* Chassis*
[mm] [kg] 2-seater 5-seater
3,095 3040
Information
Further information on the availability of individual

combinations of gross vehicle weight rating, engine,
gearbox and body variants and figures for
consumption, CO2 emissions and energy efficiency
classes can be found in the sales documents and the
configurator on the Volkswagen website:
http://www.volkswagen-nutzfahrzeuge.de/de/cc5.html
or http://umbauportal.de/konfigurator
1.4 Advantages of the concept
– One wheelbase.
– Two weight classes for Double Cab (DC): 2,820 kg and 3,040 kg. For Single Cab (SC) 3,040 kg.
– Frame with cab body and cargo box.
– Large load bed with the largest dimensions in its class.
– Through-load width of 1,222 millimetres between the wheel houses. This means Euro pallets can be loaded crossways to
save space, which is a first in a mid-size pickup. Thanks to these impressive dimensions and a payload up to 1.15 metric
tonnes, it is also possible to transport sports equipment such as quad bikes or large implements.
– Four load securing points in the corners of the load bed for securing the cargo whilst driving.
– Low, flat load bed.
– Max. trailer weight (12% uphill gradient) up to 3,200 kg possible.
– Drawbar weight 120 kg.
– Independent suspension at front and rigid axle at rear.
– cd peak value of 0.42.
– Powerful and economical engine range.
– 3 drive variants:
Basic version: rear-wheel drive (4x2).
Optionally available: permanent four-wheel drive (Double Cab) or non-permanent four-wheel drive (Single Cab + Double
Cab).
– Upshift recommendation, standard feature in all Amaroks.
– High level of vehicle safety.
– ABS and TCS are standard features in the Amarok.
– Electronic differential locks (EDL).
– Offroad-ABS activated at the push of a button to significantly shorten braking distances offroad and on dirt roads.
– Electronic stabilisation program (ESP*, standard EU27) with brake assist system.
– All vehicles with ESP are equipped with a hill-hold assist that holds the vehicle stationary when performing a hill start until the
driver accelerates sufficiently to prevent it's rolling back.
– Low maintenance requirements.
– Heavy-duty spring pack (Single Cab: standard, Double Cab: optional).
– 80 litre tank.
– Extensive range of accessories – ranging from the styling bar, running boards, loadspace cover and multiconnect attachment
system (standard from Trendline onwards) through to a range of alloy wheels.
1.5 Planning bodies
Practical note
During the planning of bodies, the right choice of

materials and thus the observance of corrosion
protection measures are important in addition to a user
and maintenance friendly design (see chap. 2.3.2.10
"Corrosion protection measures").
1.5.1 Selecting the base vehicle
The base vehicle needs to be selected carefully to ensure safe usage in the respective field.
The following must be taken into consideration during planning and adapted for the respective usage:
– Wheelbase
– Engine/gearbox
– Final drive ratio
– Gross vehicle weight rating
– Centre of gravity
– Seating version (number and arrangement)
– Electrics – scope
– Ancillary drives
are taken into consideration during planning and are adapted for the respective application.
Practical note
Before carrying out body building or conversion work,

the supplied base vehicle should be checked with
regard to the fulfilment of applicable requirements.
You will find more information on the available chassis and body versions in 1.3 "Delivery range" or from the responsible
department (see 1.2.1.1 Contact, 1.2.1.2 Conversion Portal and 1.2.2 "Body builder guidelines, consulting").
Information
On the Volkswagen AG homepage, you can put your

vehicle together with the configurator and view the
available optional equipment:
1.5.2 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 responsible department or via the
communication system for the planning of bodies (see chap. 1.2.1.1 "Contact", 1.2.1.2 "Conversion Portal" and 1.2.2 "Body
builder guidelines, consulting").
Furthermore the optional equipment available from the factory should be noted (see 1.6 "Optional equipment").
Vehicles delivered from the factory comply with EC guidelines and the national laws (except for some vehicles for countries
outside Europe).
The vehicles also need to meet the EC guidelines and the national laws after the modifications have been made.
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.
1.5.3 Vehicle approval
The officially recognised appraiser or tester must be informed by the body builder about modifications to the chassis.
Practical note
Country-specific laws, directives and approval

regulations shall be observed!
1.6 Optional equipment
We recommend using the optional equipment from Volkswagen AG that can be obtained with a PR no. for optimum adaptation
of the body to the vehicle.
You can obtain information on the optional equipment provided by Volkswagen under PR nos. from your Volkswagen Customer
Service or in the advice for body builders (see chap. 1.2.1.1 "Contact", 1.2.1.2 "Conversion portal" and 1.2.2 "Body builder
guidelines, consulting").
Please also note chapter 5 "Implementation of special bodies".
Information
Furthermore you can put your vehicle together with the

configurator on the Volkswagen AG homepage and
look at the available optional equipment:
Optional equipment (e.g. reinforced springs, frame reinforcements, anti-roll bars etc.) or equipment fitted later increase the kerb
weight of the vehicle (see also chapter 5 "Implementation of special bodies").
The actual vehicle weight and the axle loads should be determined before the body is built.
Not all additional equipment can be built into any vehicle without problems. This applies in particular if it is fitted later on.
We recommend using the reinforced springs that are available from the factory for bodies and conversions.
Practical note
Permanently installed components increase the

unladen weight of the vehicle, as a result of which the
suspension compression height on the rear axle is
reduced accordingly. In order to ensure an optimum
rear ride height as well as stable road holding in the
case of weight increase, we recommend the heavy-
duty suspension (gross vehicle weight rating 3.04 t).
This is available ex-works by means of PR no. 0WL.

2.1 Base vehicle
2.1.1 Vehicle dimensions
Fig. 2.1.1.1 Vehicle dimensions of Amarok (views: side, front and rear)
Fig. 2.1.1.2 Plan view of Amarok DC (Double Cab)
Fig. 2.1.1.3 Plan view of Amarok SC (Single Cab)
2.1.1.1 Basic data Single Cab and Double Cab
Single Cab Double Cab

Basic data Amarok (all engines)
[mm] [mm]
3,095 3,095
L101 Wheelbase with measuring load 1*
Vehicle length 5181 5181

L103
Vehicle length incl. rear bumper 5254 5254
898 898
L 104 Front overhang with measuring load 1*
1188 1188
L 105 Rear overhang with measuring load 1*
1261 (with bumper) 1,261 (with bumper)
L505 Length of load bed 2,205 1,555
1,944
1,944
W103 Vehicle width 1,954 (with wheel
1,954 (with wheel cover)
cover)
H 100 Height of body with measuring load 1* 1,820 1,834
W101-1 Front track width with measuring load 1* 1,648 1,648
W102-2 Rear track width with measuring load 1* 1,644 1,644
H156* Ground clearance with measuring load 1* 250 250
Rear entry angle to gradients ML1 limited by

23.6° 23.6°
Dimensions bumper
Rear entry angle to gradients ML1 without
28° 28°
bumper
Rear entry angle to gradients ML3 without
A116-2 15.4° 15.4°
bumper
18° 17.6°
bumper with step
15.6° 15.4°
exhaust system (petrol engine)
Front entry angle to gradients with ML1 28° 28°

A116-1
Front entry angle to gradients ML3 limited by
29.8° 30.6°
bumper
Breakover angle ML1 with skid plate 21.4° 21.4°

Without skid plate 23° 23°
A117
16.4° 16.7°
Breakover angle ML3 with skid plate
18° 18.6°
Without skid plate
Turning circle D102 Minimum turning circle 12.95m 12.95m
Single Cab Double Cab

Basic data Amarok (all engines)
[mm] [mm]
Small tyre Small tyre

205/65 R16 C 110/108T 205/65 R16 C 110/108T
Wheels / tyres. Basic tyres*
large tyre large tyre
245/65 R17 111T 245/65 R17 111T
W200 Width of load bed max. 1,620 1,620*
H502/1,
Rear load sill height, measuring load 1* 780 780
load bed H196
dimensions
H503 Tail lift height 508 508
W506 Through-load width 1222 1,222
Max. width with doors opened 3,668 3668

Garage
dimensions W114-L /
Width incl. left/right exterior mirror 2,228 2,228
W114R
Driver headroom 1,026 1,026

H61
Headroom 2nd seat row -- 1,008
H115/1 Driver entry height 520 520

Interior
dimensions
H115/2 Entry height 2nd seat row -- 529
L34-1 Legroom 1st seat row 1,019 1,019
L34-2 Legroom 2nd seat row -- 865
* Meas. loads ML1 and ML3 acc. to DIN 70020
Info from Volkswagen Commercial Vehicles intranet \Project Amarok\Basic data, status: 07.12.2009
* The vehicle dimensions concerning ground clearance and load bed differ from one another depending on the engine and equipment variant.
** The permitted tyre size varies depending on the engine and the gross vehicle weight rating.
Information
You will find additional technical data (dimensional

drawings, weight information and emissions figures) on
the Amarok according to the engine and equipment
variant on the Internet at:
http://www.volkswagen-
nutzfahrzeuge.de/de/downloads.htx
or
http://umbauportal.de/produktkataloge
2.1.2 Overhang angle and ramp angle
Fig. 1 Overhang and ramp angles, Amarok DC (Double Cab)
Fig. 2 Overhang and ramp angles, Amarok SC (Single Cab)
The values for the overhang angle (A116) and the ramp angle A117 can be found in the basic data table for the Amarok Single
Cab and Double Cab in chap. 2.1.1.1.
* The values for the overhang angle A116 may differ for petrol and diesel engines due to different exhaust systems.
2.1.3 Vehicle centre of gravity
Model L h* SV* SR* SL*

[mm] [mm] [mm] [mm] [mm]
Double Cab 3095 680 1444 ~840 ~796
Single Cab 3095 657 1350 ~ 853 ~805
2.1.4 Bodies with a high centre of gravity
The driving properties of vehicles with a high body or with an elevated overall centre of gravity can be expected to be restricted.
A centre of gravity height up to 800 mm above the carriageway is not problematical (see also chap. 2.2.6 "Brake system and
brake control system ESP").
2.1.4.1 Extremely high centres of gravity ( >800 mm)
Centre of gravity heights higher than 800 mm are only permitted following consultation with Volkswagen AG.
If necessary, the chassis and ESP** must be modified.
The vehicle needs to be taken to Volkswagen AG for an inspection of the vehicle modifications.
Information
Please use the online contact form for this:
* Position of centre of gravity measured on the vehicle without payload and without driver (status: 11.11.2010), ** Electronic stabilisation program
2.1.5 Determining centre of gravity
Volkswagen recommends having the centre of gravity determined by a recognised test institution with experience in this field
(for example, DEKRA, TÜV or others).
For the body builder to determine the centre of gravity, we recommend following the procedures described under 7.1
"Determining the centre of gravity".
2.1.6 Maximum dimensions
The ride height of the frame may change if reinforced springs, comfort springs or tyre sizes other than the standard sizes are
installed. The exact heights shall be measured prior to the start of conversion work.
Fig. 1: Max. dimensions of Amarok Double Cab
Fig. 2: Max. dimensions of Amarok Single Cab
Important notes:
– The minimum distance between the cab and body must be 20 mm.
– The minimum distance between the cab roof and superstructure must be 30 mm.
– The front overhang of the body may not affect the view of traffic lights.
It is possible to extend the overhang measurement (L105: 1,188 mm) up to 1800 mm if certain requirements
are met (see chapter 2.2.10 "Overhang extension").
The vehicle width is 1944-1954 mm (W103) without mirrors! (See also 2.1.1 "Vehicle dimensions")
The aforementioned body width is not allowed to be exceeded when standard exterior mirrors are used.
Please also comply with the following chapters:

– Chap. 2.2.1. "Permitted weights and unladen weights",
– Chap. 2.2.1.1 "One-sided weight distribution"
– Chap. 2.2.6 "Modifications to the brake system"
– Chap. 2.2.10 "Overhang extension"
– Chap. 2.2.11 "Wheelbase extension"
2.1.7 Steerability
Please note that the front axle load must be at least 38.8% of the actual gross vehicle weight rating for all load situations. The
gross axle weight ratings may not be exceeded and the minimum front axle load of 1000 kg must be met. (see also chap. 2.2.10
"Overhang extension")
The displacement of the overall centre of gravity towards the rear must be limited to retain the positive driving properties of the
Amarok in terms of self-steering effect, steering, brake functions, driver assistance functions and body longitudinal incline.
The permitted displacement of the overall centre of gravity towards the rear is ensured by observing a minimum front axle load
depending on the utilised rear axle load.
The following diagram illustrates this context:

– Up to 1575 kg rear axle load, the minimum front axle load is 1000 kg.
– From 1575 kg to maximum 1860 kg rear axle load, the minimum front axle load must increase consistently.
–
Fig. 2: Minimum front axle load for Amarok (heavy-duty chassis)
FAmin - Minimum front axle load

RA - Rear axle load
2.2 Running gear
2.2.1 Permitted weights and unladen weights
Volkswagen AG offers vehicles with rear-wheel drive (4x2) and four-wheel drive (4x4), with Single and Double Cabs, in the
weight classes 2820 kg and 3040 kg.
The Amarok SC and Amarok DC are available with a GVWR of 2820 kg and 3040 kg.
See also chapter 2.8.2 "Towing bracket".
The permitted axle loads listed in the weight tables (see chapters 6.5.1 and 6.5.2) must be observed.
Petrol engines:
2.0 l / 118 kW TFSI
Diesel engines:
2.0 l / 90 kW TDI **
2.0 l / 103 kW TDI ***
2.0 l / 120 kW BiTDI *
2.0 l / 132 kW BiTDI 4MOTION
2.0 l / 90 kW TDI 4MOTION **
2.0 l / 103 kW TDI *** (4MOTION non-permanent)
2.0 l / 120 kW BiTDI 4MOTION *
2.0 l / 132 kW BiTDI BlueMotion 4MOTION
* End of variant calendar week 26/2012
** End of variant calendar week 30/2013
*** Launch of variant calendar week 31/2013
Information
Load ratings depend on the engine. Equipment

features can influence the payload or load weight by
increasing/reducing the unladen weight. The weight
values in the technical data refer to the standard, basic
vehicle equipment. Weight tolerances of +5% in
production are permitted in accordance with DIN 70020
and must be taken into account if necessary.
Installing optional equipment reduces the payload.
The actual payload of a vehicle that is calculated from

the difference between the gross vehicle weight rating
and unladen weight can only be determined by
weighing an individual vehicle.
2.2.1.2 One-sided weight distribution
Warning note
The following weights shall not be exceeded under any

circumstances:
– Gross vehicle weight rating

– Maximum front axle weight
– Maximum rear axle weight
(see chap. 2.2.1 "Permitted weights and unladen
weights").
When planning add-ons/additions, make sure that a one-sided weight distribution is avoided – in particular involving
permanently secured add-ons.
The difference in actual wheel load between the left and right wheels on an axle is not allowed to exceed 8% of the higher wheel
load. The tyre load ratings must be observed.
Example:
Weighed axle load 1,860 kg

Wheel load left/right 893 kg / 967 kg
Difference in wheel load 74 kg
% deviation from higher value 7.7%
Information
Please also refer to chap. 2.2.1. "Permitted weights

and unladen weights" and chap. 2.1.6. Observe "Max.
dimensions".
Fig. 1: One-sided weight distribution (rear view)
Fig. 2: One-sided weight distribution (side view)
2.2.2 Turning circle
See chapter 2.1.1 "Vehicle dimensions".
2.2.3 Authorised tyre sizes
See chapter 2.1.1 "Vehicle dimensions".
2.2.4 Modifications to axles
Modifications to the axles are not permitted, because they can lead to an impairment in the driving properties and unstable
driving behaviour.
2.2.5 Modifications to the steering system
Modifications to the steering system are not permitted.

Exceptions, e.g. conversions for people with disabilities, shall be approved by Volkswagen AG prior to the conversion.
Please use the contact form on the Volkswagen Commercial Vehicles website for your enquiries:
http://umbauportal.de/kontaktformular or
http://umbauportal.de/ihr-kontakt-zu-uns
2.2.6 Brake system and brake control system ESP*
2.2.6.1 General notes
Changes to the brake system are not allowed under any circumstances:
– If the modification to the brake system goes beyond the scope of the operating permit.
– If the air inflow and outflow to and from disc brakes are modified.
Exceptions shall be approved by Volkswagen AG prior to the conversion, and shall be documented with an independent brake
approval report.
Please use the contact form on the Volkswagen Nutzfahrzeuge AG website for your enquiry:
Warning note
Work performed improperly on brake hoses, lines and

cables can impair their function. This can lead to a
failure of components or safety-relevant parts.
Therefore, work on brake hoses, lines and cables
should only be performed by a qualified specialist
workshop.
Information
Since 1 January 1991, all commercial vehicles have

had to comply with the "EC Brake Systems Directive
71/320 EEC". When this EC Directive was adopted into
national legislation (e.g. the Road Traffic Regulations
(StVZO) in Germany), the effect was that these
technical regulations also had to be complied with for
individual acceptance.
* Electronic stabilisation program
2.2.6.2 Vehicle stability and ESP*
When the vehicle with the body mounted is presented for approval, it is a requirement of the EC Brakes Directive 71/320/EEC
and ECE R13 to provide mathematical proof of the height of the centre of gravity when the vehicle is loaded.
Refer to chapter 2.1.3 "Vehicle centre of gravity" for the permitted centre of gravity heights.
Volkswagen does not make any statement about:
– Driving characteristics
– Braking behaviour
– Steering response and
– ESP control response in bodies for loadings with an unfavourably positioned centre of gravity (e.g. rear, high and side loads),
because these aspects are significantly influenced by body activities and consequently can only be assessed by the body
builder.
Warning note
Whether for conversions and installation, and also in

the ready-to-drive condition, the gross wheel and axle
weight ratings as well as the gross vehicle weight
ratings (see chap. 2.2.1) of the vehicle are not allowed
to be exceeded under any circumstances. If the gross
axle weight ratings are exceeded, the ESP* system in
vehicles with ESP will no longer be able to function
correctly. This may result in the driver losing control of
the vehicle and causing an accident.
Practical note
From November 2014, ESP will be obligatory across

Europe for all newly registered vehicles (N1 and M1.
From June 2015, for N2 vehicles). Without ESP*, it is
no longer possible for vehicles to be registered after
the cut-off date.
2.2.6.3 Influence of vehicle conversions on the function of the brake regulation system ESP*
Modification on the vehicle
Vehicle
Modification of
overhang
Extreme running gear
Modification to extension
ESP sub-systems raising of (springs, Conversion
Wheelbase the brakes within limits
centre of dampers, anti- into tractor
modification (callipers, pads, specified in
gravity roll bars, unit 2
design) body builder
> 800 mm wheels, tyres,
guidelines (<
track, steering)
1800 mm)
ABS
+ + + ++ + +
Anti-lock brake system
Offroad ABS + + + ++ + +
BAS
-- -- -- ++ -- --
Brake assist system
EDL
+ + + +++ + +
Electronic differential lock
TCS
++ + + - + +
Traction control system
ESP
Electronic stabilisation ++ +++ 1 +++ 1 +++ 1 ++++ +++
program
Trailer stabilisation
++ ++ +++ +++ ++++ ++++ 3
system
Hill Hold Control - - - ++ - -
Downhill driving assistant + + + ++ ++++ +
1 In particular, a significantly increased risk of tipping over

2 Downgrading required
3 A towing bracket cannot be fitted
-- No effect
- Very little effect
+ Noticeable effect, can be adapted if necessary
++ Significant effect, can be adapted if necessary
++ Very significant effect, can be adapted if necessary
++++ No technical solution
Warning note
Vehicles with add-ons, bodies, installed components or

conversions in which the limit values of the specific
vehicle (position of centre of gravity, axle loads,
overhangs, etc.) are not complied with are regarded as
problematical and can result in an impairment of driving
behaviour. Therefore, they should not be operated.
If specific basic conditions are met, overhang

extensions, changes to the wheelbase and conversion
into an articulated vehicle are possible to a limited
extent. (See chaps. 2.2.10 "Overhang extension",
2.2.11 "Wheelbase modification" and 5.6 "Articulated
vehicles".)
2.2.6.4 Downgrading ESP*
When the ESP is downgraded, the vehicle software needs to be updated to downgrade to the basic functions of the ABS (anti-
lock brake system) including offroad ABS and EDS (electronic differential lock).
The hill hold assist function can still be used. The downhill assist function is deactivated for technical reasons.
The disabled ESP Off or TCS Off button needs to be replaced with a cap and the connectors in the vehicle electrical system
secured.
2.2.6.5 Activating the ESP*
Practical note
If necessary, longer wheelbases can be offered with all

functions of the brake control system.
This is only permitted following consultation with

Volkswagen AG.
If necessary, the chassis and ESP shall be modified

according to the specifications of Volkswagen AG.
The vehicle needs to be taken to Volkswagen AG for

an inspection of the vehicle modifications.
2.2.7 Modification of springs, suspension mounting, dampers
The spring rates are never allowed to be modified.

We recommend using optimally matching springs from the Volkswagen delivery range for the vehicle with body.
Modifications to the springs must be assessed by a test centre/monitoring organisation/technical service responsible for this
function, and can result in invalidation of the operating permit.
2.2.8 Wheel alignment settings
Changes to wheel alignment parameters are not permitted!
2.2.9 Wings and wheel houses
The required clearance for the wheels including snow chains must be complied with.
In some bodies, it is necessary to ensure there is sufficient clearance for the wheel/tyre combination acc. to 92/23/EEC as well
as for adequate wheel coverage based on EC Directive 78/549/EEC.
2.2.10 Overhang extension
The overhang extension should allow longer superstructures that do not significantly shift the overall centre of gravity towards
the rear to be mounted on special vehicles.
Overhang extensions measuring up to a maximum of 1800 mm are permitted if the requirements listed below are met:
– Load distribution
Please note that the front axle load must be at least 38.8% of the actual gross vehicle weight rating for all load situations. The
gross axle weight ratings may not be exceeded and the minimum front axle load of 1000 kg must be met. (see Figure 1 Max.
permitted overhang extension and Figure 2 Minimum front axle load)
– Running gear:
Vehicles with overhang extensions shall always be equipped with the heavy-duty chassis (perm. RA load: 1860 kg).
– Towing bracket:
Towing brackets may never be fitted to vehicles with overhang extensions.
– Rear departure angle:
A rear departure angle of at least 12 degrees should be ensured in all load situations.
– Centre of gravity weights:
During body modifications involving an overhang extension, the maximum permitted height of the centre of gravity, which is
800 mm (see chapters 2.1.3 "Vehicle centre of gravity" and 2.1.4 "Bodies with a high centre of gravity"), must also be
observed.
All traction control system functions are still available under these conditions.
Fig. 1: Maximum permitted overhang extension (heavy-duty chassis)
FAmin - Minimum required front axle load

RAmax - Maximum permitted rear axle load
* - Heavy-duty chassis
The displacement of the overall centre of gravity towards the rear must be limited to retain the positive driving properties of the
Amarok in terms of self-steering effect, steering, brake functions, driver assistance functions and body longitudinal incline.
The permitted displacement of the overall centre of gravity towards the rear is ensured by observing a minimum front axle load
depending on the utilised rear axle load.
The following diagram illustrates this context:

– Up to 1575 kg rear axle load, the minimum front axle load is 1000 kg.
– From 1575 kg to maximum 1860 kg rear axle load, the minimum front axle load must increase consistently.
Fig. 2: Minimum front axle load for Amarok (heavy-duty chassis)
FAmin - Minimum front axle load

RA - Rear axle load
2.2.10.1 Requirements for trailer operation with overhang extension
If the specifications mentioned above in chap. 2.2.10 regarding axle loads

– and their distribution (minimum FA load) are taken into consideration,
– Suspension (heavy-duty RA springs)
– Gradient entry angle
– Centre of gravity height
an Amarok with overhang extension can be used with a towing bracket if the following conditions are met in addition:
– Overhang extension WITHOUT frame extension.
– Towing bracket in original position.
– The axle loads and their distribution (minimum FA load) incl. the axle load displacement caused by the vertical load of the
trailer must be observed.
– The axle loads and their distribution (minimum FA load) must be observed also in conjunction with the trailer (vertical load).
– Sufficient clearance between extended body and trailer (see DIN 74058 "Coupling ball; dimensions, clearance").
– Possible loading of the extended body can be limited considerably by these restrictions when a trailer is towed.
– An improvement can be achieved by extending the wheelbase while maintaining the standard overhang.
2.2.11 Wheelbase modification
Vehicles with modified wheelbases should always be downgraded in terms of brake regulation functions. (See chap. 2.2.6
"Modifications to the brake system".)
This concerns all vehicles with ESP* and all vehicles with TCS system (Traction Control System) and rear or non-permanent
four-wheel drive.
Downgrading:
The vehicle software needs to be updated to downgrade to the basic functions of the ABS (anti-lock brake system) including
offroad ABS and EDS (electronic differential lock).
The hill hold assist function can still be used. The downhill assist function is deactivated for technical reasons.
The disabled ESP Off or TCS Off button needs to be replaced with a cap and the connectors in the vehicle electrical system
secured.
If necessary, longer wheelbases can be offered with all functions of the brake control system.
This is only permitted following consultation with Volkswagen AG.
If necessary, the chassis and ESP shall be modified according to the specifications of Volkswagen AG.

2.3 Body-in-white
2.3.1 Roof loads/vehicle roof
2.3.1.1 Dynamic roof loads
Vehicle model Max. roof load
Amarok Double Cab (DC) 100 kg

Amarok Single Cab (SC) 50 kg
Risk of accident
Roof loads raise the centre of gravity of the vehicle and

lead to a high dynamic axle load shift. Also, there is
greater body lean when driving on rough roads and
when cornering.
The driving characteristics are significantly impaired.

For this reason, we recommend that you avoid roof
loads as far as possible. Please also comply with
chapter 2.1.4 "Bodies with a high centre of gravity".
2.3.1.2 Static roof loads
The maximal static roof load with the vehicle stationary (e.g. roof tent) is 225 kg for the Amarok Double Cab. The attachments
must be configured accordingly.
Please also comply with chapters:

– 2.1.4 "Bodies with a high centre of gravity"
– 2.2.6.2 "Vehicle stability and ESP"
– 2.2.6.3 "Influence of vehicle conversions"
2.3.2 Modifications to the body-in-white
Changes to the body are not allowed to impair the function and strength of units and operating devices of the vehicle, neither
may they reduce the strength of weight-bearing parts.
During vehicle conversions and installation of bodies, it is not permitted to make any modifications which impair the function and
freedom of movement of the suspension (e.g. for maintenance and inspection work) or the accessibility to the same.
2.3.2.1 Screw connections
If series-production bolts / nuts have to be renewed, it is only permitted for bolts / nuts to be used which have the:
– same diameter
– same strength
– same bolt standard or bolt type
– same surface coating (corrosion protection, coefficient of friction)
– same thread pitch.
Comply with VDI guideline 2862 during all installations.

Shortening the free clamping length, changing over to waisted shank and use of bolts with a shorter free thread proportion are
not permitted.
Furthermore, take the settling behaviour of screw connections into account.
Components that are additionally clamped as well shall have the same or a higher strength than the previous clamped
combination.
Use of Volkswagen tightening torques assumes that the total coefficient of friction is in the range μtot = 0.08 to 0.14 for the
particular items being bolted together.
If bolts are tightened by torque and angle at Volkswagen, no change of design is possible.
Risk of accident
No safety-relevant bolted connections, e.g. wheel

guidance, steering and brake functions, are allowed to
be modified. Otherwise the designated function may be
impaired. This may result in the driver losing control of
the vehicle and causing an accident. The new
installation is to be carried out according to the
instructions of VW Customer Service, using suitable
standard parts. We recommend using genuine
Volkswagen parts.
Information
Information about Volkswagen customer service

instructions can be provided by any Volkswagen
Customer Service.
2.3.2.2 Welding work
Incorrectly undertaken welding work can lead to a failure of safety-relevant components, and thus cause accidents.
Therefore, the following safety measures must be complied with when welding work is performed:
– Welding work should only be undertaken by people with appropriate qualifications.
– Before starting welding work, it is necessary to remove components which might contain gases representing a fire or
explosion hazard, e.g. fuel system, or else to protect them with a fireproof cover against airborne sparks. Gas containers
which could be damaged by airborne sparks during welding work must be removed.
– Before welding work starts in the area of seat belts, airbag sensors or the airbag control unit, the components must be
removed for the duration of the work. See chap. 2.4 "Interior" for important information on handling, transporting and storing
airbag units.
– Before starting welding work, cover springs and spring bellows to protect them against weld spatter. Springs are not allowed
to be touched with welding electrodes or welding tongs.
– No welding is allowed on mechanical units such as the engine, gearbox, axles.
– Remove and cover the battery positive and negative terminal clamps.
– Directly connect the earth clamp of the welding machine to the part to be welded. The earth clamp is not allowed to be
connected to mechanical units such as the engine, gearbox, axles.
– The housings of electronic components (e.g. control units) and electrical cables are not allowed to be touched with the
welding electrode or earth clamp of the welding machine.
– The electrodes are only allowed to be used with direct current via the positive terminal for welding. Always weld from bottom
towards the top.
Risk of injury!
Welding in the area of the restraint systems (airbag or

belts) can lead to these systems ceasing to function
properly. Welding in the area of restraint systems is
therefore prohibited.
Practical note
Disconnect the battery prior to starting welding work.

Airbags, seatbelts, the airbag control unit, airbag
sensors and fuel tanks shall be protected against weld
spatter, and removed if necessary.
2.3.2.3 Welded connections
In order to achieve high-quality welds, the following basic recommendations are given:
– Thoroughly clean the areas to be welded.
– Apply several short weld beads, rather than one long one.
– Make symmetrical beads, in order to limit shrinkage.
– Avoid making more than three welds at any one point.
– Avoid welding in work-hardened areas.
– Spot welds and stitch welding should be offset.
2.3.2.4 Selection of welding process
The mechanical properties of welds depend on which welding process is selected, and on the geometry of the parts to be
connected.
If welding overlapping metal panels, the welding process depends on the accessibility of the sides:
Accessible Welding process

sides
1 Shielding gas hole spot welding
2 Spot welding
2.3.2.5 Spot welding
Spot welding is used for overlapping parts with access on both sides. Avoid spot welding of more than two layers of metal
panels.
Distance between spot welds:

In order to avoid shunt effects, the specified distances between the spot welds must be maintained (d = 10e+10 mm).
Ratio between panel thickness and distance between welds
d Distance between spot welds
e Panel thickness
Distance from the edge of the panel:

In order to avoid damage to the molten core, the specified distances from the edge of the panel must be maintained (L = 3e+2
mm).
Ratio between panel thickness and distance from edge
e Panel thickness
L Distance from the edge of the panel
2.3.2.6 Shielding gas hole spot welding
If overlapping panels can only be welded on one side, it is possible to achieve the connection by shielding gas hole spot welding
or tacking. If the connection is achieved by punching or drilling and then spot welding the hole, the drilling area must be
deburred before welding is carried out.
Ratio between panel thickness and hole diameter
D - hole diameter [mm] 4.5 5 5.5 6 6.5 7

e - panel thickness [mm] 0.6 0.7 1 1.25 1.5 2
The mechanical quality can additionally be improved by using slots (l = 2 x b).
Ratio between width and length of slots

b Width of slot
I Length of slot
2.3.2.7 Tacking
If panels are > 2 mm thick, overlapping panels can also be connected by tacking
(30 mm < L < 40 x e; d > 2 L).
Ratio between panel thickness and distance between welds
d Distance between tack welds
e Panel thickness
L Length of tack weld
2.3.2.8 Welding is not allowed
Welding is not allowed:

– On mechanical units such as the engine, gearbox, axles etc.
– On the chassis frame except if there is a frame extension.
– On the A- and B-pillars.
– On the upper and lower chords of the frame.
– In bend radii.
– In the area of airbags.
– Hole welding is only permitted in the vertical webs of the frame longitudinal member.
2.3.2.9 Corrosion protection after welding
After all welding work on the vehicle, it is necessary to comply with the specified corrosion protection measures
(See chapter 2.3.2.10 "Corrosion protection measures")
2.3.2.10 Corrosion protection measures
Following conversion and installation work on the vehicle, surface and corrosion protection shall be applied to the affected
points.
Practical note
Only the corrosion protection agents tested and

approved by Volkswagen are allowed to be used for all
corrosion protection work.
2.3.2.11 Planning measures
Corrosion protection should be taken into account in the planning and design in the form of a suitable material selection and
component design.
Information
If two different metallic materials are connected

together by an electrolyte (e.g. moisture from the air)
then this will give rise to a galvanic connection. The
result will be electrochemical corrosion, and the less
noble metal will suffer damage. The electrochemical
corrosion will be all the greater the further apart the
metals in question are in the electrochemical series.
Therefore, the components must have a suitable

treatment or insulation applied to them in order to
prevent electrochemical corrosion, or the corrosion
must be kept at a low level by a suitable choice of
materials.
Avoidance of contact corrosion by electrical insulation
Avoidance of contact corrosion
1 Insulating washer
2 Insulating sleeve
Contact corrosion can be avoided by using electrical insulation such as washers, sleeves or tubes. Avoid welding work on
inaccessible cavities.
2.3.2.12 Component design measures
Design measures, in particular in the design of connections between the same or different materials, can be used for providing
corrosion protection:
Corners, edges, beads and folds represent locations where dirt and moisture can collect.
Suitable surfaces, drains and the avoidance of gaps at component connections represent means by which corrosion can be
counteracted by design measures.
Gaps at welded connections as a feature of the design, and how to avoid them:
Application examples of welded connections
A = Favourable B = Unfavourable
(through-welded) (gap)
2.3.2.13 Coating measures
It is possible to protect the vehicle against corrosion (see 2.3.10 "Paint work / corrosion protection measures") by applying
protective coatings (e.g. galvanizing, painting or high-temperature zinc application).
2.3.2.14 Work on the vehicle
After all work on the vehicle:

– Remove drilling chips
– Deburr edges
– Remove scorched paint and thoroughly prepare the surfaces for painting
– Apply a primer to all bare metal parts, and paint them
– Apply a wax-based corrosion protection agent to cavities
– Carry out corrosion protection measures on the underbody and frame components
2.3.3 Tailgate
The tailgate on the Amarok Double Cab and Single Cab has the following properties:
– Cannot be removed.
– Outer panel.
– Inner panel.
– Reinforcement parts (hinge/lock reinforcement left and right; lateral reinforcement).
– Closing plate for installation opening.
– Hinges.
– Lock.
– No step in the tailgate.
– 180° opening (no rear bumper).
– Can be locked in 90° position.
200 kg static load in 90° position

(Please refer to the owner's manual for further information.)
2.4 Interior
2.4.1 Modifications in the area of airbags
Modifications to the airbag system and the belt tensioner system are not permitted
Furthermore, modifications on and in the area of airbag components, the airbag sensors and the airbag control units are not
permitted. Please note chapter 5.1 "Conversions for people with disabilities"
The interior fittings shall be designed so that the airbag deployment areas are left unobstructed (see also chap. 3.2 "Interior").
For information about the deployment zones of the airbags, refer to the owner's manual of the vehicle.
Warning note
Modifications or incorrectly performed work on

seatbelts and seatbelt anchor points, belt tensioners or
airbags or their cabling could impair the correct function
of these components. They might be activated
inadvertently or fail in the event of an accident.
2.4.2 Modifications in the area of seats
Modifications to the seat system or attachment of seats on the wheel housing are not permitted, because the seats might be
torn out of the anchoring points in the event of an accident.
The strength data for seats available ex-works is only valid in conjunction with the original attachment elements.
It is essential not to exceed the height of the centre of gravity (H-point) if retrofitting seats.
If reattaching seatbelts, make sure that the specified bolts are tightened with the original torque.
2.4.3 Forced ventilation
Outlet vents may be closed through modifications only if new outlets are created, e.g. in the cab doors.
Air inlets and outlets are not allowed to be fitted in the immediate vicinity of sources of noise or exhaust gases.
2.4.4 Acoustic insulation
Pay attention to minimising interior noise levels as part of conversions, in order to avoid modifying the noise level of the vehicle.
The converted vehicle shall comply with the values for external noise given in EC Directive 70/157/EEC.
Specialists such as the manufacturer and suppliers of acoustic material should be contacted for advice on achieving the
optimum acoustic protection for bodies.
2.5 Electrics/electronics
Incorrect interventions in electronic components and their software may result in these no longer functioning correctly. Due to
the networking of electronics, systems that were not modified can be affected.
Malfunctions in the electronics can significantly impair the operational safety of your vehicle.
Work on or modifications to electronic components, in particular work on safety-relevant systems, is only allowed to be
performed by a qualified specialist workshop, and by qualified specialist personnel who have the necessary specialist
knowledge and tools for performing the necessary work.
Interventions in the vehicle electrical system/vehicle electronics can result in invalidation of the warranty/operating permit.
2.5.1 Lighting
2.5.1.1 Vehicle lighting devices
Comply with the registration provisions of the country in question with regard to the complete lighting devices (lighting and turn
indicator devices). Failing to comply can result in the operating permit being invalidated.
Comply with the basic headlight setting (see type plate).
The use of LED lights is not intended by the manufacturer.
Installing LED lights instead of the original VW lights can cause the bulb failure check to issue a warning because the lighting
system is not configured for this. The bulb failure check function cannot be activated.
We recommend using Volkswagen Genuine rear lights or a product with "e" test symbol and conventional bulbs.
2.5.1.2 Mounting special lights
Comply with the registration provisions of the country in question when installing special lights.
Comply with the following chapters during the conversion:
– 3.1 "Body-in-white"
– 3.1.4 "Modifications to the roof"
– 2.5.2.4 "Retrofitting electrical devices"
2.5.1.3 Installing 3rd brake light
When higher bodies are fitted, it may be necessary to integrate the 3rd brake light into the body.
A cover (7H0.971.341) for the 3rd brake light is available from the factory to cover the original brake light aperture. For more
information, please contact your Volkswagen partner.
Please note that installing another brake light is only possible in place of the genuine brake light, and only with the same power.
2.5.1.4 Additional load compartment light
If an additional load compartment light is required, we recommend installing an additional switch and separate wiring (see chap.
2.5.2.1 "Electrical cables / fuses"; chap. 2.5.2.2 "Additional circuits"
and chap. 2.5.2.4 "Retrofitting electrical devices"). A solution using a relay with the original lighting wiring is not recommended
because the interior light is dimmed and switched off by means of PWM (signal).
No additional wires maybe connected to the existing lighting wiring fitted by Volkswagen AG.
2.5.2 Vehicle electrical system
2.5.2.1 Electrical cables/fuses
The following points shall be complied with if routing modifications are required:
– Avoid routing over sharp edges.

– Avoid routing inside excessively narrow cavities and close to moving parts.
– Only lead-free PVC-jacketed cables with an insulation limit temperature > 105 °C are allowed to be used.
– Connections shall be made professionally and water-tight.
– The cable shall be dimensioned according to the current drawn and protected by fuses.
Rated current of
Max. continuous current [A] Wire cross-section [mm²]
fuse [A]
0–4 51 0.35
1
4.1 – 8 10 0.5
8.1 – 12 151 1
1
12.1 – 16 20 1.5
16.1 – 24 301 2.5
2
24.1 – 32 40 4
32.1 – 40 502 6
40.1 – 80 100 10
80.1 – 100 125 16
100.1 – 140 175 25
140.1 – 180 225 35
180.1 – 240 300 50
1
Shape C; DIN 72581 flat connector
2
Shape E; DIN 72581 flat connector
Warning note
No additional electrical cables or hose lines are allowed

to be secured to existing lines such as brake or fuel
lines or cables, because standard holders might
otherwise be overloaded. An independent attachment
solution must be found.
2.5.2.2 Additional circuits

If additional circuits are required, we always recommend using the electrical interface for external use (PR no. UF1) (see chap.
2.5.3).
Additional circuits shall be safeguarded against the main circuit by means of suitable fuses.
Cables shall be dimensioned according to the load, and protected against pulling off and the effects of impacts and heat.
2.5.2.3 Retrofitting electrical devices
Note the following for retrofitting additional electrical loads:

– No further loads are allowed to be connected to occupied fuses.
– No additional cables are allowed to be connected to existing cables (e.g. with insulation-piercing terminals).
– Protect loads adequately by means of additional fuses.
– All installed electrical devices shall be checked acc. to EU Directive 72/245/EEC and shall bear the "e" mark.
Warning note
Please note that in vehicles with towing brackets, the

socket for supplying the trailer electrical system
influences the control functions of the brake system
(ABS/TCS/ESP*), and it is exclusively provided for
supplying power to the trailer.
When the trailer socket is occupied
– The offroad button has no effect (no offroad ABS and

hill descent assist is no longer possible (ESP* vehicles
only)).
– ESP* functions respond more sensitively.
– The hill start assist becomes more robust.
We recommend using the interface for special vehicles to provide electrical power to special vehicle conversions. (see also
chap. 2.5.2.3 "Electrical interface for special vehicles")
2.5.2.4 Electromagnetic compatibility
Electromagnetic compatibility refers to the property of an electrical system to remain neutral whilst maintaining full functions in
the presence of other systems.
Active systems in the surrounding area are not disrupted by the system, nor is the system itself impaired.
Electrical interference in motor vehicle electrical systems is caused by the individual loads. At Volkswagen AG, the factory-fitted
electronic components have been checked for their electromagnetic compatibility in the vehicle.
When electrical or electronic systems are retrofitted, it is also necessary to check and demonstrate their electromagnetic
compatibility.
Volkswagen does not issue a manufacturer's declaration for electromagnetic compatibility when additional devices are
subsequently installed by body builders.
Devices that are regarded as "electrical/electronic subassemblies" (ESA) as defined by EC Directive 72/245/EEG in the current
version shall be type-approved and shall bear the "e" mark.
2.5.2.5 Mobile communication systems
In order to avoid subsequent disruptions to operation, it is necessary to take account of the following points when retrofitting
mobile communication systems (e.g. telephone, CB radio):
– The devices shall possess a type approval acc. to EU Directive 72/245/EEC in the current version, and shall bear the "e"
mark.
– All devices to be fitted shall possess a type approval acc. to EU Directive 72/245/EEC in the current version, and shall bear
the "e" mark.
– The maximum transmission power is not allowed to be exceeded.
– The devices and holders shall be located outside the deployment range of the airbags.
– They shall be permanently installed.
– Mobile devices within the cab are only allowed to be operated via an external aerial installed in such a way as to eliminate
reflections.
– The transmitter shall be installed in a separate location from the vehicle electronics.
– The device shall be protected against moisture and severe mechanical shocks; comply with the permitted operating
temperature.
2.5.2.6 CAN bus
Interventions in the CAN bus and connected components are not permitted.
2.5.3 Electrical interface for special vehicles
The special vehicles interface provides selected vehicle electrical system potentials.
These interfaces are only allowed to be used by authorised specialist personnel. Inappropriate interventions can result in
damage to the vehicle and breakdowns, and may also invalidate the operating permit.
Subject to technical modifications.
The following points shall be adhered to:

– Various VDE guidelines for configuration and fitting of electrical cables and components (cable cross sections, fuses, etc.).
– Only components (cables, housings, contacts) approved by Volkswagen are allowed to be used for adapting to the vehicle
electrical system. The part numbers of these components can be found in this description.
– Only the potential names normally used in VW are used in this description.
– It is not known what additional units will be connected; therefore the company fitting out the vehicle with the interface shall
ensure a balanced current distribution.
– EMC safety for connections after the interface is the responsibility of the company fitting out the vehicle.
– The cable cross sections of the interfaces shall be maintained throughout the entire circuit, i.e. no cross-section reductions
are permitted after the interface.
– Energy supply to the vehicle electrical system is only allowed to be done at potentials expressly provided for this purpose (see
description) and shall be fused externally in accordance with VDE.
– For additional information, refer to Amarok customer service documents.
– All electrical cables connected to the vehicle electrical system shall be reliably and durably protected against overload to
battery "+" and the body earth
– Earth potential: The specified potentials always refer to the vehicle body earth
2.5.3.1 Position of the interface
Fig. 1: Electrical interface for special vehicles
Fig. 2: Position of the electrical interface in the vehicle
* 1 => UF1 interface for special vehicles
** "Arrow" => Direction of travel
2.5.3.2 Assignment of the terminal strip (UF1)
Selected vehicle electrical system potentials are assigned to the 3 plugs. The interface assignment and the possibility of
drawing or supplying current depend on the equipment.
Plug 1 (violet)
1J00.937.743.K
Cross- Max.
potenti Max. current Mating plug
Pin Colour section current Fusing Use Restrictions
al supply [A] contact
[mm²] draw [A]
Black/w Not
A1 75 A 1 12.0 F37 (15 A) 1J0.937.733.K X-contact
hite permissible
BCM std: 0.21 With BCM max:

BCM std: 4.0 PWM signal, signal
Grey/ye BCM max:
A2 55 1.5 BCM max: F30 (5 A) 1J0.937.733.K Fog light output even when
llow Not left cornering lighting
0.5 is activated
permissible
With automatic
Black/bl Not No gearbox or BCM
A3 RFL 1.0 1.0 1J0.937.733.K Reversing light max:
ue permissible independent
PWM signal
Yellow/ Not
A4 56bL 0.5 1.0 F26 (10 A) 1J0.937.733.K Dipped beam (left)
black permissible A4 and A5 are phys.
connected
Yellow/r Not
A5 56bR 0.5 1.0 F28 (10 A) 1J0.937.733.K Dipped beam (right)
ed permissible
Black/g Not
A6 86S 0.5 1.0 F52 (5 A) 1J0.937.733.K S contact
reen permissible
When dimmer
Green/ Not No
A7 58d 0.5 2.0 1J0.937.733.K Terminal 58d installed:
yellow permissible independent PWM signal
Pin A8 and plug 2
White/
A8 56aL 0.5 1.0 5.01 F27 (10 A) 1J0.937.733.K High beam (left) pin A1 are phys.
black connected
Black/bl Not
A9 15 A 0.5 2.0 F50 (5 A) 1J0.937.733.K Terminal 15
ue permissible
With BCM max:
PWM signal; pick-off
Green/ Not No at left side light
A10 58LA 1 0.5 1J0.937.733.K Side lights With BCM std.: pick-
black permissible independent
off from rotary light
switch
Plug 2 (yellow)
1J00.937.743.C
Cross- Max.
[mm²] draw [A]
Pin A1 and plug 1

White/ 1J0.937.733.
A1 56aR 0.5 1.0 5.01 F27 (10 A) High beam (right) pin A8 are phys.
black C connected
White/ Not No 1J0.937.733.

A2 V 0.5 0.022 Speed signal
violet permissible independent C
Earth signal
Black/w Not No 1J0.937.733. Stat. Turn signal
A3 L 0.5 0.2 Turn signal left status no timing
hite permissible independent C
signal
Black/r No 1J0.937.733.
A4 50 0.5 0.23 - Starter
ed independent C
1J0.937.733.
A5 n.c. n.c.
C
Earth signal
Black/g Not No 1J0.937.733. Stat. Turn signal
A6 R 0.5 0.2 Turn signal right status no timing
reen permissible independent C
signal
Brown/ Not No 1J0.937.733.

A7 HB Sig 0.35 0.014 Handbrake.C Earth signal
violet permissible independent C
Pin A8 is only fitted
Black/r No 1J0.937.733. with manual
A8 50 0.5 0.2 - Starter gearboxes: same
ed independent C
signal as with pin A4
1J0.937.733.
A9 n.c. n.c.
C
Black/y Not No 1J0.937.733. Horn momentary Signal pick-off at

A10 71b 1.5 0.5 vehicle horn
ellow permissible independent C contact
Plug 3 (grey)
1J0.937.741.G
Cross- Max.
[mm²] draw [A]
Black/r Not No
A1 54 0.5 0.25 1J0.937.731.G Brake light
ed permissible independent Pin A1 and pin A2
are phys. connected
Black/r Not No
A2 54 0.5 0.2 1J0.937.731.G Brake light
ed permissible independent
Black/g Not Continued engine

A3 15 2.5 25 F31 (30 A) 1J0.937.731.G
rey permissible running tl 15
Red/bro Not HSB_FUSE_S Connection to starter

A4 30 A 4 306 1J0.937.731.G Terminal 30 battery
wn permissible 6 (40 A)
Black/y Not Continued engine

A5 75 0.5 2.5 F47 (5 A) 1J0.937.731.G
ellow permissible running tl 75
A6 n.c. 1J0.937.731.G Not assigned
1. An external fuse is required in case of external power supply. It is essential to take account of the effects on the vehicle electrical system
2. Note the specification of the instrument cluster interface
3. If the cable between pin 4 and pin 8 is disconnected (plug 2) then the ends of the cable must be insulated correctly. Note the necessary continuous current for the relay coil of ≥
200 mA
4. Note the influence / feedback on the instrument cluster
5. If the cable between pin 1 and pin 2 is disconnected (plug 3) then the ends of the cable must be insulated correctly.
6. Note parallel operation of additional loads (load balance)
7. An external fuse is required directly before the interface
2.5.3.3 Connector pin assignment and circuit diagrams for interface for special vehicles
Detailed information about the special interface can be found in the workshop manuals and circuit diagrams (no. 21/1) of
Volkswagen AG.
Information
Volkswagen AG workshop manuals and circuit

diagrams can be downloaded from the Internet at
2.5.4 Vehicle battery
If a vehicle is not operated for a long time, its battery gradually loses charge due to the electrical loads (clock, tachograph,
cigarette lighter or radio) and can suffer permanent damage.
To avoid this damage, the wiring harness is disconnected in the production facility using a connector and shall be reconnected
during transfers or vehicle delivery services.
The connector shall be disconnected again if the vehicles are to be left unused at the body manufacturer for some time.
2.5.3.1 Installation of additional battery
When installing additional batteries, please note that this may only be done in conjunction with a battery isolation relay. The
additional battery is only allowed to be used for its specified additional loads. Additional loads could be, for example:
refrigeration systems, auxiliary heating etc.
If an additional battery is accommodated in the passenger compartment, ensure that there is sufficient ventilation.
Warning note
When work is performed on the vehicle electrical

system, the earth cables should always be
disconnected from the battery and the additional
battery. Only then should you disconnect the positive
cables.
Short-circuits could occur if this is not observed.
2.5.5. Digital tachograph (EC monitoring device)
The tachograph records distance and speed data from two drivers and gives an automatic warning before driving times are
exceeded. The stored data can be printed out on the integrated printer or downloaded via the download interface.
Information
Please note when ordering your base vehicle:
The preparation for the digital tachograph (PR no.

9ND) and the digital tachograph (PR no. YAJ) can be
ordered ex-works as optional equipment.
If the vehicle is used for commercial purposes and has a max. permitted combination weight of more than 3.5 t, it is a legal
requirement of EU Regulation 3820/85 for a tachograph to be fitted.
The requirement to fit an EC/AETR monitoring device is waived acc. to Art. 3 (1) of Directive (EEC) no. 3821/85 for means of
transport specified in Art. 3 of Directive (EC) no. 561/2006 and Art. 2 AETR.
2.6 Engine peripherals/powertrain
In the event of modifications to noise-relevant components such as the engine, exhaust system, tyres, air intake system, etc.,
noise measurements shall be carried out acc. to EC directives. The permitted values are not allowed to be exceeded.
The national regulations and directives apply.
Components for sound insulation that are installed as standard are not allowed to be modified or removed
(see also chap. 2.4.4 "Acoustic insulation").
2.6.1 Engine/powertrain components
– No modifications to the engine air intake system are permitted.

– Subsequent solutions regarding engine speed control are not possible.
– Modifications to the cooling system (radiator, radiator grille, air ducts, etc.) are not permitted.
– Keep cooling air intake areas clear.
2.6.2 Drive shafts
The correct configuration and implementation of a modified powertrain prevents noise and vibration, and should only be
performed by a company which is qualified to build drive shafts.
Only genuine Volkswagen parts should be used.
2.6.3 Fuel system
Modifications to the fuel system are not permitted.
Modifications to the body in the area of the fuel tank require the fuel tank to be removed first.
Comply with the workshop manuals of Volkswagen AG.
Information
Volkswagen AG workshop manuals and workshop

information can be downloaded from the Internet at
Note the following when working on the fuel system:

– Vehicles with a petrol engine have their activated charcoal container located at the rear end of the fuel tank. The position and
attachment of the activated charcoal container are not allowed to be modified.
– Do not attach heat-conducting components or components that restrict the installation space.
– Modifications to the fuel pump, fuel line length and fuel line routing are not permitted. Modifications to these mutually
configured components can impair the function of the engine.
Please also comply with chapter 4.1.4 "Removal of the filler neck".
2.6.4 Exhaust system
Modifications to the exhaust system up to the main silencer and in the area of the components for exhaust post-treatment
(diesel particulate filter, catalytic converter, lambda probe, etc.) are never permitted.
If modifications are required to the exhaust system for the add-on/removal/conversion nevertheless, this can have effects which
are relevant to registration. Please contact us in advance regarding the scope of your conversion so that we can advise you.
We recommend that you use VW genuine parts and comply with the workshop manuals of Volkswagen AG.
Information
You will find further information on installation and

removal of the exhaust system on the Internet at
Information
Country-related regulations and guidelines shall be

complied with
Exceptions require the approval of Volkswagen AG before the conversion, and shall be documented in a registration report
detailing the modifications and adjustments made.

Warning note
Attention! Danger of fire!
The lengths and routings of the exhaust system have

been configured optimally with regard to their
temperature properties. Modifications may result in
relatively high to extreme heating of the exhaust
system and the surrounding components (drive shafts,
tank, floor pan, etc.).
2.7 Ancillary drives, engine/gearbox
When planning the special vehicle, select the equipment of the base vehicle according to the requirements of the future
application. (See also chap. 1.5.1 "Selecting the base vehicle")
You can optimise your base vehicle in advance for the conversion by selecting the following optional equipment items:
For correct operation of the ancillary drive, we recommend that you use the additional units (e.g. refrigerant compressor)
provided ex-works for the base vehicle.
For further information, see:

– Chap.1.5.1 "Selecting the base vehicle"
– Chap. 2.5.4 "Vehicle battery"
2.7.1. Retrofitting air-conditioning system
All installed electrical devices must be checked acc. to EC Directive 72/245/EEC and shall bear the "e" mark.
To retrofit air-conditioning systems, we recommend the "regulated air-conditioning system" PR no. 9AD/9AP
("Climatic/Climatronic air-conditioning system") that you can buy ex works as optional equipment.
We recommend using the original refrigerant compressor:
Engine designation Climate control Refrigerant

compressor
Type
DENSO-6SEU14
Petrol
2.0 l 118 kW
Cab (140 cc)
TFSI
2.0 l 90 kW TDI DENSO-6SEU14

Diesel
2.0 l 103 kW TDI Cab (140 cc)

2.0 l 132 kW TDI
If other air-conditioning systems are to be retrofitted, the guidelines from the equipment manufacturer and for the system
components should be observed. The body builder is then solely responsible for operating and road safety.
Retrofitting or replacing ancillaries, for example, the refrigerant compressor, is possible in place of the original refrigerant
compressor or with the aid of an additional belt pulley via the second belt track. (See chap. 2.7.3 "Specification of genuine
refrigerant compressor" and chap. 2.7.2 "Driving an ancillary via the 2nd belt track")
The following points should be observed for the compatibility with the base vehicle:
– Vehicle parts and their function should not be impaired by the installation of an air-conditioning system.
– The capacity of the battery and power supplied by the alternator must be dimensioned sufficiently.
– Additional fuse protection of the air-conditioning system circuit (see chap. 2.5.2.1 "Electrical cables/fuses").
– The refrigerant compressors should be mounted on the provided assembly carriers.
– The weight of the ancillary is not allowed to exceed the weight of the original refrigerant compressor (see table 2).
– The diameter and position of the drive pulley for the ancillary must correspond with that of the original refrigerant compressor.
(see Fig. 1-5)
– There shall be adequate space for operating the ancillary.
– The track position of the poly V-belt must be identical to the original and the poly V-belt specifications must be observed (see
table 4).
– If the standard refrigerant compressor is used, it is necessary to optimise the fill volume and conduct oil circulation and oil
return measurements. Measurements for ensuring the oil circulation in the refrigeration circuit shall be carried out by the body
builder at its own cost, and be conducted at the corresponding compressor manufacturers.
– Ensure that lines (brake hoses/cables and wires) are routed correctly.
– The accessibility of the ancillaries installed and simple maintenance possibilities may not be impaired.
– The Owner's Manual and the maintenance manual for the ancillaries should be handed over when the vehicle is delivered.
– The necessary air supply and the engine cooling may not be impaired.
– When compact systems (evaporator, condenser and fan) are mounted on the cab roof, the permitted roof loads may not be
exceeded (see chap. 2.3.1 "Maximum roof loads").
– Attachments to the roof require a safety certificate from the responsible department (see chap. 1.2.2.1 "Safety certificate").
Practical note
In vehicles without air conditioning, it is necessary to

recode the engine control unit when an ancillary is
retrofitted.
2.7.2. Driving an ancillary via the 2nd belt track*
Further ancillaries (e.g. generators, compressors or pumps) can be driven via the second belt track with the aid of an additional
pulley. You can obtain the corresponding conversion kit separately from Volkswagen Genuine Parts.
The conversion kit comprises:
– Hub (part no. 03L.105.215)
– Belt pulley, diameter: 160 mm 6PK (03L.105.255.C)
– Fastening material (N.106.517.01 + N.100.051.10)
For information on the conversion kit, please ask your VW partner or contact the superstructure manufacturer support via the
contact form:
Information
For detailed instructions about the installation and

removal, for example, of the poly V-belt, refer to the
workshop manuals of Volkswagen AG on the Internet
under erWin (Electronic Repair and Workshop
Information of Volkswagen AG):
The max. consumable power with 4-cylinder TDI engines is: 8.0 kW.
* Delivery date had not yet been defined as at the copy deadline.
2.7.3. Specifications of standard refrigerant compressor
Table 1: Maximum output of refrigerant compressor

Engine designation Refrigerant compressor Power L Cooling power
type [kW] Q
[kW]
Petrol
2.0 l 118 kW
DENSO-6SEU14 (140 cc) 5.71 1) 8.32 1)
TFSI
2.0 l 90 kW TDI
Diesel
2.0 l 103 kW TDI DENSO-6SEU14 (140 cc) 5.71 1) 8.32 1)

2.0 l 132 kW TDI
1) Figures on refrigerant compressor with high pressure Pd=1.47MPaG, suction pressure Ps = 0.196MPaG and speed N =4000rpm
Table 2: Weight of refrigerant compressor

Engine designation Refrigerant compressor Max. weight
type [kg]
Petrol
2.0 l 118 kW
DENSO-6SEU14 (140 cc) 4.62 kg
TFSI
2.0 l 90 kW TDI
Diesel
2.0 l 103 kW TDI DENSO-6SEU14 (140 cc) 4.62 kg

2.0 l 132 kW TDI
Table 3: Belt pulley diameter of refrigerant compressor

Engine designation Refrigerant Pulley Transmission
compressor diameter ratio "i"
type (crankshaft/refri
gerant
compressor)
2.0 l 118 kW
Petrol
DENSO-6SEU14 100 mm ---2)

TFSI
2.0 l 90 kW TDI
Diesel
2.0 l 103 kW TDI DENSO-6SEU14 100 mm 1.38

2.0 l 132 kW TDI
Table 4: Specifications of poly V-belt

Engine designation Refrigerant compressor Belt specification/part no.
type
Petrol
2.0 l 118 kW
DENSO-6SEU14 (140 cc) 6 PKD 1577 / 06H.903.137.H
TFSI
2.0 l 90 kW TDI
Diesel
6PK1555, SILENT GRIP /

2.0 l 103 kW TDI DENSO-6SEU14 (140 cc)
03L.903.137.H
2.0 l 132 kW TDI
2) Figures were not available at the copy deadline.
2.7.3.1 Connection measurements of standard refrigerant compressor
Fig. 1 Poly V-belt drive (here only TDI engine depicted, the original engine position differs from the picture)
1 - Alternator
2 - Poly-V-belt pulley
3 - Reversing pulley
4 - Air-conditioning compressor assembly
Fig. 2: Dimensions of air-conditioning compressor, pulley diameter 100 mm (side view)
Fig. 3: Dimensions of air-conditioning compressor Denso 6SU14 (front view)
Fig. 4: Dimensions of air-conditioning compressor Denso 6SU14 (view from above)
5.3±0.2
Fig. 5: Detail U - Denso 6SU14 air-conditioning compressor drive pulley, pulley diameter d = 100 mm
Please also comply with the following chapters during the conversion:
– 2.7.1 Ancillaries
– 2.5.4 Vehicle battery
– 2.5.2.2 Additional electrical circuits
– 3 Modifications to closed bodies
– 5.2 Refrigerated vehicles
Please observe the installation and removal regulations of Volkswagen AG when performing conversions.
Information

removal, for example, of the poly V-belt, refer to the
workshop manuals of Volkswagen AG on the Internet
under erWin (Electronic Repair and Workshop
Information of Volkswagen AG):
2.7.4 Installation and removal of the poly V-belt
Fig. 7 Belt tensioner
1 - Belt tensioner
2 - Locking pin
3 - Moveable eye
4 - Fixed eye
5 - Spring
Z - Midpoint of the central bolt
2.7.4.1 Removal of the belt
In order to remove the belt, it is necessary to turn the belt tensioner clockwise using a suitable tool until the moveable eye "3"
overlaps with the fixed eye "4", and secure it with a locking pin "2" (d = 5 mm). This means the spring of the belt tensioner is
tensioned, the tension of the belt is removed and the belt can be removed. This position of the belt tensioner is referred to below
as the locking position.
2.7.4.2 Installation of the belt
For installation, the belt must be guided over all units and reversing pulleys, and then finally placed over the belt tensioner. After
the locking pin has been removed (which is only permitted with the belt installed), the belt tensioner turns anticlockwise and
transfers the clamping force to the belt. Only poly V-belts with the approved length are allowed to be used, so that the belt
tensioner can operated within its defined operating range. This applies in particular to belt drives that no longer correspond to
the initial equipment status. The position of the tensioner in the installed position with the engine stopped is referred to below as
the nominal position. From this position, the belt tensioner is capable of compensating for tolerances and belt stretching due to
temperature, etc.
At the lower limit stop, the spring is slackened and cannot exert tension on the belt any longer.
2.7.4.3 Working range of the belt tensioner:
The following display shows various points of the working range of the belt tensioner and should make it easier to check that the
belt tensioner is in the correct position. This diagram does not provide any statement relating to the safety of a belt drive that is
different from the series production status.
Fig. 8 Working range of the belt tensioner
A - Locking position 0° (overlap)
B - Start of working range 28°
C - Nominal position 34°
D - End of working range 57°
E - Bottom stop 80°
Angle [°] Distance A [mm] Position of the belt tensioner

0 0 Locking position (overlap) – A
28 14.5 Start of working range –B
34 17.5 Nominal position (NOM) – C
57 50.3 End of working range – D
The angle is measured between the fixed eye and the movable eye. In the nominal position, it is 34°. It is not allowed to go
beyond the working range from 28°-57°. For distance A, it is necessary to specify the actual dimension between the fixed eye
and the moveable eye, assuming the moveable eye is in the working range. The distance A in the nominal position is 17.5 mm.
Information
You will find further information in the Volkswagen AG

workshop manuals on the Internet at erWin (Electronic
Repair and Workshop Information from Volkswagen
AG): http://erwin.volkswagen.de/erwin/showHome.do
2.7.4.4 Belt routing
The function of the belt tensioner can be significantly impaired if the belt routing is changed from that of series production and
passed over the idler roller of the belt tensioner. The bisector (1) between the arriving and departing sides of the belt should be
almost at right angles ( ≈
 to the le ve r a rm
of the belt tensioner in the working area. (Fig. 9)
Fig.9: Belt routing around the belt tensioner
1-Bisector of the arriving and departing sides of the belt around the belt tensioner
α – Angle of the belt routing around the belt tensioner
ß – Angle between the bisectors of the arriving and departing sides of the belt in relation to the lever arm of the belt tensioner.
Information
You will find further information in the Volkswagen AG

workshop manuals on the Internet at erWin* (Electronic
2.8 Add-ons/units
2.8.1 Roof rack
Roof loads raise the centre of gravity of the vehicle and lead to a high dynamic axle load shift. Also, there is greater body lean
when driving on rough roads and when cornering. The driving characteristics are significantly impaired. For this reason, roof
loads should be avoided if at all possible.
Where possible, the fixed points on the roof should be used for attaching racks (see the manufacturer's installation instructions).
The Amarok DC (Double Cab) has 2 contact points on each side of the roof and the Amarok SC (Single Cab) has 1 contact
point on each side (see Fig. 2.8.1.1).
Fig. 1: Roof rack contact points on Amarok DC (marked in red)
2.8.2 Towing bracket
We recommend using hitches approved by Volkswagen as towing brackets.

The "Preparation for towing bracket" (PR no: 1D7) is part of the standard equipment on vehicles from model year
2012.
The cross member (bumper) required for the towing bracket on Amarok chassis must be
sourced subsequently as a Volkswagen genuine part (see chapter 1.2.1.4 "Genuine parts online").
You can obtain the ball head towing bracket incl. electrical set as a genuine accessory (PR no. YAK) directly from Volkswagen
AG.
Fig. 1: 1 = Bumper 2 = Ball head
Maximum trailer loads:
Total towing Max. trailer Drawbar

Engine weight load1 load
[kg] [kg] [kg]
Petrol 2.0 l 118 kW TFSI
2.0 l 90 kW TDI 3000
5550 120
2.0 l 120 kW TDI 2800³
Diesel 2.0 l 132 kW BiTDI
2.0 l 132 kW BiTDI
5950² 3200² 130²
8-speed automatic
1
Unbraked trailer load: 750 kg
2
Does not apply to hot country (8Z6) and super hot country (8Z9)
3
Only applies to 4x2 / leaf spring 2+1 (comfort)
The maximum permitted gross combination weight and maximum permitted trailer load specified in the documents are not
allowed to be exceeded.
For retrofitting a towing bracket:

– Comply with the regulations of the country in question, in this regard see also ECE-R55 and RREG 94/20/EC (in the valid
version).
– The necessary clearance for the towing bracket shall be guaranteed (clearance acc. to DIN 74058).
– The vehicle shall be presented to a motor vehicle test centre with responsibility for this matter.
Practical note
There are mounting points in the vehicle's chassis rails,

or if the towing bracket preparation and step have been
ordered, then they are below the step.
Operation with the factory-fitted hitch may be excluded

at a very low ride height or if there is a long body
overhang, as well as after an extension of the
overhang.
Information
The towing brackets listed here are only valid for EU

countries. There are different variants for countries
outside the EU. You can obtain more information on
this from your Volkswagen dealer.
2.8.3 Other accessories
Please note our extensive range of accessories when ordering your base vehicle.
The available optional equipment includes a winch (max. 3.6 t) with mounting on the front of the vehicle and on the load surface
as an additional offroad package (PR no. YAJ).
Information
For further information, see: http://www.volkswagen-

zubehoer.de/
2.9 Lifting the vehicle
– With lifting platforms

The vehicle is only allowed to be raised at the lifting points provided (see owner's manual).
– With a jack:
See the owner's manual for the procedure and jacking points on all vehicle variants (in all chassis without standard add-ons).
The body maker is responsible for making sure that the jack corresponds to the weight of the body. The hard points for lifting
platforms on the ladder frame can be used (with large pads) and shall remain accessible even after the conversion.
Alternative hard points should be created if this is not possible.

3.1 Body-in-white/bodywork
Comply with the following instructions with regard to mounting bodies and making conversions on the vehicle:
– Changes to the body are not allowed to impair the function and strength of units and operating devices of the vehicle, neither
may they reduce the strength of weight-bearing parts.
– During vehicle conversions and installation of bodies, it is not permitted to make any modifications which impair the function
and freedom of movement of the suspension (e.g. for maintenance and inspection work) or the accessibility to the same.
– Interventions in the cross-member structure from the front end to the rear of the B-pillar are not allowed.
– Modifications in the roof area and on the rear gate are not allowed.
– The clearance for the fuel filler neck as well as for the tank and fuel lines shall be maintained.
– Avoid corners with sharp edges.
– Neither drilling nor welding is permitted on the A and B-pillars.
– If cutting is performed on the C and D-pillars (rear gate), including the corresponding roof bows, then rigidity shall be restored
by means of additional components.
– The permitted axle loads are not allowed to be exceeded.
– Holes in the frame longitudinal member are the result of the production process and are not suitable for attaching add-ons,
bodies, installations and conversions; otherwise, the frame may be damaged.
– The standard tank cap is not allowed to be removed or covered with a part which creates a block.
Please also refer to chapter 4.1 "Cargo box removal".
3.1.1 Side wall and rear wall cut-outs
The body and underbody form a self-supporting unit. Weight-bearing parts of this self-supporting unit are not allowed to be
removed without replacement.
Windows, roof hatches and air inlets and outlets shall be surrounded by a stable frame. This frame shall be connected to other
body elements by means of a force-locking connection.
Information
You will find further information on body assembly work

on the Internet at erWin (Electronic Repair and
Workshop Information from Volkswagen AG):
3.1.2 Installation of windows
Information

removal of windows, refer to the workshop manuals of
Volkswagen AG on the Internet under erWin (Electronic
3.1.3 Roof cut-outs
The roof cut-out shall be provided with an all-round frame having a force-locking connection with the adjacent, weight-bearing
parts (bows and roof frame).
Information

3.1.4 Modifications to the roof
The following points shall be observed if modifications are made to the roof structure:
– The all-round concept shall be retained, and adequate replacement rigidity shall be guaranteed.
– Impairments to the function of the rain/light sensor shall be avoided.
– The vehicle constraints (strength, overall vehicle dimensions, registration, etc.) shall be considered with regard to attachments
on the roof panel. (This does not apply to area illumination and spotlights.)
– The replacement rigidity of the new roof structure shall correspond to that of the standard roof.
– Following all conversion and installation work on the vehicle, surface and corrosion protection shall be applied to the affected
points.
Information

3.2 Interior
The following points shall be observed without fail for conversions:

– The driver and front passenger airbag units, the airbags and belt tensioners are pyrotechnical objects.
– Their handling, transport and storage 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 personnel in accordance with the corresponding safety regulations.
– Modifications in the cockpit area and above the shoulder line shall be conducted in accordance with the criteria of the head
impact tests acc. to ECE-R21 or 74/60/EEC as amended by 2000/4/EC. This applies in particular to the deployment areas of
airbags (wood décor, additional installations, mobile phone holders, bottle holders, etc.).
– Painting or surface treatment of the instrument panel, steering wheel impact absorber and the tear seams of the airbags is not
permitted.
– The permitted centre of gravity position and axle loads are not allowed to be exceeded.
– The interior fitting-out shall be configured with soft edges and surfaces.
– Installations shall be manufactured from flame-retardant materials, and be firmly installed.
– Unhindered access to the seats shall be guaranteed.
– No projecting parts, corners or edges that could cause injuries are allowed to be located in the area of the seats.
3.2.1 Safety equipment
Warning note
In case of interventions by the body builder in the

structure of the vehicle, such as
– modifications to the seats and consequently altered

kinematics of the occupants in case of a crash
– modifications to the front body
– installations of parts in the vicinity of the exit openings
and the deployment range of the airbags (see owner's
manual of the vehicle)
– installation of third-party seats
– modifications to the doors
the safe function of the front airbag, side airbag and

belt tensioners is no longer guaranteed. This could
result in personal injuries.
No vehicle components that give rise to vibration are allowed to be attached in the vicinity of the airbag control unit or the sensor
installation locations.
Modifications to the floor structure in the area of the airbag control unit or the satellite sensors are not allowed.
(See also chapter 2.4.1 "Modifications in the area of airbags")
For information about the deployment zones of the airbags, refer to the owner's manual of the vehicle.

4.1 Removal of the cargo box
Fig. 4: Cargo box removal
The following work is required in order to remove the cargo box (1):
– Removal of the tail lights (3).
– Disconnecting of the cable routing for the number plate light and the earth cable.
– Releasing the parking brake cable from underneath (4).
– Removing the left wheel housing liner (5).
– Unscrewing the filler neck (6).
– Removing the electrical cables from the load bed.
– Unscrewing the bolts (2) on the left and right.
– Removing the complete rear bumper (7) or at least the cover and the plastic trim (only applies to vehicles with rear bumpers).
– Lifting the cargo box, e.g. with a crane (attaching the cargo box at the 4 standard load securing points).
To do this, the vehicle should be lifted on a lifting platform so its suspension is fully extended.
To avoid damage to the metal panels during removal, carefully pull the cargo box towards the rear out of the overlapping area
with the driver's cab prior to lifting.
You will find further information on removal of the rear bumper (7) and the cargo box in the Volkswagen AG workshop manuals.
Information

Important notes:
– The spare wheel is secured to the cargo box using a support bracket. A replacement attachment of the spare wheel shall be
provided if the cargo box is dispensed with/removed.
– A suitable holder shall be created for the filler neck of the fuel tank (a new type approval may be required).
– Provide suitable tail lights with the same performance figures as the standard ones.
Furthermore, comply with the data for special bodies listed in chapter 3.2 "Interior".
4.1.1 Removal of tail lights
The following work is required to remove the tail light:

– Switch off the ignition and all electrical loads, and pull out the ignition key.
– Open the tailgate.
– Unscrew and remove the fastening screws (arrows) from the tail light (Fig. 1).
– Guide the tail light sideways out of the ball head in the direction of the arrow. (Fig. 2)
– Disconnect the plug connection -arrow- at the tail light. (Fig. 3)
Fig. 4.1.1.1: Removal of the tail light (Figs. 1, 2 and 3)
4.1.2 Releasing the parking brake cable at the rear
The following steps are required to release the parking brake cable:
– Lift the vehicle (see also chap. 2.9 "Lifting the vehicle")
– Remove rear wheels.
– Following this, pull the parking brake cable (A) out of the holders on the body (bottom arrow).
Fig. 4.1.2.1: Releasing the parking brake cable
4.1.3 Removal of the wheel housing liner
The following work shall be performed in order to remove the wheel housing liner:
– Remove the wheel.
– Unscrew and remove the bolts (3).
– Unscrew the hexagon nut (2).
– Pull the rear wheel housing liner (1) out of the wheel housing.
Fig. 4.1.3.1: Removal of the wheel housing liner
4.1.4 Removal of the filler neck
Important safety note:

Work on the filler neck is only allowed to be performed when the tank is empty or has been removed!
The following work shall be performed in order to remove the filler neck:
Unscrew the bolt (2) for the filler neck (1) on the underbody.
– Open the tank flap and clean the inside of the tank flap unit thoroughly.
– Unscrew the cover.
Fig. 4.1.4.1: Detaching the filler neck on floor
– Unscrew and remove the bolt (2) on the tank flap unit.
– Unclip the tank flap unit and remove it completely.
Fig. 4.1.4.2: Releasing the tank flap unit
– Unscrew and remove nuts (2) from the filler neck (1) on the top of the cut-out
for the tank flap unit.
– Remove the filler neck (1) from below; this requires turning the filler neck.
– In vehicles with central locking, the plug for the filling station element shall be
disconnected.
Fig. 4.1.4.1: Releasing the filler neck
Please also comply with the following chapters for your conversion:
– Recommendations for attaching the filler neck (chap. 4.1.7)
– Standard mounting points for special bodies (chap. 4.3)
4.1.5 Unscrewing securing bolts
The following work shall be performed:

– Remove bolts (2) on left and right.
Fig. 4.4.5.1: Unscrewing securing bolts
4.1.6 Removal of the bumper
You will find further information on removal of the rear bumper (7) and the cover on the plastic trim in the Volkswagen AG
workshop manuals.
Information

You can order the Amarok (Single Cab or Double Cab) without rear bumper and with 180° folding tailgate as optional equipment
(PR no. 0S0) directly ex-works.
4.1.7 Recommendations for attaching the filler neck
Warning note
Please note that work on the filler neck may only be

performed when the tank is empty or has been
removed!
If the cargo box is removed for a body modification or is modified in the corresponding area, a suitable new fastening must be
created for the filler neck. The fastening must meet the requirements of regulation ECE-R 34 "Prevention of fire risks".
Comply with the following points during the work:

– The filler pipe shall be fixed to the ladder frame if possible, or else to components attached to that.
– The whole system with fuel filler pipe, filler neck and filler cap may not be damaged.
– The whole system must be permanently leak-proof in all operating conditions.
– The hose clamp must have the same retention force and durability as the production solution.
– All parts of the fuel filler system must be routed at a sufficient distance from moving parts and sharp edges to avoid damage.
Sufficient distance from the rear wheel should be ensured in particular.
– Components of the fuel filler system may not be attached to safety-related parts, for example, brake lines.
– All materials used must be petrol- or diesel-resistant.
– A sufficient angle of the filler pipe to the tank should be ensured. Pipe routing that could cause a siphon effect must be
avoided.
– If the standard tank cap is not used, it must be ensured that the overpressure and vacuum protection functions integrated into
the standard tank cap are retained.
– The accessibility of the pump nozzle to the filler neck should be guaranteed as with the production solution.
In addition, and depending on the fuel, the following requirements and recommendations shall be complied with when routing
the filler neck for diesel and petrol "filler pipes".
4.1.7.1 Diesel filler pipe
Fig. 1: Filler pipe assembly (ASSY)
1 Ventilation valve
2 Fastening lug for closure neck
2 Closure cap (tank cap):
- Opening pressure at 0.025 to 0.045 bar negative pressure (rel.)
- Opening pressure at 0.150 to 0.250 bar positive pressure (rel.)
Requirements on the Amarok diesel filler pipe:

– An earthing path from the filler pipe via the closure neck and fastening lug to the vehicle body work (screw connection) shall
be guaranteed.
– A ventilation function for the fuel tank via the filler pipe shall be provided.
– The connecting hose and vent line are not allowed to be kinked.
– The filler pipe, connecting hose and vent line are not allowed to be in contact with adjacent components, in order to prevent
any chafing or leaks.
Recommendations for the conversion:

– The positive pressure and negative pressure protection functions integrated in the closure cap (tank cap) shall be retained if
at all possible.
– The filler pipe shall be fixed to the ladder frame if possible, or else to components attached to that.
4.1.7.2 Petrol filler pipe
Fig. 2: Petrol filler pipe
1 Ventilation line
2 Activated charcoal container
Requirements on the Amarok petrol filler pipe:

– An earthing path from the filler pipe via the closure pipe and fastening lug to the vehicle body work (screw connection) shall
be guaranteed (same as diesel).
– The positive pressure protection function for the fuel tank shall be ensured in the filler pipe (Amarok petrol standard solution:
protection valve in the tank cap).
– The connecting hose and vent line are not allowed to be kinked.
– The filler pipe, connecting hose and vent line are not allowed to be in contact with adjacent components, in order to prevent
any chafing or leaks.
– The air intake for the activated charcoal canister (ACC) shall be routed in an area where no water can be sucked in even
when driving through water.
(Amarok petrol standard solution: ACC ventilation line for air intake routed in the area of the fuel filler pipe in the wheel
housing).
4.1.8 Weight of cargo box
Component Amarok DC Amarok SC

Cargo box* 121 kg 151 kg
* incl. the add-on parts for the tailgate, hinges, tail light cluster, wheel housing liner and tailgate lock
4.2 Chassis frame
4.2.1 Ladder frame Amarok DC (Double Cab)
Fig. 4.2.1.1: Plan view of Amarok DC without cargo box
Fig. 4.2.1.2: Plan view of ladder frame Amarok DC
4.2.2 Ladder frame Amarok SC (Single Cab)
Fig. 4.2.2.1: Plan view of Amarok SC (Single Cab) without cargo box
Fig. 4.2.2.2: Plan view of ladder frame Amarok SC
4.2.3 Sections, Amarok SC (Single Cab)/Amarok DC (Double Cab)
Ø21
~ 162
~169
~ 67
Fig. 4.2.2.1: Section Q-Q (Amarok SC) Fig. 4.2.2.2 Section R-R (Amarok SC/DC)
Fig. 4.2.2.3: Section S-S (Amarok SC/DC) Fig. 4.2.2.4: Section T-T (Amarok SC/DC)
Please refer to the Amarok DoubleCab and SingleCab build dimension drawings for further connection sizes
(see chapter 6.1 "Technical data").
4.3 Standard mounting points for special bodies
Special bodies are possible after the cargo box has been removed (see chap. 4.1).
Comply with the following points when mounting special bodies:

– Use standard mounting points.
– If the cargo box is replaced by other bodies, the new body shall have a maximum static torsional rigidity of CT=1400 Nm/°
(see Fig. 4.3.3).
– The wheel clearance on the rear axle shall be maintained.
– A suitable holder shall be created for the filler neck of the fuel tank (a new type approval may be required).
– Suitable tail lights with the same performance data as the standard ones shall be used.
The frame is a hollow section construction consisting of pressed sheet metal parts.
Brackets are welded onto the longitudinal members for attachment of the cargo box. Holes or slots
with the dimension 21 mm, 23 mm or 21x30 mm are provided for attachment of the cargo box (Fig. 4.3.1/4.3.2).
For more information, refer to chap. 4.2 "Chassis frame".
The attachment between the body and vehicle frame shall always use all brackets.
The screw connections onto the brackets shall be force-locking.
Fig. 4.3.1: Amarok Double Cab – mounting brackets for cargo box (see red mark)
Fig. 4.3.2: Amarok Single Cab – mounting brackets for cargo box (see red mark!)
Fig. 4.3.3: Static rigidity of cargo box between the bolting points at the front (1) and rear (2) of body-in-white, CT = 1,400 Nm/°
4.4 Subframe (mounting frame)
The subframe shall be designed to be self-supporting according to the load.
The preferred material is steel. If alternative materials are used, the strength of the subframe shall at least correspond to that of
a steel frame.
Cross members shall be provided at least in the front and rear areas to ensure the structure is torsionally rigid.
The subframe is required for bodies in which point loads are applied to the chassis, e.g. for tippers and semitrailer tractors.
The purpose of the subframe is to distribute the applied point loads evenly over the vehicle frame. For this purpose, it should lie
on top of the longitudinal members, be continued up to the cab and be tapering in the front area.
The various air gaps between the cab and subframe shall not be filled in. Self-supporting bodies can be attached directly to the
standard brackets on the frame by means of a base frame.
The subframe and self-supporting bodies shall be attached to the chassis using all available brackets.
Bolts with strength class 10.9 shall be used for securing.
Information
For further information, see:
– Chap. 4.1 "Removal of the cargo box"

– Chap. 4.3 "Standard mounting points
for special bodies"

5.1 Conversions for people with disabilities
Depending of the type of disabilities, a large number of driving aids are available as optional equipment from Volkswagen AG.
For more information, please contact your Volkswagen partner.
Notes on installing manual operating devices for the service brake:

– Do not modify the brake pedal when installing manual operating devices.
– The operating travel of the manual operating device must also be sufficient for a blocking braking, with reserve travel for a
circuit failure.
Information
For more information about this topic, refer to:
http://umbauportal.de/technische-zusatzinformationen
as well as the Volkswagen AG website at:
nutzfahrzeuge.de/de/kunden/menschen_mit_behinderung.html
Deactivation of airbags:
In exceptional cases, e.g. drivers with a disability (entered accordingly in the driving licence), if there is insufficient distance from
the steering wheel or if the steering wheel is too small with drivers in a wheelchair (self-drive), and no airbag can be installed,
the customer service workshop can also deactivate the driver airbag.
For more information, please contact Volkswagen customer service.
Please also comply with the following chapters as part of the conversion:
– 2.5.2.1 "Electrical cables and fuses"
– 3.2.1 "Safety equipment"
5.2 Refrigerated vehicles
Comply with the following chapters during the conversion:

– 2.2.1 "Permitted weights and unladen weights"
– 2.3.2 "Modifications to the body-in-white"
– 2.5.3 Electrical interface for special vehicles
– 2.7.2 "Auxiliary drives"
– 3.1.4 "Modifications to the roof"
Information
5.3 Shelf installation/workshop vehicles
– 2.6.3 "Fuel system"
– 2.6.4 "Exhaust system"
Information
5.4 Conversions for caravans
Information
http://umbauportal.de/umbauten
or at:
nutzfahrzeuge.de/de/kunden/sonderabnehmer/freizeitmobile.html
5.5 Conversions for municipal vehicles
Information
5.6 Articulated vehicles
Vehicles with ESP* are not suitable for use as articulated vehicles.
Otherwise the ESP system in vehicles with ESP will no longer function correctly
and will fail. This may result in the driver losing control of the vehicle and causing an accident.
Downgrading the ESP (see chapter 2.2.6.4 "Downgrading ESP") is generally necessary when the Amarok is converted into an
articulated vehicle.
A safety certificate from the responsible department is required for the conversion.
Information
5.7 Elevated work platforms
Practical note
If bodies have moving attachments, ensure sufficient

clearance from the base vehicle. Otherwise
attachments could collide with the base vehicle and
cause damage.
Practical note
The elevated work platform may only be operated if the

vehicle has been fully raised on outriggers. The vehicle
may not be moved if the elevated work platform has
been raised. The frame could be damaged if the
vehicle is moved while the elevated work platform is
raised. The superstructure manufacturer must install a
safety mechanism so that the vehicle cannot be moved
while the elevated work platform is raised.
There must be no additional loads in or on the cab

while the vehicle is raised on its outriggers. Otherwise
the frame could be damaged.
Please also comply with the following chapters for your conversion:
– 2.2 "Running gear"
Information
5.8 Crane superstructures and lift systems
Please comply with the following points during the conversion:

– The crane size must be suitable for the chassis size.
– Loading cranes must be secured on a mounting frame to reduce the load on the frame.
– The compliance with the permitted axle loads should checked with the aid of a weight assessment.
– The stability of the vehicle must be guaranteed by the body builder.
– The swivel range of the crane must be limited accordingly.
– In Germany, loading cranes mounted on vehicles must comply with the accident prevention regulations.
– Please observe the applicable regulations in your respective country.
– The assembly instructions from the crane manufacturer must be followed.
Information
Please also comply with the following chapters of the Body builder guidelines for your conversion:
– 2.2 "Running gear"
6 Technical data
6 Technical data
6.1 Build dimension drawings
6.1.1 Amarok Double Cab
Please refer to our dimensional drawings for the dimensions of the Amarok. They are available for download in DXF, TIFF and
PDF format at the Conversion Portal of Volkswagen AG.
Information
Current dimensional drawings can be downloaded from

the Conversion Portal of Volkswagen AG at:
http://umbauportal.de/technische-zeichnungen
6.1.2 Amarok Single Cab
The individual dimension drawings are available in the formats DXF, TIF and PDF. All files (except PDFs) are packed as Zip
archives. The files can be unpacked using Winzip (PC) or ZipIt (MAC).
Information
Current dimensional drawings can be downloaded from

the Conversion Portal of Volkswagen AG at:
http://umbauportal.de/technische-zeichnungen
6 Technical data
6.2 Diagrams (foil templates)
Vehicle views in 1:10 scale are available for download in TIF, DXF and EPS format to help you create diagrams. All files are
packed as Zip archives. The files can be unpacked using Winzip (PC) or ZipIt (MAC).
6.2.1 Amarok Double Cab (all views)
Information
Current diagrams (foil templates) can be downloaded

from the Internet Conversion Portal of Volkswagen AG
at:
http://umbauportal.de/vignetten
6.2.2 Amarok Single Cab (all views)
Information

at:
6 Technical data
6.2.3 Side view all derivatives
To help you create diagrams, you can download the side views of all derivatives on the Conversion Portal of Volkswagen
Nutzfahrzeuge AG.
Information

at:
The following side views are available:
Designation Picture
Amarok Double Cab basic
Amarok Double Cab
Amarok Single Cab
6 Technical data
6.3 Circuit diagrams
For detailed information about this topic, refer to the workshop manuals and circuit diagrams of Volkswagen AG.
Information

6.4 CAD models
On request, body builders can receive 3D data models in the formats CATIA V.5/STEP/JT for design purposes.
Information
For more information about CAD data, refer to the

Conversion Portal of Volkswagen AG on the Internet:
http://umbauportal.de/cad-daten
6 Technical data
6.5 Weight tables
6.5.1 Weight tables Amarok Double Cab
(Kerb weights with driver, ready to drive with 90% tank fill)
6.5.1.2 Amarok Double Cab
Perm. weights Unl. weight incl. driver

Pay-
[kg] [kg]
Gearbo load
Engine PR no. Front axle
x Total Rear axle Total weight max.
load FA RA
weight load (RA) (min.) [kg]
(FA)
2.0 l TFSI 118 kW
0WA 2820 1300 1620 1854 1036 818 966
petrol 2)
MG
2.0 l TFSI 118 kW
Petrol
0WL 3040 1310 1860 1871 1036 835 1169

petrol 3)
2.0 l TDI 90 kW 2) ** 0WA 2820 1315 1620 1868 1044 824 952
MG
Diesel
2.0 l TDI 90 kW 3) ** 0WL 3040 1325 1860 1889 1044 845 1151
2.0 l TDI 103 kW 2) *** 0WA 2820 1315 1620 1877 1049 828 943
MG
Diesel
3) ***
2.0 l TDI 103 kW 0WL 3040 1325 1860 1894 1049 845 1146
2.0 TDI 120 kW 2) * 0WA 2820 1325 1620 1898 1068 830 922
2.0 TDI 120 kW 3) * 0WL 3040 1335 1860 1919 1068 851 1121
MG
3)
2.0 l TDI 132 kW 0WA 2820 1325 1620 1897 1069 828 923
Diesel
2.0 l TDI 132 kW 3) 0WL 3040 1335 1860 1914 1069 845 1126
2.0 l TDI 132 kW 4) * 0WA 2820 1415 1620 1975 1141 834 845
A
Diesel
4) *
2.0 l TDI 132 kW 0WL 3040 1415 1860 1992 1141 851 1048
2.0 l TDI 90 kW 2) ** 0WA 2820 1375 1620 1931 1105 826 889
4Mo
Diesel
1) 3) **
2.0 l TDI 90 kW 0WL 3040 1375 1860 1968 1115 853 1072
2.0 l TDI 103 kW 2) ** 0WA 2820 1375 1620 1939 1109 830 881
4Mo
Diesel
1) 3) **
2.0 l TDI 103 kW 0WL 3040 1375 1860 1972 1119 853 1068
6 Technical data
2.0 l TDI 120 kW 2)* 0WA 2820 1385 1620 1961 1129 832 859
2.0 l TDI 120 kW 1) 3)* 0WL 3040 1385 1860 1998 1139 859 1042
4Mo
3)
2.0 l TDI 132 kW 0WA 2820 1385 1620 1971 1134 837 849
Diesel
2.0 l TDI 132 kW 1) 3) 0WL 3040 1385 1860 1992 1139 853 1048
Status: 22 February 2013
1) Non-permanent 4-wheel drive; 2) 2+1 leaf springs (comfort); 3) 3+2 leaf springs (heavy duty); 4) Permanent Torsen
Gearbox abbreviations: MG = manual gearbox, 4Mo = 4-wheel drive gearbox, A = automatic
6 Technical data
6.5.1.3 Amarok Double Cab chassis/CabChassis

Pay-
[kg] [kg]
Gearbo load
load FA RA
(FA)
2.0 l TFSI 118 kW
0WA 2820 1300 1620 1736 1050 686 1084
petrol 2)
MG
2.0 l TFSI 118 kW
Petrol
0WL 3040 1310 1860 1753 1050 703 1287

petrol 3)
2.0 l TDI 90 kW 2) ** 0WA 2820 1315 1620 1750 1058 692 1070
MG
Diesel
3) **
2.0 l TDI 90 kW 0WL 3040 1325 1860 1771 1058 713 1269
2) ***
2.0 l TDI 103W 0WA 2820 1315 1620 1759 1063 696 1061
MG
Diesel
3) ***
2.0 l TDI 103 kW 0WL 3040 1325 1860 1776 1063 713 1264
2.0 l TDI 120 kW 2) * 0WA 2820 1325 1620 1780 1082 698 1040
2.0 l TDI 120 kW 3) * 0WL 3040 1335 1860 1801 1082 719 1239
MG
3)
2.0 l TDI 132 kW 0WA 2820 1325 1620 1779 1083 696 1041
Diesel
2.0 l TDI 132 kW 3) 0WL 3040 1335 1860 1796 1083 713 1244
2.0 l TDI 132 kW 4) 0WL 3040 1415 1860 1874 1155 719 1166
A
Diesel
2)
2.0 l TDI 132 kW 0WA 2820 1415 1620 1857 1155 702 963
2.0 l TDI 90 kW 2) ** 0WA 2820 1375 1620 1813 1119 694 1007
4Mo
Diesel
2.0 l TDI 90 kW 1) 3) ** 0WL 3040 1375 1860 1850 1129 721 1170
2.0 l TDI 103 kW 2) *** 0WA 2820 1375 1620 1821 1123 698 999
4Mo
2.0 l TDI 103 kW 1) 3)
Diesel
***
0WL 3040 1375 1860 1854 1133 721 1186
2.0 l TDI 120 kW 2)* 0WA 2820 1385 1620 1843 1143 700 977
2.0 l TDI 120 kW 1) 3)* 4Mo 0WL 3040 1385 1860 1880 1153 727 1160
Diesel
2.0 l TDI 132 kW 2) 0WA 2820 1385 1620 1853 1148 705 967
6 Technical data

Pay-
[kg] [kg]
Gearbo load
load FA RA
(FA)
2.0 l TDI 132 kW 1) 3) 0WL 3040 1385 1874 1153 1149 721 1168
1) Non-permanent 4-wheel drive; 2) 2+1 leaf springs (comfort); 3) 3+2 leaf springs (heavy duty); 4) Permanent Torsen
6 Technical data
6.5.2 Weight tables Amarok Single Cab
(Kerb weights with driver, ready to drive with 90% tank fill)
6.5.2.1 Amarok Single Cab:

Pay-
[kg] [kg]
Gearbo load
load FA RA
(FA)
Petrol
2.0 l TFSI 118 kW MG 0WL 3040 1255 1860 1772 1020 752 1268
2.0 l TDI 90 kW ** 0WL 3040 1270 1860 1795 1027 768 1245
2.0 l TDI 103 kW *** 0WL 3040 1270 1860 1795 1033 762 1245
MG
2.0 l TDI 120 kW * 0WL 3040 1280 1860 1812 1042 770 1228
Diesel
0WL 3040 1280 1860 1815 1053 762 1225

2.0 l TDI 132 kW
2.0 l TDI 90 kW 1) ** 0WL 3040 1335 1860 1874 1098 776 1166
2.0 l TDI 103 kW 1) *** 0WL 3040 1335 1860 1873 1103 770 1167
4Mo
2.0 l TDI 120 kW 1)* 0WL 3040 1345 1860 1905 1127 778 1135
2.0 l TDI 132 kW 1)

Diesel
0WL 3040 1345 1860 1893 1123 770 1147
1) Non-permanent four-wheel drive; 2) 2+1 leaf springs (comfort); 3) 3+2 leaf springs (heavy duty)
6 Technical data
6.5.2.2 Amarok Single Cab - chassis/CabChassis

Pay-
[kg] [kg]
Gearbo load
load FA RA
(FA)
Petrol
2.0 l TFSI 118 kW MG 0WL 3040 1255 1860 1624 1025 599 1416
2.0 l TDI 90 kW ** 0WL 3040 1270 1860 1647 1032 615 1393
2.0 l TDI 103 kW *** 0WL 3040 1270 1860 1647 1038 609 1393
MG
2.0 l TDI 120 kW * 0WL 3040 1280 1860 1664 1047 617 1376
Diesel
0WL 3040 1280 1860 1667 1058 609 1373

2.0 l TDI 132 kW
2.0 l TDI 90 kW 1) ** 0WL 3040 1335 1860 1726 1103 623 1314
2.0 l TDI 103 kW *** 0WL 3040 1335 1860 1725 1109 616 1315
4Mo
2.0 l TDI 120 kW 1) * 0WL 3040 1345 1860 1757 1132 625 1283
2.0 l TDI 132 kW 1)

Diesel
0WL 3040 1345 1860 1745 1129 616 1299
1) Non-permanent four-wheel drive; 2) 2+1 leaf springs (comfort); 3) 3+2 leaf springs (heavy duty)
7 Calculation
7 Calculation
7.1 Determining the centre of gravity
The overall centre of gravity height (vehicle with add-ons or complete body without load) should be kept as low as possible.
The centre of gravity in the vehicle longitudinal direction is given in relation to a vehicle axle.
The centre of gravity height is related to the wheel hub or related to the road.
Volkswagen recommends having the centre of gravity determined by a recognised test institution with experience in this field
(for example, DEKRA, TÜV or others).
For the body builder to determine the centre of gravity, we recommend following the procedure described under 7.1.1
"Determining the centre of gravity in x-direction" and 7.1.2 "Determining the centre of gravity in z-direction" and using personnel
with the corresponding qualifications to obtain usable results.
7.1.1 Determining the centre of gravity in x-direction
Procedure:
– The vehicle must be weighed with the add-ons or complete body without load.
– Inflate the tyres up to the tyre pressure that is specified for the respective maximum permitted axle load.
– Completely fill all fluid containers (fuel tank, washer fluid reservoir, if applicable, hydraulic tank, water tank etc.).
– The vehicle is on the scales, the engine switched off, gearbox in neutral and the brakes released.
– The vehicle must be standing horizontal and level for weighing.
– First weigh the individual axle loads (front and rear axle load) and then the gross weight of the vehicle.
– The measured values can be used to calculate the position of the centre of gravity in the vehicle longitudinal direction with the
equations (3) and (4). The equation (2) should be used to check the results of (3) and (4).
Fig. 1: Determining the overall centre of gravity of the vehicle in the x-direction
Determining the total weight of the unladen vehicle with add-ons and body:
7 Calculation
𝐺𝐺 = 𝐺𝐻𝐴 + 𝐺𝑉𝐴 (1)
Calculating the position of the overall centre of gravity 𝑆𝐺 in x - direction
𝐿 = 𝐿𝑉 + 𝐿 𝐻 (2)
𝐺𝐻𝐴
𝐿𝑉 = 𝐿 (3)
𝐺𝐺
𝐺𝑉𝐴
𝐿𝐻 = 𝐺𝐺
𝐿 (4)
Abbreviations and parameters used:
𝐺𝐺 - Total weight of unladen vehicle.

𝐺𝑉𝐴 - Front axle load of unladen vehicle (specification or weighing of respective chassis).
𝐺𝐻𝐴 - Rear axle load of unladen vehicle (specification or weighing of respective chassis).
𝑆𝐺 - Overall centre of gravity.
𝐿 - Wheelbase.
𝐿𝑉 - Distance from the overall centre of gravity of the empty vehicle to the front axle.
𝐿𝐻 - Distance from the overall centre of gravity of the empty vehicle to the rear axle.
Practical note
The practical determination of the centre of gravity

height may only be performed by appropriately
qualified personnel with the help of suitable and
calibrated scales.
To reduce measuring errors, each measured value

should be calculated at least three times and an
average value calculated from the three results. This
value is then used for calculating in accordance with
the equations (3) and (4).
Information
The wheelbase "L" is defined by the vehicle prototype

(see order) or should be defined by measuring the
length in accordance with DIN 70020, part 1.
7 Calculation
7.1.2 Determining the centre of gravity in z-direction
For the body builder to determine the overall vehicle centre of gravity hS (see Fig.1), Volkswagen AG recommends
the following procedure once the complete vehicle has been finished:
– After conversion, the vehicle should be weighed on board scales or on suitable wheel load scales in two subsequent driving
positions.
– Here, the measured axle loads should be determined with the vehicle in a level state GFA and GRA (see 2.1.5.1 "Determining
the centre of gravity in x-direction") and the axle loads on an axle QRA or QFA increased by the quantity h'. The raising height
h' should be as large as possible in accordance with the front and rear overhang angles of the vehicle (also known as entry or
exit angles). The target value is > 600 mm.
– To reduce measuring errors, at least six individual measurements should be made in the axle load calculation for each axle:
three per axle with vehicle level and three each with raised axle. The average value for each axle should be calculated from
the three measurements for a state.
– The average value should be calculated from these three values and used in the calculations with the equations (5) to (9). To
improve the accuracy of the final result, the axle load modification should be determined with raised rear axle and raised front
axle.
Practical note
Observe the following to avoid incorrect If the vehicle suspension cannot be locked due to the body or
measurements: available space, further axle load measurements must be carried
out at different levels (for example, 600 mm, 700 mm and 800
– The vehicle must be standing perfectly horizontal for
mm). This also allows errors to be limited by averaging. The
weighing in level vehicle state. Height differences
centre of gravity height results from the arithmetic average of the
between the axles caused by scales should be
individual centre of gravity heights for each raising height.
compensated accordingly.
– When raising to the required lifting height, the axle
being weighed should be locked to prevent suspension
compression or extension.
– When raising to the required lifting height, no part of
the vehicle may touch the ground.
– All vehicle wheels must be able to rotate freely: select
neutral, release all brakes including handbrake and
place chocks at sufficient distance from the wheels, if
necessary.
– Move vehicle with own power (to weigh the respective
other vehicle axle) to relieve any tension in the vehicle.
– Ensure that no objects inside the vehicle can move
during the measurements.
7 Calculation
Example of procedure
1. The vehicle must be weighed with the add-ons or complete body without load.
2. Inflate the tyres up to the tyre pressure that is specified for the respective maximum permitted axle load.
3. Completely fill all fluid containers (fuel tank, washer fluid reservoir, if applicable, hydraulic tank, water tank etc.).
4. On the scales, switch off the engine, set gearbox to neutral and release the brakes.
5. Position the vehicle with the rear axle (RA) horizontal and level on the scales and measure the axle load.
6. Raise the front axle (FA) by the value h', at least 600 mm. A greater height h' taking the other vehicle-related conditions into
consideration is more favourable for the final result. The value h' must be measured for all individual measurements with
raised axle and should be as identical as possible. Alternatively to the raised height h', the angle α between the wheel hubs
can be defined.
7. Determine the axle load displacement QRA that occurs at the rear on the scales.
8. Lower and turn the vehicle around and perform the corresponding measurements on the front axle (first GFA with level and
then QFA with the rear axle raised by h').
9. Perform steps 4–7 a total of three times (with locked suspension).
10. The measured values can be used to calculate the height of the centre of gravity with the equations (5) to (9).
11. In the calculations using the equations (3) to (9), all length measurements should be in millimetres (mm) and all weight
figures in decanewton (1 daN = 10 N).
12. Raised the raised axle further (by e.g. 100 mm) and measure the height of the centre of gravity again to confirm the
measuring result.
Practical note
The practical determination of the centre of gravity

height may only be performed by appropriately
qualified personnel with the help of suitable and
calibrated measuring systems and measuring tools.
7 Calculation
Fig. 2: Determining the position of the overall centre of gravity in z-direction
7 Calculation
Determining the overall centre of gravity 𝑆𝐺 in z-direction:
ℎ𝑆 = ℎ𝑎 + 𝑟𝑠𝑡𝑎𝑡 (5)
Determining the overall centre of gravity 𝑆𝐺 in z-direction for the raised front axle:
𝑄𝐻𝐴 −𝐺𝐻𝐴 1
ℎ𝑆 = � 𝐺𝐺
×𝐿× � + 𝑟𝑠𝑡𝑎𝑡 (6)
tan 𝛼
ℎ′
sin 𝛼 = (6a)
𝐿
ℎ′
𝛼 = 𝑎𝑟𝑐 sin � � (6b)
𝐿
1 𝑄𝐻𝐴 −𝐺𝐻𝐴
ℎ𝑆 = � × × √𝐿2 − ℎ′2 � + 𝑟𝑠𝑡𝑎𝑡 (7)
ℎ′ 𝐺𝐺
Determining the overall centre of gravity 𝑆𝐺 in z-direction for the raised front axle:
𝑄𝑉𝐴 −𝐺𝑉𝐴 1
ℎ𝑆 = � ×𝐿× � + 𝑟𝑠𝑡𝑎𝑡 (8)
𝐺𝐺 tan 𝛼
ℎ′
sin 𝛼 = (8a)
𝐿
ℎ′
𝛼 = 𝑎𝑟𝑐 sin � � (8b)
𝐿
1 𝑄𝑉𝐴 −𝐺𝑉𝐴
ℎ𝑆 = � × × √𝐿2 − ℎ′2 � + 𝑟𝑠𝑡𝑎𝑡 (9)
ℎ′ 𝐺𝐺
Abbreviations and parameters used:
𝑟𝑠𝑡𝑎𝑡 - Static tyre radius.

𝑄𝑉𝐴 - Front axle load when vehicle raised at rear.
𝑄𝐻𝐴 - Rear axle load when vehicle raised at front.
𝐺𝐺 - Total weight of unladen vehicle.
𝐺𝑉𝐴 - Front axle load of unladen vehicle (specification or weighing of respective chassis).
𝐺𝐻𝐴 - Rear axle load of unladen vehicle (specification or weighing of respective chassis).
𝐿 - Wheelbase.
𝐿𝑉 - Distance from the overall centre of gravity of the empty vehicle to the front axle.
𝐿𝐻 - Distance from the overall centre of gravity of the empty vehicle to the rear axle.
ℎ𝑆 - Centre of gravity height over road.
ℎ𝑎 - Centre of gravity height over centre of wheel.
ℎ′ - Height by which the vehicle has been raised.
1 - Weighing system.
7 Calculation
Information
The wheelbase "L" is defined by the vehicle prototype

(see order) or should be defined by measuring the
length in accordance with DIN 70020, part 1.
Practical note
The measured centre of gravity may not exceed the

limit values named in chap. 2.1.3 "Vehicle centre of
gravity".
8 Listings
8 Listings
8.1 List of changes
Changes to the body builder guidelines compared to the data status of November 2012
Chapter
Chapter heading Scope of change
No.
0. Title page
1. General information
1.1 Introduction
1.1.1 Concept of these guidelines
1.1.2 Means of representation
1.1.3 Vehicle safety
1.1.4 Operating safety
1.2 General notes
1.2.1 Product and vehicle information for body builders
1.2.1.1 Contact Chapter revised
1.2.1.2 Conversion Portal Chapter revised
1.2.1.3 Electronic repair and workshop information (erWin)
1.2.1.4 Genuine parts online ordering portal
1.2.2 Body builder guidelines and consulting
1.2.2.1 Safety certificate
1.2.2.2 Application for the safety certificate
1.2.2.3 Legal entitlements
1.2.3 Warranty and product liability of the body builder
1.2.4 Ensuring traceability
1.2.5 Badges
1.2.5.1 Positions on rear of vehicle
1.2.5.2 Appearance of overall vehicle
1.2.5.3 Non-Volkswagen trademarks
1.2.6 Recommendations for vehicle storage
1.2.7 Compliance with environmental rules and regulations
1.2.8 Recommendations for inspection, maintenance and repair
1.2.9 Accident prevention
1.2.10 Quality system
1.3 Delivery range
1.4 Advantages of the concept
1.5 Planning bodies "Information" box deleted
1.5.2 Vehicle modifications "Practical note" box content revised
1.5.3 Vehicle acceptance
1.6 Optional equipment
2. Technical data for planning
2.1 Base vehicle
2.1.1 Vehicle dimensions
2.1.1.1 Basic data Single Cab and Double Cab
2.1.2 Overhang angle and ramp angle
8 Listings
Chapter
No.
2.1.3 Vehicle centre of gravity

2.1.4 Bodies with a high centre of gravity
2.1.4.1 Extremely high centres of gravity (> 800 mm)
2.1.5 Determining centre of gravity Reference to new chapter 7. Calculations.
2.1.6 Maximum dimensions
2.1.7 Steerability
2.2 Running gear Chapter updated
Weight tables moved / 103 kW engine
2.2.1 Permitted weights and unladen weights
added
2.2.1.2 One-sided weight distribution Chapter number changed/adapted
2.2.2 Turning circle
2.2.3 Authorised tyre sizes
2.2.4 Modifications to axles Chapter revised
2.2.5 Modifications to the steering system
2.2.6 Modifications to the brake system

2.2.6.1 General notes
2.2.6.2 Vehicle stability and ESP*
2.2.6.3 Influence of vehicle conversions
2.2.6.4 Downgrading ESP
2.2.6.5 2.2.6.5 Activating the ESP
2.2.7 Modification of springs, suspension mounting, dampers Chapter revised
2.2.8 Wheel alignment settings
2.2.9 Wing and wheel housing
2.2.10 Overhang extension
2.2.10.1 Requirements for trailer operation with overhang extension
2.2.11 Wheelbase modification

2.3 Body-in-white
2.3.1 Roof loads/vehicle roof
2.3.2 Modifications to the body-in-white
2.3.2.1 Bolted connections
2.3.2.2 Welding work
2.3.2.3 Welded connections
2.3.2.4 Selection of welding process
2.3.2.5 Spot welding
2.3.2.6 Shielding gas hole spot welding
2.3.2.7 Tacking
2.3.2.8 Welding is not allowed
2.3.2.9 Corrosion protection after welding
2.3.2.10 Corrosion protection measures
2.3.2.11 Planning measures
2.3.2.12 Component design measures
2.3.2.13 Coating measures
2.3.2.14 Work on the vehicle
2.3.3 Tailgate
8 Listings
Chapter
No.
2.4 Interior
2.4.1 Modifications in the area of airbags Chapter revised
2.4.2 Modifications in the area of seats
2.4.3 Forced ventilation
2.4.4 Acoustic insulation
2.5 Electrical/electronic systems
2.5.1 Lights
2.5.1.1 Vehicle lighting devices
2.5.1.2 Mounting special lights

2.5.1.3 Installing 3rd Brake light
2.5.1.4 Additional load compartment light
2.5.2 Vehicle electrical system
2.5.2.1 Electrical cables / fuses
2.5.2.2 Additional electrical circuits Chapter revised
2.5.2.3 Retrofitting electrical devices
2.5.2.4 Electromagnetic compatibility
2.5.2.5 Mobile communication systems
2.5.2.6 CAN bus
2.5.3 Electrical interface for special vehicles
2.5.3.1 Position of the interface
2.5.3.2 Assignment of the terminal strip (UF1) Chapter title and content revised!
Connector pin assignment and circuit diagrams for interface
2.5.3.3
for special vehicles
2.5.4 Vehicle battery
2.5.4.1 Installation of additional battery
2.5.5 Digital tachograph
2.6 Engine peripherals/powertrain
2.6.1 Engine/powertrain components

2.6.2 Drive shafts
2.6.3 Fuel system
2.6.4 Exhaust system Chapter revised
2.7 Ancillary drives, engine/gearbox
2.7.1 Retrofitting air-conditioning system
2.7.2 Driving an ancillary via the 2nd belt track Chapter revised
2.7.3 Specifications of standard refrigerant compressor
2.7.3.1 Connection dimensions of original refrigerant compressor
2.7.4 Assembly and disassembly of the poly V-belt
2.7.4.4 Belt routing New chapter added
2.8 Add-ons/units
2.8.1 Roof rack
2.8.2 Towing bracket Chapter revised
2.8.3 Other accessories Chapter supplemented
2.9 Raising the vehicle
3. Modifications to closed bodies
8 Listings
Chapter
No.
3.1 Body-in-white/bodywork
3.1.1 Side wall and rear wall cut-outs
3.1.2 Installation of windows
3.1.3 Roof cut-outs

3.1.4 Modifications to the roof
3.2 Interior
3.2.1 Safety equipment Chapter revised
4. Modifications to open bodies

4.1 Cargo box removal
4.1.1 Removal of tail lights
4.1.2 Releasing the parking brake cable at the rear
4.1.3 Removal of the wheel housing liner
4.1.4 Removal of the filler neck
4.1.5 Unscrewing securing bolts
4.1.6 Removing bumper
4.1.7 Recommendations for attaching the filler neck
4.1.7.1 Diesel filler pipe
4.1.7.2 Petrol filler pipe
4.1.8 Weight of the cargo box
4.2 Chassis frame
4.2.1 Ladder frame AMAROK DC (Double Cab)
4.2.2 Ladder frame Amarok SC (Single Cab)
4.2.3 Sections, Amarok SC/Amarok DC
4.3 Standard mounting points
4.4 Subframe
5. Implementation of special bodies
"Practical note" info box text adapted /
5.1 Conversions for people with disabilities
chapter completely revised
5.2 Refrigerated vehicles Infobox text adapted
5.3 Shelf installation/workshop vehicles Infobox text adapted
5.4 Conversions for caravans Infobox text adapted
5.5 Conversions for municipal vehicles Infobox text adapted
5.6 Articulated vehicles
5.7 Elevated work platforms
5.8 Crane superstructures and lift systems
6. The technical data
6.1 Build dimension drawings
6.1.1 Amarok Double Cab
6.1.2 Amarok Single Cab
6.2 Diagrams (foil templates) Heading adapted
6.2.1 Amarok Double Cab (all views)
8 Listings
Chapter
No.
6.2.2 Amarok Single Cab (all views)
6.2.3 Side view all derivatives

6.3 Circuit diagrams
6.4 CAD models Chapter revised (format JT added)
Contents of chapters 6.5 to 6.5.2.2 moved /
6.5 Weight tables previously formed part of chapters 2.2 and
2.2.1 / contents revised/supplemented
7. Calculations Chapter moved
7.1 Determining centre of gravity Chapter moved
8. Listings Was chapter 7 / updated
8.1 List of modifications Updated
8 Listings

Amarok
Subject to modifications
Edition May 2013
Internet: www.volkswagen-nutzfahrzeuge.de
Consulting for body builders in Germany is available from the listed address.
Volkswagen Nutzfahrzeuge
Brieffach 2963
Postfach 21 05 80
D-30405 Hannover
Fax. +49 (0)511/798-8500

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Body builder guidelines 2013

Body builder guidelines

2.2.2 Turning circle............................................................................................................................................................................... 39

2.5.2.3 Retrofitting electrical devices ...................................................................................................................................... 60

4.2 Chassis frame ....................................................................................................................................................................................... 95

* Electronic Stabilisation Program

1.1.1 Concept of these guidelines

For further information see 1.2.1.1 "Contact", 1.2.2

The limit values selected in chapter 2 "Technical data

1.1.2 Means of representation

A danger note draws your attention to possible

An environmental note provides you with information

This note draws your attention to a possible risk of

This note indicates additional information.

1.1.3 Vehicle safety

Before installing external add-ons or mechanical units,

It is essential to comply with national registration

– modifications which change the vehicle type approved

1.1.4 Operational safety

Incorrect interventions in electronic components and

1.2 General notes

1.2.1 Product and vehicle information for body builders

Volkswagen Customer Support

Contact form: http://www.volkswagen-nutzfahrzeuge.de/de/kontakt/ihr_kontakt_zu_uns.htx

Contact for questions about http://www.volkswagen-nutzfahrzeuge.de/de/kontakt/technische_frage.htx

1.2.1.2 Conversion Portal

The Conversion Portal of Volkswagen AG can be

The contact form of Volkswagen AG can be reached at

– Additional technical information

– List of questions (technical FAQs)

For more information about the partnership system and

* Advantages for integrated partners automatically also apply to premium partners.

1.2.1.3 Electronic Repair and Workshop Information from Volkswagen AG (erWin*)

Body builders can access repair and workshop information, e.g.

Volkswagen AG workshop manuals and workshop

* Information system from Volkswagen AG, subject to payment

1.2.1.4 Genuine parts online ordering portal*

* Information system from Volkswagen AG, subject to payment

1.2.2 Body builder guidelines and consulting

Please use the online contact form:

1.2.2.1 Safety certificate

Volkswagen AG issues safety certificates on a voluntary basis, as follows:

Country-specific laws, directives and approval

1.2.2.2 Application for the safety certificate

1.2.2.3 Legal entitlements

– There is no legal entitlement for a safety certificate to be issued.

1.2.3 Warranty and product liability of the body builder

1.2.4 Ensuring traceability

1.2.5.1 Positions on rear of the vehicle

1.2.5.2 Appearance of overall vehicle

1.2.5.3 Non-Volkswagen trademarks

Non-Volkswagen trademarks are not allowed to be attached next to Volkswagen badges.

1.2.6 Recommendations for vehicle storage

1.2.7 Compliance with environmental rules and regulations

The following principles of environmentally friendly

– EU Directive 2000/53/EC must be adhered to.

1.2.8 Recommendations for inspection, maintenance and repair

1.2.9 Accident prevention

Berufsgenossenschaft für Fahrzeughaltungen, Fachausschuss,