Body Builder Guidelines Amarok EN 45 2017 PDF

Table of contents
Body builder guidelines

Edition November 2017
Body builder guideline

The Amarok (as of model year 2017)
Volkswagen Commercial Vehicles – Body builder guidelines – November 2017 edition The Amarok – Page 1 of 160
Table of contents
Table of contents
Table of contents.................................................................................................................................................................................... 2
1 General information ............................................................................................................................................................................ 5
1.1 Introduction .................................................................................................................................................................................. 5
1.1.1 Concept of these guidelines ................................................................................................................................................. 6
1.1.2 Means of representation ...................................................................................................................................................... 6
1.1.3 Vehicle safety ....................................................................................................................................................................... 7
1.1.4 Operational safety ............................................................................................................................................................... 8
1.2 General notes ................................................................................................................................................................................ 9
1.2.1 Product and vehicle information for body builders ............................................................................................................. 9
1.2.2 Body builder guidelines and advice ................................................................................................................................... 11
1.2.3 Warranty and product liability of the body builder ........................................................................................................... 14
1.2.4 Ensuring traceability .......................................................................................................................................................... 14
1.2.5 Trademarks ........................................................................................................................................................................ 15
1.2.6 Recommendations for vehicle storage .............................................................................................................................. 16
1.2.7 Compliance with environmental rules and regulations ..................................................................................................... 18
1.2.8 Recommendations for inspection, maintenance and repair .............................................................................................. 19
1.2.9 Accident prevention ........................................................................................................................................................... 19
1.2.10 Quality system ................................................................................................................................................................. 20
1.3 Planning bodies ........................................................................................................................................................................... 21
1.3.1 Selecting the base vehicle .................................................................................................................................................. 21
1.3.2 Vehicle modifications ........................................................................................................................................................ 22
1.3.3 Vehicle acceptance............................................................................................................................................................. 23
1.4 Optional equipment .................................................................................................................................................................... 24
2 Technical data for planning ............................................................................................................................................................... 25
2.1 Base vehicle ................................................................................................................................................................................. 25
2.1.1 Vehicle dimensions ............................................................................................................................................................ 25
2.1.2 Overhang angle and breakover angle ................................................................................................................................ 29
2.1.3 Vehicle centre of gravity .................................................................................................................................................... 31
2.1.4 Bodies with a high centre of gravity .................................................................................................................................. 32
2.1.5 Determining the centre of gravity ..................................................................................................................................... 32
2.1.6 Maximum dimensions ........................................................................................................................................................ 33
2.1.7 Steerability......................................................................................................................................................................... 35
2.2 Running gear ............................................................................................................................................................................... 36
2.2.1 Permitted weights and unladen weights ........................................................................................................................... 36
2.2.2 Turning circle ..................................................................................................................................................................... 38
2.2.3 Authorised tyre sizes.......................................................................................................................................................... 38
2.2.4 Modifications to axles ........................................................................................................................................................ 38
2.2.5 Modifications to the steering system ................................................................................................................................ 38
2.2.6 Brake system and brake control system ESC/ESP* ............................................................................................................ 39
2.2.7 Modification of springs, suspension mounting, dampers .................................................................................................. 43
2.2.8 Wheel alignment settings .................................................................................................................................................. 43
2.2.9 Wings and wheel housings ................................................................................................................................................ 43
2.2.10 Overhang extension ......................................................................................................................................................... 44
2.2.11 Wheelbase modification .................................................................................................................................................. 46
2.3 Body-in-white ............................................................................................................................................................................. 47
2.3.1 Roof loads/vehicle roof ...................................................................................................................................................... 47
2.3.2 Modifications to the body-in-white .................................................................................................................................. 48
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2.3.3 Tailgate .............................................................................................................................................................................. 55

2.4 Interior ........................................................................................................................................................................................ 56
2.4.1 Modifications in the area of airbags .................................................................................................................................. 56
2.4.2 Modifications in the area of seats ...................................................................................................................................... 56
2.4.3 Forcetd ventilaion .............................................................................................................................................................. 57
2.4.4 Acoustic insulation............................................................................................................................................................. 57
2.5 Electrics/electronics .................................................................................................................................................................... 58
2.5.1 Lighting .............................................................................................................................................................................. 58
2.5.2 Vehicle electrical system.................................................................................................................................................... 59
2.5.3 Electrical interface for special vehicles .............................................................................................................................. 63
2.5.4 Vehicle battery ................................................................................................................................................................... 69
2.5.5. Digital tachograph (EC monitoring device) ....................................................................................................................... 70
2.5.6 Driver assistance systems .................................................................................................................................................. 70
2.6 Engine peripherals/drive train .................................................................................................................................................... 72
2.6.1 Engine/powertrain components ........................................................................................................................................ 72
2.6.2 Drive shafts ........................................................................................................................................................................ 72
2.6.3 Fuel system ........................................................................................................................................................................ 73
2.6.4 Exhaust system .................................................................................................................................................................. 74
2.6.5 SCR system (Euro 6) ........................................................................................................................................................... 77
2.7 Power take-off systems, engine/gearbox ................................................................................................................................... 80
2.7.1 Compatibility with base vehicle ......................................................................................................................................... 80
2.7.2. Retrofitting an air conditioning system ........................................................................................................................... 82
2.7.3. Specifications for the genuine refrigerant compressor .................................................................................................... 83
2.7.4 Installation and removal of the poly V-belt....................................................................................................................... 90
2.8 Add-ons/units ............................................................................................................................................................................. 93
2.8.1 Roof rack ............................................................................................................................................................................ 93
2.8.2 Towing bracket .................................................................................................................................................................. 94
2.8.3 Styling bar (tubular frame on the cargo box) ................................................................................................................... 100
2.8.4 Add-on parts on the cargo box ........................................................................................................................................ 102
2.9 Lifting the vehicle...................................................................................................................................................................... 103
3 Modifications to closed bodies ........................................................................................................................................................ 104
3.1 Body-in-white/bodywork ......................................................................................................................................................... 104
3.1.1 Side wall and rear wall cut-outs ...................................................................................................................................... 104
3.1.2 Installation of windows ................................................................................................................................................... 105
3.1.3 Roof cut-outs ................................................................................................................................................................... 105
3.1.4 Modifications to the roof ................................................................................................................................................. 105
3.2 Interior ...................................................................................................................................................................................... 106
3.2.1 Safety equipment............................................................................................................................................................. 106
3.3 Cargo box .................................................................................................................................................................................. 107
3.3.1 Removal of the cargo box ................................................................................................................................................ 107
3.3.2 Weight of cargo box......................................................................................................................................................... 109
3.4 Add-on parts on the cargo box.................................................................................................................................................. 110
3.4.1 Add-on parts on the cargo box ........................................................................................................................................ 110
3.4.2 Hardtop with additional roof rack ................................................................................................................................... 111
4 Modifications to open bodies (cab chassis) ..................................................................................................................................... 112
4.1 SCR tank system and fuel filler neck ......................................................................................................................................... 112
4.1.1 Fastening the SCR tank system ....................................................................................................................................... 113
4.1.2 Attaching the fuel filler pipe ............................................................................................................................................ 113
4.2 Chassis frame ............................................................................................................................................................................ 117
4.2.1 Ladder frame Amarok DC (Double Cab) ............................................................................................................................ 117
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4.2.2 Ladder frame Amarok SC (Single Cab).............................................................................................................................. 118

4.2.3 Sections, Amarok SC (Single Cab)/Amarok DC (Double Cab) ............................................................................................ 119
4.3 Standard attachment points for special bodies ........................................................................................................................ 121
4.4 Subframe (mounting frame) ...................................................................................................................................................... 123
4.4.1 General notes ................................................................................................................................................................... 123
4.4.2 Bodies with subframes .................................................................................................................................................... 123
4.4.3 Bodies without subframes ............................................................................................................................................... 123
5 Implementations of special bodies ................................................................................................................................................. 124
5.1 Vehicles for conveying persons with restricted mobility .......................................................................................................... 124
5.1.1 Notes on installing manual operating devices for the service brake: .............................................................................. 124
5.1.2 Deactivating the airbag/belt tensioner systems ............................................................................................................. 124
5.2 Refrigerated vehicles ................................................................................................................................................................ 126
5.3 Shelf installation/workshop vehicles ........................................................................................................................................ 127
5.4 Conversions for caravans .......................................................................................................................................................... 128
5.5 Conversions for municipal vehicles ........................................................................................................................................... 129
5.6 Tractor unit................................................................................................................................................................................ 130
5.7 Elevated work platforms ........................................................................................................................................................... 131
5.8 Crane superstructures and lift systems .................................................................................................................................... 132
5.9 Box bodies (dry freight boxes)................................................................................................................................................... 133
5.10 Platform bodies (open boxes).................................................................................................................................................. 134
5.11 Platform bodies (open boxes).................................................................................................................................................. 135
6 Technical data ................................................................................................................................................................................. 137
6.1 Build dimension drawings ......................................................................................................................................................... 137
6.2 Diagrams (foil templates) .......................................................................................................................................................... 138
6.3 Circuit diagrams ........................................................................................................................................................................ 139
6.4 CAD models ............................................................................................................................................................................... 140
7 Calculations ..................................................................................................................................................................................... 141
7.1 Determining the centre of gravity............................................................................................................................................. 141
7.1.1 Determining the centre of gravity in x-direction ............................................................................................................. 141
7.1.2 Determining the centre of gravity in z-direction ............................................................................................................. 143
8 Weight tables .................................................................................................................................................................................. 147
8.1 Weight tables Amarok Double Cab (EU6)............................................................................................................................ 148
8.2 Weight tables Amarok Double Cab (market: non-EU) ............................................................................................................... 149
8.3 Weight tables Amarok Double Cab (EU6) cab chassis ............................................................................................................... 150
8.4 Weight tables Amarok Double Cab (market: non-EU) cab chassis ............................................................................................ 151
8.5 Weight tables Amarok Single Cab (market: non-EU) ................................................................................................................ 152
8.6 Weight tables Amarok Single Cab (market: non-EU) cab chassis ............................................................................................. 153
9 Listings ............................................................................................................................................................................................ 154
9.1 List of changes .......................................................................................................................................................................... 154
*Electronic Stability Control
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 9 chapters so that you can find information rapidly:
1. General information
2. Technical data for planning
3. Modifications to closed bodies
4. Modifications to open bodies
5. Implementation of special bodies
6. Technical data
7. Calculations
8. Weight tables
9. Directories
Information
For more information, see chapter 1.2.1.1 “Contact”,

and 1.2.2 “Body builder guidelines and consulting”.
It is essential that the limit values selected in chapter 2

“Technical data for planning” are complied with and are
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.
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 to the electronics can significantly

impair the operational safety of the vehicle.
Have work on or modifications to electronic components

performed by a qualified specialist workshop which
has the necessary specialist knowledge and tools for
performing the necessary work.
Volkswagen AG recommends a Volkswagen AG customer

service workshop for this purpose.
Service by a qualified specialist workshop is essential,

in particular for safety-relevant work and work on
safety-relevant systems.
Some safety systems only operate when the engine is

running. Therefore, do not switch the engine off
when driving.
1.2 General notes
The following pages contain technical guidelines for custom body builders and equipment fitters designing and mounting bodies.
The body builder guidelines must be strictly adhered to when performing any modifications to the vehicle. The German version of
the body builder guidelines is the exclusive authority for the most up-to-date information.
This also applies to legal claims.
1.2.1 Product and vehicle information for body builders
1.2.1.1 Contact in Germany
If you have questions concerning vehicle models from Volkswagen Commercial Vehicles, you can contact us via the Internet on
the Volkswagen AG Conversion Portal (www.umbauportal.de) using one of the following methods:
Free hotline 0800-86228836

(from a German landline)
Contact (email): [email protected]
Personal points of contact: https://umbauportal.de/jctumbau/web/guest/ihre-ansprechpartner
Alternatively, registered users can get in touch with us directly using the contact form. There, you can store vehicle-specific
information in advance, which will help us to deal with your request faster.
Contact form: https://umbauportal.de/jctumbau/de/web/guest/allgemeine-fragen
1.2.1.2 International contact
Please contact the body builder support personnel at the responsible importer for technical advice relating to Volkswagen
Commercial Vehicles models and as a point of contact for conversions. To find the right contact person, please register on
the Bodybuilder Database, the international portal of Volkswagen AG: www.bb-database.com.
Help is available for the registration option using the Help menu.
Login information: https://bb-database.com/jctumbau/web/international/hilfe#faq_7
1.2.1.3 Electronic repair and workshop information from Volkswagen AG (erWin*)
Body builders can access repair and workshop information, e.g.

 Current flow diagrams
 Workshop manuals
 Maintenance
 Self-study programmes
by means of the Electronic Repair and Workshop Information System from Volkswagen AG (erWin*):
http://erwin.volkswagen.de/erwin/showHome.do
Second stage manufacturers with Integrated Partner or Premium Partner status have access to discounted annual licenses,
which can be applied for in My Conversion Portal/Requirements/Planning and Development.
Second stage manufacturers in export with the Partner status receive information in this regard from their point of contact at
the importer.
*Information system from Volkswagen AG, fee required
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:
http://www.partslink24.com
1.2.1.5 Online owner’s manuals

The Volkswagen AG website contains a “Service & Accessories” menu which provides access to the digital owner’s manual for
your vehicle:
http://www.vwn-bordbuch.de
Once you have entered the vehicle identification number for your Volkswagen, you can see all the manuals associated with
your vehicle.
1.2.1.6 European Type Approval (ETA) and EC Certificate of Conformity (CoC)

Directive 2007/46/EC of the European Parliament establishes the standard for the approval of motor vehicles and their trailers,
and of systems, components and separate technical units intended for such vehicles.
In these guidelines, provisions were also adopted for approving vehicles that are produced in several stages: the multi-stage
approval process. Accordingly, each manufacturer involved in the construction of a vehicle is itself responsible for the approval of
modified or added scopes in its production stage.
The manufacturer may choose one of the four following methods:
 EC type approval (ETA)
 EC type approval for small series
 National small series type approval
 Individual approval
CoC = Certificate of Conformity. A document that verifies the conformity of certain goods – and therefore also of vehicles
and bodies – in accordance with the recognised (international) standards. The purpose of this EC Certificate of Conformity is to
facilitate the approval of goods on international markets. As a result, the document is needed above all in import and export as
part of the customs clearance procedure.
The manufacturer, who is the holder of an EC type approval or EC small series type approval, is required
to enclose a Certificate of Conformity with every vehicle conforming to an approved type.
If you are planning to apply multi-stage type approval, an agreement must be concluded in accordance with 2007/46/EC Annex XVII
Paragraph 1.1. Please get in touch with us for information on this matter. (see 1.2.1.1 “Contact in Germany”
and 1.2.1.2 “International contact”)
1.2.2 Body builder guidelines and advice
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 in case of inquiries for proposed modifications.
We require precise information from you in order to respond to your inquiry quickly and comprehensively.
When inquiring, 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 inquiry.
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 EU 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 relates to the presented overall vehicle, and not
 to the design of the overall body,
 its functions or
 the planned use.
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 for the product, or from its obligation to carry out its
own calculations, tests and a trial of the entire vehicle in order to ensure that the operational safety, road safety and driving
properties of the overall vehicle it has manufactured are acceptable. Accordingly, it is necessary to ensure that the body builder
exclusively accepts its responsibility for ensuring that its body activities are compatible with the base vehicle as well as
the operational and road safety of the vehicle. It is expressly stated that the safety certificate from Volkswagen AG does not
represent a technical approval for the investigated changes.
In the course of assessment of a presented vehicle, an assessment report is written as a means of obtaining a safety certificate
(safety certificate report).
 The following assessment results are possible:

Classified as “safe”
If the overall vehicle is classified as “safe”, the Sales department can subsequently issue the safety certificate.
 Classified as “not safe”
Classification as “not safe” in the individual categories:
 base vehicle configuration
 impairment of the base vehicle and possibly
 sole body item
leads to a corresponding classification of the overall vehicle. This means no safety certificate can be issued initially.
In order for a not-safe classification to be resolved, the safety certificate report states the necessary change for each item in
question. In order for the safety certificate to be obtained, these points will have to be addressed by the body builder and
documented in a clearly comprehensible manner in a report along the same lines as the safety certificate report. On the basis of
this detailed report, it is possible for the desk-review assessment to be completed with a positive result.
Depending on the defective points, it may be necessary not only to provide documentation of the defect resolution but also for
the vehicle from the first inspection to be presented again. The first report indicates if it will be necessary for a new assessment to
be carried out on the vehicle.
The assessment report may also contain “notes/recommendations”.

Notes/recommendations are technical remarks which do not have any effect on the final result of a safety certificate. They should
be regarded as advice and suggestions for further consideration to support the continuous improvement of the final product for
the customer.
In addition, “notes/recommendations solely relating to the conversion” can also be formulated. The notes and recommendations
stated as “solely relating to the body/conversion” must be dealt with and documented before the vehicle can be included in
the body builder portal.
Practical note
Country-specific laws, directives and approval

regulations shall be observed!
1.2.2.2 Application for the safety certificate
Before starting any work on the vehicle, auditable technical documentation and drawings must be submitted to the responsible
department as part of the safety certificate evaluation (see 1.2.1 “Product and vehicle information for body builders”).
For a swift approval process, the following is required:
 Documentation preferably in current, standard digital formats (e.g. PDF, DXF and STEP)
 Technical data and documentation should be complete
The following details must be included:

 Vehicle type
 Vehicle equipment (chassis, panel van, window van etc...)
 Wheelbase
 Frame overhang
 Vehicle identification number (if already available)
 Any deviations from these body builder guidelines must be indicated on all documentation
 Axle load calculation
 All data about dimensions, weight and centre of gravity (weighing certificate)
 Special operating conditions (e.g. poor road conditions, extreme dust, high altitude, or ambient temperature extremes)
 Certificates (e-registration, seat tensile test)
 Attachment of the body on the vehicle
 Subframe:
 Material and profiles
 Dimensions
 Type of profile
 Features of the subframe construction (profile modifications, additional reinforcements, offsets etc...)
 Type of fixation for the body or add-ons to the vehicle frame (e.g. bolted connections)
 Position (in relation to vehicle chassis)
 Type
 Size
 Number
 Property class
All fixation brackets on the vehicle frame must be used for bolted connections to the subframe, or body.
 Type of fixation for the body or add-ons to the vehicle frame (bolting, bonding, welding)
 Photographic documentation of the conversion
 All documents must clearly correlate with the conversion (e.g. drawings marked with with allocated numbers).
 General (functional) description of deviations from the series vehicle, or added components.
 Electric wiring diagram
 Details of the consumption of additional electrical equipment.
Complete documentation avoids the need for clarification queries and accelerates the processing.
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 evidence 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. For this purpose, it is also recommended that customers’ addresses are stored and that subsequent
owners are provided with a means of registration.
1.2.5 Trademarks
VW badges and VW emblems are trademarks of Volkswagen AG. Volkswagen badges and Volkswagen 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 shall 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:
 Open all ventilation flaps, set blower to maximum speed.
 Put manual gearbox into 1st gear or lever of automatic gearbox into park position. Do not engage reverse gear. Do not apply
the parking brake.
If incomplete vehicles are stored outdoors (e.g. chassis), the fuel tank and its pipes, all components between the longitudinal
members up to the rear bumper and the spare wheel must be protected (covered) against direct exposure to sunshine,
snow and liquids.
Check tyre pressure at least once a month. The tyre pressure sticker states the correct tyre pressure for tyres fitted at the factory.
The information applies to summer tyres, all-season tyres and winter tyres. The tyre pressure sticker is located either on the driver
seat console or on the inside of the tank flap (see 2.1.5 2 “Online owner’s manuals”).
Check the battery’s open-circuit voltage:
Battery open-circuit voltage Reading/measure

<10% or Battery defective/totally discharged/
<11.6 V fully charge battery immediately
10% to 80% or Battery not able to start/
11.6 <12.5 V fully charge battery immediately
≥ 80% or Battery voltage OK.
≥ 12.5 V
A maximum charging voltage of 14.8 volt must not be exceeded.
After delivery of vehicle:

 Check weekly for aggressive deposits (e.g. bird droppings, industrial deposits) and clean if necessary.
 Brake clean every 3 months.
 Check tyre pressure every 3 months.
Pump up the tyre pressure to the required value of 4 bar using a suitable device. Then check that the valve caps are attached
and tightened properly.
 Check the battery open-circuit voltage as per the maintenance cycle in the vehicle care programme:
 Every 6 weeks for vehicles without transport mode
 Every3 months for vehicles with transport mode or
 Every 6 months if there is a permanently attached solar panel.
Practical note
For recharging the battery, use only a current-controlled

battery charger with voltage limiter and IU or IUoU
characteristic and a minimum charge current of 10 amps.
A maximum charging voltage of 14.8 volt shall not be
exceeded. All batteries must always be charged for at
least 24 hours. This does not apply when using a charger
with a full-charge indicator.
When connecting the battery charger, the following

connection specification must be observed under all
circumstances:
 Positive: always connect to jump-start terminal,

if present, otherwise to battery positive terminal
 Negative: always connect to vehicle body ground
terminal intended for battery charging
Practical note
Removal of the battery for charging as well as series or

parallel charging are unauthorised.
Practical note
Directly connecting a battery charger to the starter

battery can lead to incorrect battery status recording by
the vehicle electronics in some vehicles.
Information
You can find further information about vehicle storage in

the following documents:
 Vehicle wallet
 Vehicle care programme
1.2.7 Compliance with environmental rules and regulations
Environmental note
The following principles of environmentally friendly

design and material selection should be followed right
from the planning stage of fitted components or bodies,
and the statutory requirements in the EU Directive on
End-of-Life Vehicles 2000/53/EC should also be taken
into account.
Second stage manufacturers ensure that attachments and add-on parts (conversions) comply with all applicable environmental
rules and regulations, especially EU directive 2000/53/EC concerning end-of-life vehicles and the REACH Regulation
(EC) 1907/2006 relating to restrictions on the marketing and use of certain dangerous substances and preparations
(“low flammability” and certain flame-retardant agents).
The registered keeper must keep all assembly documentation concerning the modification and hand it over together with
the vehicle to the dismantler.
This ensures that modified vehicles are processed in compliance with environmental rules and regulations at the end of their
life cycle.
Materials which represent a potential risk such as halogen additives, heavy metals, asbestos, CFCs and chlorinated hydrocarbons
shall be avoided.
 EU directive 2000/53/EC must be adhered to.

 Preferably, materials which allow valuable substance recycling and closed material cycles shall be used.
 The material and production process shall be selected so that only low amounts of easily recyclable waste are generated.
 Plastics shall only be used where these offer advantages in terms of cost, function or weight.
 In the case of plastics, especially composite materials, only mutually compatible substances from one material family may be
used.
 With regard to components that are relevant for recycling, the number of plastic types used shall be kept as low as possible.
 It is necessary to check whether a component can be manufactured from recycled material or with recycled additives.
 Care shall be taken to ensure that recyclable components can be removed easily, e.g. by means of snap-lock connections,
predetermined breaking points, good accessibility, use of standard tools.
 Simple, environmentally friendly removal of the fluids shall be ensured by means of drain plugs etc.
 Wherever possible, the components shall not be painted or coated; instead, dyed plastic parts shall be used.
 Components in areas at risk of accident shall be designed to be tolerant of damage, repairable and easy to exchange.
 All plastic parts shall be identified according to the VDA material sheet 260 (“Components of motor vehicles; Identification of
materials”), e.g. “PP-GF30R”.
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. It is also important to specify parts
and components with a limited service life which are to be checked at regular intervals in order to ensure service reliability
and timely replacement where required.
This should be supported by a repair manual including tightening torques, settings and tolerances as well as other relevant
specifications. Special tools, including their source of supply, must also be stated.
The manual must also state which type of work must 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.
Please observe the Volkswagen AG owner’s manual for the inspection, maintenance and repair of base vehicles.
Please only use brake fluids and engine oils approved by Volkswagen for your vehicle.
More information about brake fluids and engine oils can be found in the owner’s manual of your vehicle:
http://www.vwn-bordbuch.de
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:
Postal address: Berufsgenossenschaft für Fahrzeughaltungen,

Fachausschuss “Verkehr”
Sachgebiet “Fahrzeuge”
Ottenser Hauptstrasse 54
D-22765 Hamburg
Telephone: +49 (0) 40 39 80 - 0
Fax: +49 (0) 40 39 80-19 99
Email: [email protected]
Homepage: http://www.bgf.de
1.2.10 Quality system
Worldwide competition, increased quality requirements placed on the overall product by customers, national and international
product liability legislation, new forms of organisation and increasing pressure on costs are demanding effective quality assurance
systems in all areas of the automotive industry.
The requirements for a quality management system of this kind are described in DIN EN ISO 9001.
For the reasons stated above, Volkswagen AG strongly recommends that all body builders should set up and maintain a quality
management system with the following minimum requirements:
 Definition of responsibilities and authorisations including organisational plan.
 Description of the processes and procedures.
 Appointment of a quality management representative.
 Performing contract and build feasibility checks.
 Performing product checks based on specified instructions.
 Regulating the handling of faulty products.
 Documentation and archiving of test results.
 Ensuring the quality records of employees are up to date.
 Systematic monitoring of test equipment.
 Systematic material and parts identification.
 Performing quality assurance measures at the suppliers.
 Ensuring the availability of process, working and test instructions, and that they are up to date, in the departments and in
the workplace.
1.3 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”).
1.3.1 Selecting the base vehicle

The base vehicle needs to be selected carefully to ensure safe usage in the respective field.
 When planning, please consider the following for the use in question:
 Wheelbase
 Engine/gearbox
 Final drive ratio
 Gross vehicle weight
 Centre of gravity
 Seating version (number and arrangement)
 Electrics – scope
 Power take-off systems
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.
Information
On the Volkswagen AG homepage, you can plan your

vehicle with the configurator and view the available
optional equipment:
http://www.volkswagen-nutzfahrzeuge.de/de/cc5.html
1.3.2 Vehicle modifications
Before starting work on the body, the body builder should check whether
 the vehicle is suitable for the planned body
 the chassis type and the equipment also correspond with the operating conditions after the conversion
Build dimension drawings, product information and technical data can be obtained from the responsible department or via
the communication system for the planning of bodies (see 1.2.1.1 “Contact in Germany”, 1.2.1.2 “International contact”
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 European directives and the national laws (except for some vehicles for countries
outside Europe).
The vehicles also need to meet the European directives and the national laws after the modifications have been made.
Information
Please note that a majority of the EC directives

announced to date have been annulled by Regulation
(EC) 661/2009 “General Safety”. The EC directives
have been replaced by new EU directives or UNECE
regulations with the same corresponding content.
Practical note
Sufficient space must be provided in order to guarantee

the function and operating safety of the components.
Warning note
Do not modify the steering or brake system!

Modifications to the steering and brake system can
result in these systems no longer working correctly
and failing. This may result in the driver losing control of
the vehicle and causing an accident.
Practical note
Modifications to the noise encapsulation can have

effects which are relevant to registration.
1.3.3 Vehicle acceptance
The officially recognised appraiser or tester from the body builder must be informed about modifications to the chassis.
Practical note
Country-specific laws, directives and approval

regulations shall be observed!
1.4 Optional equipment
We recommend using the optional equipment from Volkswagen AG that can be obtained with a PR number for optimum adaptation
of the body to the vehicle.
You can obtain information on the optional equipment available from Volkswagen as PR numbers from your Volkswagen customer
service or from the body builder consultants (see chap. 1.2.1. “Contact possibilities”). 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 special equipment:
http://www.volkswagen-nutzfahrzeuge.de/de/cc5.html
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 by weighing 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 kerb

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. This is available ex-works by means
of PR number 0WL.
2 Technical data for planning

2.1 Base vehicle
2.1.1 Vehicle dimensions
Fig. 1: Vehicle dimensions of Amarok SC/DC (view: side)
Fig. 2: Vehicle dimensions of Amarok (views: front and rear)
Fig. 3: Plan view of Amarok DC (Double Cab)
Fig. 4: Plan view of Amarok SC (Single Cab)
2.1.1.1 Basic data Single Cab and Double Cab (ML1*)
Basic data Amarok (all engines) Single Cab [mm] Double Cab [mm]
Dimensions L101 Wheelbase 3,090 3,090
L103 Vehicle length 5,191 5,191

Vehicle length incl. bumper 5,254 5,254
Vehicle length incl. design underbody guard at front 5,264 5,264
L102 Vehicle length with towing bracket (ball head 5,321 5,321
accessory on preparation bumper with step)
L 104 Front overhang length 898 898
L 105 Rear overhang length 1,196 1,196

With bumper 1,259 1,259
L202 Length of cargo floor 2,266 1,616
W103 Vehicle width (measuring point: door handle) 1,944 1,944

Vehicle width with wheel arch trim 1,954 1,954
H 100 Height of body 1,821 1,834
Height of body with styling bar

(chrome-plated tube) 1,876 1,878
Height of body with hardtop --- 1,844
Height of body with light bar incl. lights (Canyon) --- 2,093
Height of body with support (ladder transport frame) --- 1,965
W101 Front track, rim offset 62 1,628 1,628

52 1,648 1,648
49
1,654 1,654
45
43 1,662 1,662
1,666 1,666
W102 Rear track, rim offset 62 1,624 1,624

52 1,644 1,644
49
1,650 1,650
45
43 1,658 1,658
1,662 1,662
H157 Ground clearance between axles 228 226
A116-1 Front entry/exit angle (ML3**) limited by bumper

with design underbody guard at front 28.8° 29.5°
26° 26.7°
A116-2 Rear entry/exit angle (ML3**) limited by bumper 18.1° 18°

with step
Rear entry/exit angle (ML3**) limited by exhaust 15.6° 15.4°

system (petrol engine)
A117 Breakover angle (ML3**) 15.4° 15.6°
Turning circle D102 Minimum turning circle 12.95 m 12.95 m
Basic data Amarok (all engines) Single Cab [mm] Double Cab [mm]
Wheels/tyres Basic tyres*** Small tyre Small tyre

205 R16 C 205 R16 C
110/108T 110/108T
Large tyre Large tyre
255/60 R18 112H 255/60 R18 112H
Loadbed H196 Load sill above ground plane 780 780

dimensions H503 Tail lift height 508 508
L505 Loadbed length (on the floor) 2,205 1,555
W500 Largest luggage compartment width 1,620 1,620
W506 Smallest luggage compartment width 1,222 1,222
W206 Largest width of rear opening 1,364 1,364
Garage W120 Vehicle width, front doors open 3,768 3,768

dimensions Vehicle width, rear doors open --- 3,414
W114- Width incl. left/right exterior mirror 2,228 2,228

L/W114R
Vehicle interior H61 Driver headroom 1,026 1,026

dimensions Headroom 2nd seat row -- 1,008
L34 Legroom 1st row of seats 1,019 1,019
L34 Legroom 2nd row of seats -- 865

Version dated: May 2017
* Measurement load ML1 = vehicle unloaded
** Measurement load ML3 = vehicle loaded
*** The permitted tyre size varies depending on the engine and the gross vehicle weight rating.
The vehicle dimensions concerning ground clearance and loadbed differ from one another depending on the engine and equipment variant.
Information
You will find additional technical data (dimensional

drawings, weight information and emissions figures)
for the Amarok according to the engine and equipment
variant on the Internet at:
http://www.volkswagen-
nutzfahrzeuge.de/de/downloads.htx
2.1.2 Overhang angle and breakover angle
Fig. 1: Overhang angle of Amarok DC (Double Cab)
Fig. 2: Breakover angle of Amarok DC (Double Cab)
Fig. 3: Overhang angle of Amarok SC (Single Cab)
Fig. 4: Breakover angle of Amarok SC (Single Cab)
The values for the overhang angle (A116) and the breakover 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
Fig. 1: Centre of gravity position of the Amarok
Model L h* SV* SR* SL*

[mm] [mm] [mm] [mm] [mm]
Double Cab 3,095 680 ~1,444 ~840 ~796
Single Cab 3,095 657 1,350 ~853 ~805

* Position of centre of gravity measured on the base vehicle without load rating and without driver
Please note that the centre of gravity position depends on the respective equipment. (see chapter 7.1)
2.1.4 Bodies with a high centre of gravity
2.1.4.1 Permissible height of the overall centre of gravity for vehicles with a comfort running gear
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 uncritical (see also chap. 2.2.6 “Brake system and brake
control system ESP”).
2.1.4.2 Extreme height of the overall centre of gravity (>800 mm) for vehicles with comfort running gear
Centre of gravity heights greater than 800 mm are only permitted following consultation with Volkswagen AG.
If necessary, the running gear and ESP** must be modified.
The vehicle needs to be taken to Volkswagen AG for an inspection of the vehicle modifications.
**Electronic Stability Control
2.1.4.3 Permissible height of the overall centre of gravity for vehicles with a heavy-duty running gear
Please note that the permissible height of the overall centre of gravity for vehicles with a heavy-duty running gear depends on
the ESP/ESC coding and the gross vehicle weight rating of the base vehicle. (see table!)
ESP coding Permissible height of the overall centre of gravity “H” for gross vehicle weight
rating*
3,080 kg 3,200 kg 3,290 kg
Normal centre of gravity H ≤ 800 mm H ≤ 770 mm H ≤ 750 mm

height
Medium centre of gravity 800 < H ≤ 850 mm 770 < H ≤ 820 mm 770 < H ≤ 800 mm
height
High centre of gravity 850 < H ≤ 910 mm 820 < H ≤ 880 mm 800 < H ≤ 860 mm
Information
When making contact, please comply with chapter

1.2.1 “Product and vehicle information for body builders”
2.1.5 Determining the 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 20mm.
 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: 1,196mm) up to 1800 mm if certain requirements
 are fulfilled (see chapter 2.2.10 “Overhang extension”).
The vehicle width is 1,944–1,954 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 braking 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 maximum gross axle weight ratings must not be exceeded and the minimum front axle load of 1,000 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 running gear)
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 following weight classes:
 The Amarok SC is available with a gross vehicle weight rating of 3,040 kg (non-EU).
 The Amarok DC is available with a gross vehicle weight rating of 2,920 kg and 3,080 kg (3,290 kg only for UK).
 For the non-EU market, the Amarok DC is available with a gross vehicle weight rating of 2,820 kg and 3,040 kg.
See also chapter 2.8.2 “Towing bracket” for information.
The gross axle weight ratings listed in the weight tables (see chapter 8) must be observed.
Warning note
IMPORTANT! The maximum gross axle weight rating

specified in this body builder guideline must be adhered
to for conversions that lead to an increase to the base
vehicle’s axle weight rating (e.g. weight increases).
If these values are exceeded, the durability of all
components (and in particular the wheel hubs) must be
checked and safeguarded using suitable measures.
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 stated 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.
2.2.1.1 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 kerb 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 must 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. “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

The Volkswagen owner’s manual provides information about the wheel/tyre combinations authorised by Volkswagen AG in
conjunction with snow chains. As a rule, Volkswagen only checks and authorises suitability for chains for the rear axle with
the wheel/tyre combinations specified in the manual.
Volkswagen does not provide for snow chains to be used on the front axle, and does not authorise this either.
This also applies to four-wheel drive vehicles.
Further information is available in 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:
Please contact us before a conversion (see chap. 1.2.1)
2.2.6 Brake system and brake control system ESC/ESP*
2.2.6.1 General information

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.
Please note that the brake cable of the parking brake (FBA) as well as its cable support bracket are safety-relevant parts,
and form part of the type approval for the brake system. Any modification will require a new approval process.
Exceptions shall be approved by Volkswagen AG prior to the conversion, and shall be documented with an independent brake
approval report.
Please contact us before starting your conversion (see chap. 1.2.1)
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.
2.2.6.2 Vehicle stability and ESC*
According to UNECE-R 13 (brake system), the acceptance procedure for the vehicle with body must include
determination of the centre of gravity height when the vehicle is loaded.
Refer to chapter 2.1.3 “Vehicle centres of gravity” for the permissible centre of gravity heights.
Volkswagen does not make any statement about:
 Driving behaviour
 Braking behaviour
 Steering response and
 ESC 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 must not be exceeded
under any circumstances. If the gross axle weight ratings
are exceeded, the ESC* system in vehicles with ESC 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* is mandatory for all new

vehicles registered in Europe. Vehicles can be exempted
from this obligation in special, exceptional cases.
Volkswagen Commercial Vehicles offers you specially
adapted ESC data for various special vehicles so that
the statutory requirement can be met and the safety
standard can continue to be fulfilled.
2.2.6.3 Influence of vehicle conversions on the function of the brake regulation system ESC*
ESP sub-systems Wheelbase Extreme Modification of Modification Vehicle

modification raising of running gear to the brake overhang
centre of (springs, (callipers, extension
gravity dampers, anti- pads, design) within limits
>800 mm roll bars, specified in
wheels, tyres, body builder
track, steering) guidelines
(<1,800 mm)
ABS + + + ++ +
Anti-lock brake system
Offroad ABS + + + ++ +
BAS -- -- -- ++ --
Brake Assist system
EDL + + + +++ +
Electronic differential
lock
TCS ++ + + - +
Traction control system
ESP ++ +++ 1 +++ 1 +++ 1 +++

Electronic stabilisation
program
Trailer stabilisation ++ ++ +++ +++ ++++ 2
Hill Start Assist - - - ++ -
Hill Descent Assist + + + ++ +
1 In particular, a significantly increased risk of tipping over
2 Hardware adaptation of the wheel speed sensors required
-- no effect
- Very little effect
+ Noticeable effect
++ Significant effect
+++ Very significant effect
++++ 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 chap. 2.2.10 “Overhang extension”,
2.2.11 “Wheelbase modification” and 5.6 “Articulated
vehicles”.)
2.2.6.4 Activating the ESP*

Add-ons and conversion can be offered with all functions of the brake control system.
Volkswagen Commercial Vehicles provides special ESC data records for some special conversions in order to comply with
the statutory ESC requirement (Europe).
Information
You can find more information on this subject in

the “Electronic Stabilisation Program” document.
You will find this document under the menu option
“Additional technical information” on the Volkswagen AG
body builder portal:
https://umbauportal.de or
https://www.bb-database.com
If necessary, the running gear and ESP* shall be modified according to the specifications of Volkswagen AG.
Please contact us before starting your conversion (see chap. 1.2.1).
2.2.6.5 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 Start Assist can still be used. The Hill Descent Assist is deactivated for technical reasons.
If it is necessary to downgrade, please contact the relevant customer service consultant at your VW partner or importer.
Practical note
The body builder must check whether and for how long
vehicles with downgraded ESP* can still be registered in
the particular country of registration.
2.2.6.6 Routing additional lines along the brake hoses/brake lines
No other additional lines are allowed to be fastened to brake hoses and brake lines.
Additional lines must remain at a sufficient distance from brake hoses and brake lines under all operating conditions,
and are not allowed to touch or chafe against such brake hoses/lines under any circumstances.
(See also chap. 2.5.2.1 Electrical cables/fuses.)
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 housings

The required clearance for the wheels including snow chains must be complied with.
You will find more detailed information in the build dimension drawings.
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 arch trim 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 whole centre of gravity towards
the rear to be mounted on special vehicles.
Overhang extensions measuring up to a maximum of 1,800 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 maximum gross axle weight ratings must not be exceeded and the minimum front axle load of 1,000 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 running gear (perm. rear axle load: 1,860 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.
The slip control systems continue to function fully under these preconditions.
Fig. 1.: Maximum permitted overhang extension (heavy-duty chassis)
FAmin - Minimum required front axle load
RAmax - Maximum permitted rear axle load
* - Heavy-duty running gear
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 running gear)
FAmin - Minimum front axle load
RA - Rear axle load
Please contact us before starting your conversion (see chapter 1.2.1.).
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,
 running gear (heavy-duty RA suspension)
 ramp 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 a 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 Start Assist can still be used. The Hill Descent Assist is deactivated for technical reasons.
The disabled ESP Off or ASR Off button needs to be replaced with a cover 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 running gear and ESP shall be modified according to the specifications of Volkswagen AG.
To do this please use the online contact form on the body builder portal of Volkswagen AG.
2.3 Body-in-white
2.3.1 Roof loads/vehicle roof
2.3.1.1 Dynamic roof loads
Vehicle type Max. roof load
Amarok Double Cab (DC) 100 kg
Amarok Single Cab* (SC) 50 kg

* not for the European market.
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 if possible. Please also comply with chapter:
2.1.4 “Bodies with a high centre of gravity”.
2.3.1.2 Static roof loads

The maximum static roof load with the stationary vehicle (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 ESC”
 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 to use bolts/nuts that 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.
When attaching components to the base vehicle using screws, make sure that no panels or other components of the base vehicle
are bent or damaged.
The use of Volkswagen tightening torques assumes that the total coefficient of friction is in the range of 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 the use of Volkswagen
genuine 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 the 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 wiring 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 sides Welding process
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).
Fig. 1: 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).
Fig. 2: 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.
Fig. 3: 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).
Fig. 4: 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).
Fig. 5: Ratio between panel thickness and distance between spot welds
d Distance between tack welds
e Panel thickness
L Length of tack welding
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 measures.
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
Fig. 6: 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:
Fig. 7: 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
 180° opening (no rear bumper), as optional equipment (PR number 0S0), without rear bumper and with 180° folding tailgate:
Order directly ex works.
 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 house 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.
See also chap. 3.2.1.
If reattaching seatbelts, make sure that the specified bolts are tightened with the original torque.
Information
You will find detailed information on torques, etc. in

the workshop manuals.
Volkswagen AG workshop manuals and workshop

information can be downloaded from the Internet at
erWin* (Electronic Repair and Workshop Information
from Volkswagen AG):
2.4.3 Forcetd ventilaion
Outlet vents may be closed through modifications only if new outlets are created, e.g. in the cab doors.
This is important in several respects:

 Closing comfort of the doors
 Possible flow rate of the heating blower
 Pressure equalisation on airbag deployment
If installing non-factory-fitted cab rear panels, make sure that the selected forced ventilation cross sections correspond to those of
the original factory-fitted rear panel.
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 as intended.
Due to the networking of electronics, systems that were not modified can be affected.
Malfunctions to the electronics can significantly impair the operational safety of 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.
Fitting LED lights instead of genuine VW lights can result in the bulb failure monitor being triggered, because the lighting system is
a self-contained and harmonised system. The bulb failure monitor cannot be deactivated.
We recommend using Volkswagen Genuine rear lights or a product with “e” test symbol and conventional bulbs.
Practical note
Please note that in the completed (converted) vehicle,

it is necessary to comply with the add-on regulations
and dimensions of all technical lighting equipment acc.
to UNECE-R 48.
The 3rd brake light for M1 and N1 vehicles with a closed
body has been mandatory in Germany since 1 November
2013 in accordance with UNECE-R 48, section 6.7.
2.5.1.1.2 Adjusting the headlights

The national registration provisions apply.
The basic setting for the headlights must be put into effect and must be included in the configuration of the new
construction status (e.g. fixed installations or add-on parts or changes to running gear components) of the vehicle.
It must be ensured that the adjustment range of the headlight range control complies with potential load levels.
For springs that deviate from the base vehicle and for settings for the headlight range control potentiometer (LWR Poti) that
deviate from the vehicle wallet, these must be documented with regard to load levels, and must be attached to the vehicle wallet.
2.5.1.2 Installing the 3rd brake light
When high bodies are fitted, it may be necessary to integrate the 3rd brake light into the body.
An adapter with part number 2H0.971.170 (incl. seal) for the 3rd brake light is available from the factory to cover the original
brake light aperture. It is essential to ensure that the adapter is installed carefully with the seal to prevent moisture penetration.
For more information, please contact your Volkswagen dealership.
Please note that installing another brake light is only possible in place of the genuine brake light, and only with the same power
rating (2 W).
2.5.1.3 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”
2.5.1.4 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 (pulse-width modulation signal).
No additional wires may be connected to the existing lighting wiring fitted by Volkswagen AG.
2.5.2 Vehicle electrical system

Please note that, for add-ons and conversions with electromagnetic switching devices (such as relays, solenoid switches, contactors
and solenoid valves), the components must be fitted with integrated protective diodes (free-wheeling diodes) in order to keep
interference voltage peaks away from the vehicle electrical system and the control units. If no protective diodes are integrated,
these must be retrofitted antiparallel to the switch coil.
Information
Please refer to “Additional technical information”

in the conversion portal for more information on
protecting the control units integrated in the vehicle
electrical system from interference voltage peaks of
electromagnetic ABH conversions.
Please contact us (see 1.2.1 “Product and vehicle

information for body builders”).
2.5.2.1 Electrical wiring/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.
 No additional lines are allowed to be fastened to brake hoses and brake lines.
 Additional lines must remain at a sufficient distance from brake hoses and brake lines under all operating conditions,
and are not allowed to touch or chafe against such brake hoses/lines under any circumstances.
 Only lead-free PVC jacketed cables with an insulation limit temperature > 105°C are permitted for use.
 Connections must be made professionally and must be water-tight.
 The cable shall be dimensioned according to the current drawn and protected by fuses.
Max. continuous current [A] Rated current of fuse [A} Wire cross-section [mm²]
0–4 5* 0.35
4.1–8 10* 0.5
8.1–12 15* 1
12.1–16 20* 1.5
16.1–24 30* 2.5
24.1–32 40** 4
32.1–40 50** 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
* Shape C; DIN 72581 blade-type connector
** Shape E; DIN 72581 blade-type connector
Warning note
No additional electrical cables or other 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 number IS1)
(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 consumers:
 The no-load current of the basic vehicle is optimised at 20 mA. Additional electrical equipment (e.g. data loggers) which is
permanently connected to the permanent positive terminal 30 reduces the time after which the vehicle engine can be reliably
started by discharging the starter battery. Even 100 mA of additional no-load current takes 2.4 Ah per day from the battery.
 If the electrical power requirement is higher, the alternators approved by Volkswagen for the vehicle must be used.
 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).
 Fuse electrical equipment adequately by means of additional fuses.
 All installed electrical devices shall be checked acc. to UNECE-R 10 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
(ESC/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 (EMC) is defined as the property of an electrical system enabling it to behave neutrally with full
functionality in the
vicinity of other systems.
Active systems in the surrounding area are not disrupted by the system, nor is system itself impaired.
Electrical interference in motor vehicle electrical systems is caused by the individual electrical 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.
The devices shall possess a type approval in accordance with UNECE regulation 10 and shall bear the “e” mark.
Volkswagen does not issue a manufacturer’s declaration for electromagnetic compatibility when additional devices are
subsequently installed by body builders.
Should you have any questions, please contact Volkswagen AG. Please refer to Chapter 1.2.1 “Product and vehicle information for
body builders”
2.5.2.5 Mobile communication systems

1. Mobile phones
Commercially available mobile phones may be operated in the vehicle interior. Observe the respective national regulations for
the transmission powers during use. Information about the radio bands can be found in the current vehicle-related manufacturer’s
declaration.
We will be pleased to provide you with the current vehicle-related manufacturer’s declaration.
Please contact us (see chap. 1.2.1.1 “Contact in Germany” and 1.2.1.2 “International contact”).
An installation set with external aerial is recommended for an optimum transmission and reception quality and to connect to
wireless networks outside of the vehicle. The appropriate interface is available for the mobile phone ex-works as optional
equipment.
2. Mobile phones for authorities and organisations with security tasks

Two-way radios complying with the technical guidelines of authorities and organisations with security tasks may be installed and
operated in the vehicle with the appropriate installation set (according to the vehicle-specific manufacturer’s declaration).
We will be pleased to provide you with the current vehicle-related manufacturer’s declaration.
Please contact us (see chap. 1.2.1.1 “Contact in Germany” and 1.2.1.2 “International contact”).
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 must be observed at all times:

 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 adaptation 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, and 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 must only be supplied to the vehicle electrical system 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
The electrical interface for special vehicles (IS1) is installed in the vehicle, behind the trim on the front left-hand side of the dash
panel. The connectors for the interface are located on the wiring harness behind the fuse box. They can be accessed from
the footwell in the driver cab.
Fig. 1: Electrical interface for special vehicles
Fig. 2: Location of the electrical interface IS1 (driver footwell, behind the fuse box)
1 Fuse box
2 Electrical interface IS1 (connector 1 and 2)
2.5.3.2 Assignment of the terminal strip (UF1)
Selected vehicle electrical system potentials are assigned to the 2 plugs. The interface assignment and the possibility of drawing or supplying current depend on the equipment.
Plug 1 (blue)
4F0.972.483.D
Pin potential Colour Cross Max. current Max. current Validation Counter Use Restrictions
section draw [A] supply [A] connector,
[mm²] Contact
A1 75A Black/red 1 12.0 Not permissible F47 (15A) 4F0.972.575.D Terminal 75A
N.107.768.01 (electronic ignition
lock)
A2 55 Grey/yellow 0.5 0.5 Not permissible F30 (5A) 4F0.972.575.D Fog lights PWM signal, signal output even when left
N.105.982.01 cornering lighting is activated
A3 RFL Black/blue 1.0 1.0 Not permissible Not independent 4F0.972.575.D Reversing light PWM signal
N.107.768.01
A4 56b Violet/black 0.35 1.0 Not permissible F48 (5A) 4F0.972.575.D Dipped beam A4 and A5 are phys. connected
Pin A2 N.105.981.01 PWM signal
A5 56b Violet/black 0.35 1.0 Not permissible F48 (5A) 4F0.972.575.D Dipped beam
Pin A2 N.105.981.01
A6 86S Black/green 0.35 1.0 Not permissible F52 (5A) 4F0.972.575.D Terminal 86S
N.105.981.01 (electronic ignition
lock)
A7 58d Grey/yellow 0.35 2.0 Not permissible Not independent 4F0.972.575.D Terminal 58d When a dimmer switch is installed: PWM signal
N.105.981.01 (Side lights)
A8 56aL White/black 0.35 1.0 1.01 F44 (5A) 4F0.972.575.D Left main beam
N.105.981.01
[mm²] Contact
A9 15A Black/blue 0.35 2.0 Not permissible F22 (5A) 4F0.972.575.D Terminal 15
N.105.981.01
A10 58LA Grey/black 1 0.5 Not permissible Not independent 4F0.972.575.D Side light PWM signal; pick-off at left side light
N.107.768.01
A11
A12
A13
A14
A15 15 Black/grey 1 Not 12 F26 (15A) 4F0.972.575.D Terminal 15

permissible N.103.189.01 Continued engine
running
A16 30A Red/brown 4 305 Not permissible F61 (40A) 4F0.972.575.D Terminal 30
N.103.193.01
A17
Connector 2 (green)
4F0.972.483.F
[mm²] Contact
A1 56aR White 0.35 1.0 1.01 F46 (5A) 4F0.972.575.F Right main beam
N.105.981.01
A2 V White/violet 0.5 0.02² Not permissible Not independent 4F0.972.575.F Speed signal
N.105.982.01
A3 L Black/white 0.5 0.2 Not permissible Not independent 4F0.972.575.F Left turn signal Earth signal
N.105.982.01 Stat. Turn signal status no timing signal
A4 50 Red/black 0.35 0.2³ - F18A (5A) 4F0.972.575.F Starter Same signal as pin A7
N.105.981.01
A5 R Black/green 0.5 0.2 Not permissible Not independent 4F0.972.575.F Right turn signal Earth signal
N.105.982.01 Stat. Turn signal status no timing signal
A6 HB Sig Brown/violet 0.35 0.014 Not permissible Not independent 4F0.972.575.F Handbrake Earth signal
N.105.981.01
A7 50 Red/black 0.35 0.2 - F18A (5A) 4F0.972.575.F Starter Same signal as pin A4
N.105.981.01
A8 71b Black/yellow 1 0.5 Not permissible Not independent 4F0.972.575.F Horn Signal pick-off at vehicle horn
N.107.768.01
A9 54 Black/red 0.5 0.2 Not permissible No independent 4F0.972.575.F Brake light Pin 8 and 9 are physically connected
N.105.982.01
A10 54 Black/red 0.5 0.2 Not permissible No independent 4F0.972.575.F Brake light Pin 8 and 9 are physically connected
N.105.982.01
[mm²] Contact
A11 75 Black/yellow 0.5 Not 2.5 F37 (5A) 4F0.972.575.F Terminal 75

permissible N.105.982.01 Continued engine
running
A12
A13
A14
A15
A16
A17
Detailed information about the special interface can be found in the workshop manuals and circuit diagrams (no. 21/1) of Volkswagen AG.
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 7 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. Note parallel operation of additional loads (load balance)
6. An external fuse is required directly before the interface
Information
Volkswagen AG workshop manuals and circuit diagrams

can be downloaded from the Internet at erWin
(Electronic Repair and Workshop Information from
Volkswagen AG):
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 builder for some time.
To prevent damage to the battery clamps, we recommend only tightening the screws on the battery clamp in accordance with the
instructions in the workshop manual. Please observe the tightening torques specified in the workshop manual (see chap. 1.2.1.3).
2.5.4.1 Installation of additional battery

No additional battery is available ex-works at the moment.
If it is necessary for an additional battery to be fitted, this can only be done by the body builder. The body builder bears sole
responsibility for this.
Installing an additional battery is only allowed in conjunction with a battery isolator relay.
The additional battery may only be used for your specific additional consumers. Additional consumers 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.
Make sure the battery is securely attached and covered.
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
When configuring your vehicle, please consider the

optional equipment which can be ordered ex works:
– Preparation for the digital tachograph

(PR number 9ND)
– Digital tachograph (PR number 9NE)
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 Regulation (EC) no. 561/2006 and Art. 2 AETR.
2.5.6 Driver assistance systems
Warning note
Improper interventions in, or installations in, vehicle

systems, safety-relevant components or driver assist
systems can impair their function. This can result in
failure or malfunctions of components or safety-
relevant components. Accidents or damage to
the vehicle may occur as a result.
Practical note
In vehicles with assistance systems (such as the

Lane Assist), add-ons and conversions may result in
falsification of the calibration. Flawless function of
the front camera for driver assist systems and the ACC
would not be ensured. Once a body has been built or
conversion made, a calibration of the driver assist
systems installed must therefore be carried out by an
authorised specialist workshop.
Information
Further information concerning the installation

and removal of assist systems, such as the ACC and
multifunction camera, can be found in the workshop
manuals (repair group 44 Wheels, tyres, wheel alignment
and repair group 96 Electrical system) on the Internet
at erWin* (Electronic Repair and Workshop Information
https://erwin.volkswagen.de/erwin/showHome.do
2.6 Engine peripherals/drive train
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
No modifications are permitted to the fuel system, and any such modifications may result in invalidation of the vehicle’s operating
permit.
In the event that the fuel system must be modified, the body builder is solely responsible for the work being carried out correctly,
including all the components and materials used.
A new operating permit must be applied for from the registration authority.
Comply with the following points if making any modifications to the fuel system:
 The whole system must be permanently leak-proof in all operating conditions.
 Ensure good quality refuelling if modifications are made to the tank filler pipe, and avoid any siphon effect in the pipe routing.
 All components that come into contact with fuel must be suitable for the particular type of fuel used (e.g. petrol/diesel/ethanol
additive, etc.) and the ambient conditions in the installation location.
 Hoses must retain their shape and remain adequately stable throughout the service life, in order to ensure that there is no
constriction in the cross section (hoses acc. to DIN 73379-1)
 Multi-ply hoses should be favoured
 Install reinforcing support sleeves at the connections between hose sections so as to prevent any constriction at the clip
connection and to guarantee air-tightness.
 At the connections, use spring-type clips which automatically compensate for possible settling behaviour of the material and
to maintain the preload. Hose clips with worm threads must be avoided.
 All parts of the fuel filler system must be routed at a sufficient distance from moving parts, sharp edges and components at
high temperature, in order to avoid damage.
 Vehicles with a petrol engine have their activated charcoal container located at the front on top 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
matched components can impair the function of the engine.
 Modifications to the body in the area of the fuel tank require the fuel tank to be removed first.
 If the body builder replaces the standard tank with a different fuel tank, make certain that the ground clearance with the new
tank is no less than with the standard one.
Comply with the workshop manuals of Volkswagen AG.
Information
Volkswagen AG workshop manuals and workshop

information can be downloaded from the Internet at
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 centre 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 still required to the exhaust system for the add-on/removal/conversion, this can have effects which are relevant
to the 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 the 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.
Please contact us before starting your conversion (see chapter 1.2.1).
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.).
2.6.4.1 Exhaust system with SCR system
Modifications to exhaust systems with an SCR system are not permitted under any circumstances. Neither the geometry nor
the position of the sensors are allowed to be changed.
If a modification to the exhaust system due to body design, removal or conversion is nevertheless required, this can have
consequences relevant to registration. Please contact the body builder support personnel in advance regarding the scope of
your conversion so that we can advise you.
Changes as a result of add-ons or conversions are only possible outside of the SCR emission control area indicated by X
(see Fig. 1 Exhaust system with SCR system).
Fig. 1: Exhaust system with SCR system
1 AdBlue tank
2 SCR tank filler neck
3 Fuel tank (diesel)
4 Emission control module
5 Heated metering line
6 Ammonia trap
7 Control unit for NOx sender
Fig. 2: Exhaust system with SCR emission control
1 AdBlue tank
X Area in which modifications are not permitted
Practical note
When working on lines carrying AdBlue®, comply

with the workshop manuals from Volkswagen AG.
Otherwise, AdBlue® could crystallise and lead to
damage to system components.
2.6.5 SCR system (Euro 6)
To meet EURO 6 emissions regulations for diesel engines, engines are available ex-works with different performance levels,
with SCR system.
The abbreviation SCR stands for “Selective Catalytic Reduction” of nitrogen oxides using the “AdBlue®” reducing agent.
The SCR catalytic converter selectively converts the nitrogen oxide (NOx) exhaust component into nitrogen and water. This
conversion is undertaken using AdBlue®, a synthetically manufactured, aqueous reducing agent. AdBlue® comprises 32.5 per cent
high-purity urea and demineralised water. The AdBlue® solution is not mixed with the fuel, but carried in a separate tank.
From here, the AdBlue® is injected continuously into the exhaust gas line in front of the SCR catalytic converter. The AdBlue® reacts
with the nitrogen oxides in the SCR catalytic converter and is split into nitrogen and water. The dosing is determined by the exhaust
mass flow. The engine management system is informed by an NOx sender after the SCR catalytic converter and ensures exact
dosing. The AdBlue® reducing agent is non-poisonous, odourless and water-soluble.
2.6.5.1 Installation position of the AdBlue® tank in the vehicle
The AdBlue tank is installed at the rear of the vehicle underneath the cargo box.
Fig. 3: Installation position of the AdBlue tank on the vehicle
1 AdBlue tank
X Area of the exhaust system in which modifications are not permitted
The SCR system consists of an AdBlue tank, line and a metering valve and forms an optimised electrical-hydraulic unit.
The location of the AdBlue® tank, the heated metering line and their relative position to the vehicle shall not be changed
(see chapter 2.6.4. Exhaust system).
2.6.5.2 Filling opening of the AdBlue® tank
The filling opening of the AdBlue tank is located behind the tank flap next to the fuel filler neck.
The capacity of the AdBlue® tank is approx. 13 litres.
Fig. 4: Filling opening of the AdBlue® tank
- Filler neck of the AdBlue tank
- AdBlue tank
Practical note
Once a particular residual range is reached, the display

on the instrument cluster displays a reminder to top up
the AdBlue®. The AdBlue® consumption depends on
the individual driving style and can be up to 1% of fuel
consumption.
When the AdBlue® tank is empty, the vehicle can only be

driven at reduced power and lower engine torque.
If topping up AdBlue® while the operating range display

is active, always add the minimum replenishment
amount.
Never run the AdBlue® tank empty.
Practical note
AdBlue® attacks surfaces such as painted surfaces,

aluminium, plastics, clothing and carpets. If AdBlue® is
spilled, wipe it up as quickly as possible with a damp
cloth and plenty of cold water. Remove crystallised
AdBlue® with warm water and a sponge.
More information about AdBlue® is available in

ISO standards ISO 22241-1 to 4.
Practical note
To ensure the purity of AdBlue®, never reuse AdBlue®

that has been extracted from the reducing agent tank.
Comply with the laws and regulations of the country

in question regarding correct storage and disposal.
Information
More information and safety instructions for the SCR

system can be found in the owner’s manual for your
vehicle and the Workshop Manuals of Volkswagen AG
on the Internet:
2.7 Power take-off systems, engine/gearbox
When planning the special vehicle, select the equipment of the base vehicle according to the requirements of the future application.
(see chap. 1.3.1 “Selecting the base vehicle”)
Practical note
In vehicles with a high proportion of engine running

times with the vehicle stationary (working mode),
the normal maintenance intervals specified by
Volkswagen AG for the belt drive (poly V-belt,
tensioning pulley, idler roller, etc.) shall be reduced
according to the application and customer profile.
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.
2.7.1 Compatibility with base vehicle

If retrofitting or renewing ancillaries such as the refrigerant compressor, ensure that these are compatible with the base vehicle.
It is also essential to comply with the following points:

 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 wiring/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 chap. 2.7.3.2).
 The diameter and position of the drive pulley for the ancillary must correspond with that of the original refrigerant compressor.
(see chap. 2.7.3.3)
 There must 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 chap. 2.7.3.4).
 The specifications for the belt pulley must exactly match the specifications for the poly V-belt (identical width and number of
grooves, e.g. 6PK).
 To ensure the belt is guided properly, “shouldered washers” (with leading edge) must be used.
 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 must 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”).
 If the standard refrigerant system is modified, the fill volumes of refrigerant and refrigerant oil must be redefined and
indicated accordingly on a plate in the vehicle.
 In order for a safety certificate to be issued, it is necessary to submit documentation relating to the design of the additional
auxiliary drives, specifying the tolerance position, to Volkswagen AG.
 Standard dynamic belt tensioners with spring/shock absorber systems should always be used. Rigid belt tensioning elements
are not allowed to be used.
 It is of great importance that the dynamic properties of the belt drive should be investigated in operation, or ideally that a belt
dynamics measurement should be performed.
 In the event of a faulty ancillary (increased torque requirement or blocking of the ancillary), the pulley in the
belt drive must be able to continue turning freely. Example solution: Thermal fuse in the magnetic clutch.
2.7.2. Retrofitting an 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 number 9AP
(Climatic air conditioning system) which you can buy ex works as optional equipment.
We recommend using the original refrigerant compressor:
Engine designation Air conditioning Refrigerant compressor Capacity Component no.

Type [cm³]
Petrol
2.0 l 118 kW TFSI Cab DENSO-6SEU14 140 2H0.820.803.A
2.0 l 90 kW TDI*
2.0 l 103 kW TDI* Cab DENSO-6SEU14 140 7E0.80.803.J
Diesel
2.0 l 132 kW TDI*
3.0 l 165 kW TDI* Cab DENSO-6SES14 140 2H6.820.803
If other air conditioning systems are to be retrofitted, the guidelines from the equipment manufacturer, and those for the system
components, should be observed. The body builder is then solely responsible for operating and road safety.
Subsequent installation or replacement of additional equipment such as the refrigerant compressor is only possible in the main
belt track instead of the genuine refrigerant compressor.
Compatibility with the base vehicle must be observed without fail (see chap. 2.7.1 Compatibility with base vehicle
and chap. 2.7.3 Specifications of genuine refrigerant compressor).
Practical note
Please note that subsequent modifications to the

factory-fitted air conditioning system by the body
builder are solely the responsibility of the body builder.
In such cases, Volkswagen is unable to make any
statement about the lubrication of the compressor and
the effects on its service life. An extensive measuring
procedure must be carried out at the compressor
manufacturer in order to ensure oil circulation in
the refrigerant circuit.
As a result, Volkswagen AG does not offer any warranty

for the compressor in this case.
In order for the warranty to be retained, it would be

necessary for an extensive measurement of the oil
circulation in the refrigerant circuit to be carried out.
Practical note
In vehicles without air conditioning, it is necessary to

recode the engine control unit when an ancillary is
retrofitted.
2.7.3. Specifications for the genuine refrigerant compressor
2.7.3.1 Maximum cooling output
Engine designation Refrigerant compressor Power L Cooling power

type [ kW] Q
[ kW]
Petrol
2.0 l 118 kW TFSI DENSO-6SEU14 (140 ccm) ≤3.01) ≥4.6 1)
2.0 l 103 kW TDI*

DENSO-6SEU14 (140 ccm) ≤3.01) ≥4.6 1)
2.0 l 132 kW TDI*
Diesel
3.0 l 165 kW TDI* DENSO-6SES14 (140 ccm) ≤2.81) ≥4.91)
1 – Figures on refrigerant compressor with high pressure Pd=16 bar, suction pressure Ps=2.8 bar and speed N=2,000 rpm
2.7.3.2 Weight of the refrigerant compressor
Engine designation Refrigerant compressor Max. weight

type [kg]
Petrol
2.0 l 118 kW TFSI DENSO-6SEU14 (140 ccm) 4.62 kg
2.0 l 103 kW TDI*

DENSO-6SEU14 (140 ccm) 4.62 kg
2.0 l 132 kW TDI*
Diesel
3.0 l 165 kW TDI* DENSO-6SES14 (140 ccm) 4.36 kg
2.7.3.3 Pulley diameter of the refrigerant compressor
Engine designation Refrigerant Pulley Diameter of Transmission ratio “i”

compressor Diameter crankshaft drive (crankshaft/refrigeran
type [mm] wheel [mm] t compressor)
Petrol
2.0 l 118 kW TFSI DENSO-6SEU14 100 138 1.38
2.0 l 103 kW TDI*

DENSO-6SEU14 100 138 1.38
Diesel
2.0 l 132 kW TDI*
3.0 l 165 kW TDI* DENSO-6SES14 110 138 1.25
2.7.3.4 Specification of the poly V-belt
Engine designation Refrigerant compressor Belt specification Part number

type
Petrol
2.0 l 118 kW TFSI DENSO-6SEU14 (140 ccm) 6PKD-1577 06H.903.137.H
2.0 l 103 kW TDI* 6PK-1555,

DENSO-6SEU14 (140 ccm) 03L.903.137.H
Diesel
2.0 l 132 kW TDI* SILENT GRIP
3.0 l 165 kW TDI* DENSO-6SES14 (140 ccm) 6PK-2567 059.903.137.BQ
2.7.3.5 Connection dimensions for the genuine 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 ASSY
Fig. 2: Dimensions of air conditioning compressor, pulley diameter (side view)
Fig. 3: Connection dimensions of air conditioning compressor (front view)
Fig. 4: Connection dimensions of refrigerant compressor (view from above)
5.3±0.2
Fig. 5: Detail of U-drive pulley of the Denso 6SU14 air conditioning compressor, pulley diameter d=100 mm
Fig. 6: Detail of U-drive pulley of the Denso 6SES14 air conditioning compressor, pulley diameter d=110 mm
Engine designation Refrigerant compressor Capacity d D E Number
type [cm³] [mm] [mm] [mm] Grooves
Petrol
2.0 l 118 kW TFSI DENSO-6SEU14 (140 ccm) 140 100 106.6 114 6
2.0 l 103 kW TDI*

DENSO-6SEU14 (140 ccm) 140 100 106.6 114 6
Diesel
2.0 l 132 kW TDI*
3.0 l 165 kW TDI* DENSO-6SES14 (140 ccm) 140 110 116.6 114 6
Please observe the installation and removal regulations of Volkswagen AG when performing conversions.
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):
Please also comply with the following chapters during the conversion:
 2.7.1 “Ancillaries”
 2.5.4 “Vehicle battery”
 2.5.2.2 “Additional circuits”
 3 “Modifications to closed bodies”
 5.2 “Refrigerated vehicles”
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 can no longer exert any tension on the belt.
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° (rated)
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 0.3 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 of 28°–57°. For distance A, it is necessary to specify the actual dimension
between the fixed eye and the moveable eye provided that the moveable eye is within 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):
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 lever arm of the belt tensioner in the working area. (Fig. 9)
Fig. 9: Belt routing around the belt tensioner (2.0 l TDI engine shown)
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

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 fig. 1 and fig. 2)
Please also observe the manufacturer’s installation instructions!
Fig. 1: Roof rack bolt attachment points on Amarok DC (marked in red)
Fig. 2: Roof rack bolt attachment points on Amarok SC (marked in red)
2.8.2 Towing bracket
We recommend using hitches (PR number 1D1/1M0) approved by Volkswagen as towing brackets.
- 1D1 (in combination with ESP including trailer stabilisation)–
Trailer load max. 750 kg unbraked and 2,900–3,500 kg brakes (depending on engine) with 12% hill climbing ability.
The gross vehicle weight rating may not be exceeded.
The permitted drawbar load is 120–140 kg, depending on the version. The precise specification can be found in chapters
“2.8.2.1 Maximum trailer weights V6 TDI (market: EU)” and “2.8.2.2 Maximum trailer weights (market: non-EU)”.
The Preparation for towing bracket (PR number 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 directly from Volkswagen AG.
Fig. 1: Towing bracket
1 = Bumper
2 = Ball hitch
2.8.2.1 Maximum trailer weights V6 TDI (market: EU):
Climate zone / Total Max. trailer Total traction Drawbar

type approval weight weight* weight load [kg]
country [kg]) [kg] [kg]
3.0 l TDI 120 kW 8Z4/8Z5 2,900 2,900 5,550 120

6-speed manual 8Z6/8Z9
8Z4/8Z5 3,080 3,000
8Z6/8Z9
3.0 l TDI 120 kW 8Z4/8Z5 2,920 3,000 5,550 120

6-speed manual 8Z6/8Z9
4Motion
8Z4/8Z5 3,080
Diesel
8Z6/8Z9
B09 3,200 5,700
3.0 l TDI 150 kW 8Z4/8Z5 2,920 3,000 5,700 120

6-speed manual 8Z6/8Z9 5,550
4Motion
8Z4/8Z5 3,080
8Z6/8Z9
B09 3,200 5,700
3.0 l TDI 150 kW 8Z4/8Z5/8Z7 2,920 3,500/3,300 6,000 140

8-speed automatic 8Z6/8Z9 3,000 5,550 120
4Motion
8Z4/8Z5/8Z7 3,080 3,300
8Z6/8Z9 3,000
B09 3,290 3,100 6,000 130

Diesel
3.0 l TDI 165 kW 8Z4/8Z5/8Z7 2,920 3,500/3,300 6,000 140

8-speed automatic 8Z6/8Z9 3,000 5,550 120
4Motion
8Z4/8Z5/8Z7 3,080 3,300
8Z6/8Z9 3,000
B09 3,290 3,100 6,000 130

*Maximum trailer weight unbraked: 750 kg
Legend for PR number:
8Z4: temperate hot climate
8Z5: not hot climate
8Z6: hot climate / 8Z9: super-hot climate
8Z7: cold climate
B09: UK only
2.8.2.2 Maximum trailer weights (market: non-EU):
Climate zone / Total Max. trailer Total traction Drawbar

type approval weight weight* weight load [kg]
country [kg]) [kg] [kg]
2.0 l TFSI 118 kW --- 3,040 3,000 5,550 120

Petrol
manual 6-speed 2,820 2,800
2.0 l TDI 103 kW --- 3,040 3,000 5,550 120

6-speed manual
2.0 l TDI 132 kW
6-speed manual
2.0 l TDI 132 kW 2,820 2,800
Automatic
6-speed
2.0 l TDI 103 kW --- 3,040 3,000 5,550 120

6-speed manual
4Motion
2.0 l TDI 132 kW
Diesel
2,820
6-speed manual
4Motion
2.0 l TDI 132 kW 8Z4/8Z5 3,040 3,200 5,950 130

Automatic 8Z6/8Z9 3,000 5,550 120
8-speed 4Motion
8Z4/8Z5 2,820 3,200 5,950 130
8Z6/8Z9 3,000 5,550 120
3.0 l TDI 165 kW 8Z4/8Z5 2,920 3,000 5,700 120

Manual 8Z6/8Z9 5,550
6-speed 4Motion
8Z4/8Z5 3,080 5,700
8Z6/8Z9 5,550
*Maximum trailer weight unbraked: 750 kg
Legend for PR number:
8Z4: temperate hot climate
8Z5: not hot climate
8Z6: hot climate; 8Z9: super-hot climate
The maximum permitted gross combination weight and maximum permitted trailer load specified in the documents
must not be exceeded.
2.8.2.3 Retrofitting a towing bracket
For retrofitting a towing bracket:

 Comply with the regulations of the country in question, in this regard see also UNECE-R55 (in the valid version). See figures.
 The necessary clearance for the towing bracket shall be guaranteed (clearance acc. to UNECE-R 55).
 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 longitudinal

members, 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 bracket listed here is only valid for EU

countries. There are different variants for countries
outside the EU. Please contact your Volkswagen
dealership for further information.
2.8.2.4 Clearance according to UNECE-R 55
When fitting a towing bracket in the EU, the installation dimensions and clearances specified in UNECE-R 55 must be observed.
Any other applicable national regulations must be taken into account.
When the vehicle is loaded with the permitted total mass, the centre of the coupling ball is permitted to hang between 350 mm
and 420 mm above the road surface. This applies to vehicles with a permitted total mass < 3,500 kg. Off-road vehicles are excepted.
Unspecified details shall be selected in a reasonable manner.
The test of dimensions and angles shall be undertaken with suitable length and/or angle measuring instruments.
Ball hitch
The specified clearances shall be observed.
Clearance according to the height of the coupling ball according to UNECE-R 55 (side view)
1 Clearance
2 Vertical plane through end points of the total length of the vehicle
3 Floor
Clearance according to the height of the coupling ball as per ECE-R 55 (side view)
Clearance of the coupling ball according to UNECE-R 55 (top view)
1 Clearance
2 Vertical plane through end points of the total length of the vehicle
Plan view
2.8.3 Styling bar (tubular frame on the cargo box)
A styling bar for the Amarok is available as a Volkswagen genuine accessory ex-works.
We recommend only using Volkswagen Genuine Accessories for this purpose.
Information
For further information see: http://www.volkswagen-

nutzfahrzeuge.de/de/service-und-zubehoer/volkswagen-
zubehoer-und-lifestyle.html
For independent constructions or commercially available accessories, please note that relative movements between the two tubes
in styling bars with a double tube design are ruled out by suitable connecting elements in the upper area of the tubular frame
(see Fig. 1 and 2). Otherwise, the cargo box might be damaged as a result of vibrations.
Fig. 1: Example of styling bars in a double tube design (plan view)
Fig. 2: Example of attachment of the tubes in the front and rear (section A-A)
Position Designation
1 Front tube made from rust-proof steel ∅76.2 x 1.2 mm
2 Rear tube made from rust-proof steel ∅76.2 x 1.2 mm
3 Right and left connecting plate, plate thickness 2 mm
4 Pop rivet nut, short hexagonal M8 x 1.25 (0.5-3.5 mm)
5 Washer M8, ∅16 mm
6 Round-head screw with hexagon socket M8x1.25x25 (8.8), self-securing with Loctite 270
Practical note
Please note that the side walls of the factory-designed

cargo box are not intended for connection to a working
bar. To connect a working bar, please calculate the stress
and reinforce the box if necessary.
2.8.4 Add-on parts on the cargo box
Practical note

cargo box are not intended for connecting add-on parts.
Add-on parts must be fastened on the intended load
points/lashing points on the base of the cargo box.
Stress calculations should be performed and, if
necessary, appropriate reinforcement measures
provided.
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 builder 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 Modifications to closed bodies

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 fuel tank lines and fuel lines shall be maintained.
 The standard tank cap must not be removed or covered with a part which creates a block.
 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 gross axle weight ratings must not 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.
 Forced ventilation openings are not allowed to be covered or closed.
 If the factory-fitted forced ventilation is converted or dispensed with, the body builder must provide suitable replacement
openings.
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 breather and ventilation openings must 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
For detailed instructions about the installation and

removal of windows, refer to the Workshop Manuals of
Volkswagen AG on the Internet at erWin (Electronic
3.1.3 Roof cut-outs

The roof cut-out must be provided with an all-round frame having a force-locking connection with the adjacent weight-bearing
parts (cross strut and windscreen frame).
Information

work on the Internet at erWin (Electronic Repair and
Workshop Information from Volkswagen AG):
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

work on the Internet at erWin (Electronic Repair and
Workshop Information from Volkswagen AG):
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 UNECE-R 21. 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 dash 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 must not 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 permissible.
(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.
3.3 Cargo box
3.3.1 Removal of the cargo box
Fig. 1: 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).
You will find further information on the removal of the rear bumper (7) and the cover on the plastic trim in the Volkswagen AG
workshop manuals.
 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 that 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.
Information

Workshop Manuals on the Internet at erWin (Electronic
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.
 A suitable replacement fastening must be provided for the handbrake cable attachment.
Warning note
If the cargo box is removed for a body modification or is

modified in the corresponding area, a suitable
replacement fastening must be created for the
parking brake attachment.
The same applies to the Amarok cab chassis.

The dimensions of the new brake cable holder should
correspond those of the series production version.
(See Fig. 2.)
A brake cable holder (7H0.711.453) is available as

a replacement part ex-works for the Transporter.
This can be used irrespective of the body and
the available space.
Fig. 2: Dimensions of the handbrake cable holder
3.3.2 Weight of cargo box
Component Amarok DC Amarok SC
Cargo box* 121 kg 151 kg

* Incl. the add-on parts for the rear lid, hinges, tail light cluster, wheel housing liner and rear lid lock
3.4 Add-on parts on the cargo box

Add-on parts on the cargo box include:
 Hardtop
 Attachments with the option of loading from the side in order to transport tools and materials
These are referred to as “hardtop” in the following, for the purposes of simplification.
The side panels of the standard cargo box are not designed to support loads on the handrail.
Retrofitted add-on parts on the cargo box require additional reinforcement in the area of the D-pillar.
Note the following if retrofitting a hardtop:

 Suitable fastening (clamping elements, bolted connections) must ensure that the add-on on the cargo box remains in position
even during dynamic driving.
 On condition that a rivet is added as a reinforcement measure at both the left and right rear of the cargo box in the area of
the D-pillar (part number N902.866.04), a hardtop with a dead weight (with loading, if possible) of up to 80 kg can be placed on
the upper edge of the cargo box/handrail. (See figure for the installation positions of the rivets)
 If the mass of the hardtop exceeds 80 kg, the load of the attachment must also be placed on four vertical supports on
the cargo box (in addition to the rivets), preferably on the lashing points.
 Mounting the hardtop obstructs the third brake light. The lighting facilities must comply with the applicable national
regulations. (See also chapter 2.5.1.2 Installing the 3rd brake light)
Installation position of rivet N 902 866 04
1 rivet
Necessary work steps:

1. Mark out the position of the side panel
2. Drill a Ø 5.0 mm hole
3. Deburr the drilled hole
4. Protect the edges of the hole against corrosion with clear coat (see also chapters 2.3.2.9 Corrosion protection after welding
and 2.3.2.10 Corrosion protection measures)
5. Insert rivet N902 866 04
3.4.2 Hardtop with additional roof rack
Note the information in chapter 3.4.1.
We differentiate between two types of roof rack:

1. Roof racks that have the same length as the cargo box or hardtop.
2. Roof racks that stretch as far as the driver’s cab and are designed for transporting long materials.
For version 2, it is important to note that there must not be any mechanical coupling between the cargo box and the driver’s cab by
means of the fastening of the roof rack for long material, as the cargo box is bolted in position onto the retaining frame while
the driver’s cab has elastic bearings.
4 Modifications to open bodies (cab chassis)

4.1 SCR tank system and fuel filler neck
For add-ons and conversions, the Amarok can be ordered as a cab chassis ex works.
The Amarok cab chassis is delivered without a cargo box and with a transport frame (market: EU) for the fuel filler pipe and the SCR
tank system or with a transport support (market: non-EU) for the fuel filler pipe. (see Fig. 1 and Fig. 2.)
Please note that the transport frame (fig. 1) and the transport support (fig. 2) are only designed for use when the vehicle is being
transported to the body builder. They are neither intended for continuous use, nor must they be left in the vehicle.
The body builder must provide a suitable bracket for continuous use.
Fig. 1: Transport frame (Amarok DC with SCR system)
1 Transport frame (cab chassis)
2 SCR tank
3 SCR filler pipe
4 SCR closure
5 Fuel filler pipe
Fig. 2: Transport support for the fuel filler pipe (Amarok without SCR system)
1 Transport support
4.1.1 Fastening the SCR tank system

The body builder is responsible for fastening the SCR tank system to the body.
In order to ensure that all functions work correctly, the SCR tank system must be installed in the position in which it is delivered.
Any deviating installation is only permissible subject to restrictions.
When installing the SCR system and routing the filler neck for the reducing agent (AdBlue), the “SCR tank system installation
instructions for body builders” must be observed.
Information
The “SCR tank system installation instructions for body

builders” are available on the body builder portal of
Volkswagen AG under the “Additional technical
information” menu option*.
*Registration required
4.1.2 Attaching the fuel filler pipe
Warning note
Please note that work on the filler neck may only be

performed when the tank is empty or has been removed!
For conversions based on the Amarok Cab Chassis or vehicles with a removed cargo box, it is necessary to create a suitable new
holder for the fuel filler pipe for continuous use.
The connection dimensions for attaching the fuel filler pipe can be found in Fig. 3 as well as in the Amarok’s build dimension
drawing (see chap. 6.1 “Build dimension drawings”).
Fig. 3: Fuel filler neck with standard attachment flange
The fastening must meet the requirements of regulation UNECE-R 34 Prevention of fire risks.
Comply with the following points during the work:
 The filler pipe shall be fixed to the ladder frame or else to components attached to that.
 The whole system with fuel filler pipe, filler neck and tank cap must 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 standard 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-resistant or diesel-resistant.
 A sufficient gradient of the filler pipe towards the tank must 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 connecting hose and vent line must be attached free of stress and must not be bent.
 In the same way as it is for the production solution, the pump nozzle must have easy access to the fuel filler neck.
Information
A conversion kit for the diesel or petrol filler pipe

(order number: 2H0.298.129/2H0.298.129A) can be
obtained from Volkswagen Genuine Parts. Please contact
us (see 1.2.1.1 “Contact in Germany” and 1.2.1.2
“International contact”).
In addition, the requirements and recommendations in chapters 4.1.2.1 and 4.1.2.2 must be complied with when routing the filler
neck for diesel and petrol “filler pipes”.
4.1.2.1 Requirements of the Amarok diesel filler pipe
Fig. 4: Filler pipe assembly (ASSY)
1 Ventilation valve
2 Fastening lug for closure neck
3 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.)
Please observe the following items for conversions:

 An earthing path from the filler pipe via the closure neck and fastening lug to the vehicle body (screw connection) must be
guaranteed.
 A ventilation function for the fuel tank via the filler pipe shall be provided.
The breather line can be purchased as a conversion kit (order number: 2H0.298.129) from Volkswagen Genuine Parts.
Please contact us (see 1.2.1.1 “Contact in Germany” and 1.2.1.2 “International contact”).
 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 positive pressure and negative pressure protection functions integrated in the closure cap (tank cap) must not be
impaired in any way.
 The filler pipe shall be fixed to the ladder frame if possible, or else to components attached to that.
4.1.2.2 Requirements of the Amarok petrol filler pipe
Fig. 5: Petrol filler pipe
1 Ventilation line
2 Activated charcoal container
Please observe the following items for conversions:

 An earthing path from the filler pipe via the closure neck and fastening lug to the vehicle body (screw connection)
must be guaranteed (same as diesel).
 The positive pressure protection function for the fuel tank must be ensured in the filler pipe (Amarok petrol standard solution:
protection valve in the tank cap).
The breather line can be purchased as a conversion kit (order number: 2H0.298.129.A) from Volkswagen Genuine Parts.
Please contact us (see 1.2.1.1 “Contact in Germany” and 1.2.1.2 “International contact”).
 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
neck in the wheel housing).
4.2 Chassis frame
4.2.1 Ladder frame Amarok DC (Double Cab)
Fig. 1: Plan view of Amarok DC (without cargo box)
Fig. 2: Plan view of ladder frame Amarok DC
4.2.2 Ladder frame Amarok SC (Single Cab)
Fig. 3: Plan view of Amarok SC (Single Cab) without cargo box
Fig. 4: Plan view of ladder frame Amarok SC
4.2.3 Sections, Amarok SC (Single Cab)/Amarok DC (Double Cab)
Fig. 5: Section Q-Q (Amarok SC) Fig. 6: Section R-R (Amarok SC/DC)
Fig. 7: Section S-S (Amarok SC/DC) Fig. 8: Section T-T (Amarok SC/DC)
Please refer to the Amarok Double Cab and Single Cab build dimension drawings for further connection sizes
(see chapter 6.1 “Technical data”).
4.3 Standard attachment points for special bodies
Special bodies are possible after the cargo box has been removed (see chap. 3.3.1).
Always make sure that the fuel tank and its lines and all components between the longitudinal members and the rear bumper
and spare wheel are covered and protected from direct sunlight, snow and liquids when assembling standard and special bodies or
when using the vehicle as a tractor unit. Avoid operating the vehicle without the body outdoors without these protective covers.
Please note the following points when assembling special bodies:
 The attachment between the body and vehicle frame shall always use all brackets.
(see Fig. 1 and Fig. 2.)
 The screw connections onto the brackets must be force-locking.
 When replacing the cargo box with other bodies, the maximum static torsional rigidity for the body may not exceed that for
the cargo box. For the Amarok Single Cab CT=1,200 Nm/° and for the Amarok Double Cab CT=1,300 Nm/°. The static torsional
rigidity can be determined in a test. (See fig. 3).
 The wheel clearance on the rear axle must 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 of the ladder frame for attaching the cargo box. Holes or slots with
the dimension 21 mm, 23 mm or 21x30 mm are provided for the attachment of the cargo box
(see Fig. ½). For more information, refer to chap. 4.2 “Chassis frame”.
Fig. 1: Amarok Double Cab – mounting brackets for cargo box (see red mark!); schematic diagram without transport frame and SCR tank.
The towing bracket shown here and 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”).
Fig. 2: Amarok Single Cab – mounting brackets for cargo box (see red mark!); schematic diagram
The cross member (bumper) shown here on Amarok chassis must be sourced subsequently as a Volkswagen genuine part (see chapter 1.2.1.4 “Genuine parts online”).
Fig. 3: Determining the static torsional rigidity for the cargo box
1 Front contact point
2 Rear contact point
MT Torsional moment, in the middle of the cargo box
4.4 Subframe (mounting frame)
4.4.1 General notes
 When replacing the cargo box with other bodies, the maximum static torsional rigidity for the new body (assembly consisting
of the body, subframe and flexible suspension) may not exceed that for the cargo box. For the Amarok Single Cab
CT=1,200 Nm/° and for the Amarok Double Cab CT=1,300 Nm/°.
The static torsional rigidity can be determined in a test. (See Fig. 3).
 The subframe and self-supporting bodies must be attached to the chassis using all available brackets.
(There are six threaded connection points in the Amarok Single Cab and eight threaded connection points in the Amarok Double
Cab).
 In addition to the threaded connection points, the cargo box is equipped with spacers/sliding runners (2H5.810.967.B) as
standard. These are clipped into the lower side of the cargo box. The spacer displaces pressure onto the ladder frame. When
screwing a case onto the ladder frame, using the spacers is recommended.
 The two front threaded connection points located directly behind the Single Cab/Double Cab must be compressible. A
compressible connection could be achieved using a coil spring or several dished springs with a suitable spring rate in the screw
connection.
 Standard washers should be avoided on the threaded connections. Instead, moulded parts should be used when possible.
These parts should use the entire available space on the bottom of the brackets as a contact surface. Furthermore, any
notching effect in the brackets’ rounded areas caused by the moulded part should be avoided.
 Bolts with the same strength class as the standard screws should be used for securing.
4.4.2 Bodies with subframes
 The subframe shall be designed to be self-supporting according to the load.

 Cross members shall be provided at least in the front and rear areas to ensure the structure is stable.
 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.
 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 on the ladder frame, continue up to the cab and taper in
the front area.
 The various air gaps between the chassis and subframe do not need to be filled in.
 The subframe sits only on the bracket points and sliding runners.
4.4.3 Bodies without subframes

Self-supporting bodies can be attached directly to the standard brackets on the frame by means of a base frame.
5 Implementations of special bodies

5.1 Vehicles for conveying persons with restricted mobility
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 dealership.
Please note that certain conversions are only allowed to be used by people with corresponding entries in their driving licence.
Information
For more information, refer to the Volkswagen AG

website at:
nutzfahrzeuge.de/de/kundenloesungen/menschen-mit-
behinderung.html
5.1.1 Notes on installing manual operating devices for the service brake:
Notes on installing manual operating devices for the service brake:
 Do not modify the brake pedal when installing manual operating devices. Select a clamped solution for connecting the manual
operating device.
 The operating travel of the manual operating device must also be sufficient for a blocking braking, with reserve travel for
a circuit failure.
 If a manual operating device is used for the accelerator and brake, the standard pedals must be covered by suitable means.
5.1.2 Deactivating the airbag/belt tensioner systems

The customer service workshop can also deactivate/reprogram the driver airbag/belt tensioner in exceptional cases, e.g. for drivers
with a disability (entered accordingly in the driving licence), if there is insufficient distance to the steering wheel or smaller steering
wheel for wheelchair users (self-drive) and no airbag can be installed. For more information, please contact Volkswagen customer
service.
The following points must be observed when deactivating the airbag/belt tensioner:
1. The registration document for airbag/belt tensioner systems issued by Volkswagen Dealership must be stored in the vehicle
wallet and handed over to the next owner on sale of the vehicle.
2. A warning sticker indicating this deactivation must be attached to the dash panel in clear view and must not be removed
before the airbag is reactivated.
3. Alterations to/deactivations of functions (airbag, belt tensioner, seat-occupied sensor etc.) must be entered immediately in
the vehicle documents (TÜV, DEKRA, responsible technical service).
4. Other users/purchasers of the vehicle must be informed that the specified safety systems have been deactivated and of
the increased safety risk this entails.
5. We strongly recommend that deactivated airbags/belt tensioner systems are reactivated by a Volkswagen Dealership before
the vehicle is sold. This applies in particular if the vehicle is sold or permanently transferred to persons who do not fulfil
the requirements for airbag deactivation.
Warning note
Deactivation means that the additional safety function of

the airbag/belt tensioner is no longer ensured. Accidents
may result in more severe injuries than those in which
the airbag/belt tensioner is activated. Vehicle occupants
have a greater risk of injury.
Practical note
Please note that permanently deactivating or removing

the driver airbag also invalidates the belt unit type
approval (belt tensioner, belt retractor). If an airbag is
deactivated, the corresponding belt unit (for systems
without airbags) must always also be adapted.
Follow the procedure for deactivating airbags specified
in the Workshop Manual (see General body repairs,
interior, repair group 1.8 Airbag deactivation
and repair group 69 Passenger protection).
The workshop manual can be found online at erWin
(Electronic Repair and Workshop Information of
Volkswagen AG):
https://erwin.volkswagen.de/erwin/showHome.do
Special information for deactivating side airbags (replacing driver seat with disability seat):
1. In Germany, the second regulation (2.SprengV) of the Explosives Act (SprengG) applies to the storage and preservation of seats
with side airbags. Customers who wish to store removed seats at their homes must first clarify the requirements for private
storage with the responsible trade supervisory board.
2. To store a removed seat, a safety plug must be fitted on the detached cables.
Please also comply with the following chapters during your conversion:
 1.3.1 Selecting the base vehicle

 2.2.1 Permitted weights and unladen weights
 2.3.2 Modifications to the body-in-white
 2.5.2.1 Electrical wiring and fuses
 2.5.2.3 Retrofitting electrical devices
 2.5.4 Vehicle battery
 3.2.1 Safety equipment
5.2 Refrigerated vehicles
(See also chap. 1.3.1 “Selecting the base vehicle”)
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”
 2.5.2.1 “Electrical cables and fuses”
 2.5.3 Electrical interface for special vehicles
 2.7.2 “Power take-off systems”
 3.1.4 “Modifications to the roof”
Information
For more information about this topic, refer to the

“Additional technical information” on the body builder
portal of Volkswagen AG.
5.3 Shelf installation/workshop vehicles
Please also comply with the following chapters as part of the conversion:
 2.6.3 “Fuel system”
 2.6.4 “Exhaust system”
 3.2.1 “Safety features”
 2.8.4 “Add-on parts on the cargo box”
Information
For more information about this topic, refer to

the “Additional technical information” on the
body builder portal of Volkswagen AG.
Practical note

cargo box are not intended for connecting add-on parts,
e.g. workshop box with roof rack.
The load of add-on parts such as these should be

transferred to the base of the cargo box via
the lashing points.
Stress calculations should be performed and, if
necessary, appropriate reinforcement measures
provided.
5.4 Conversions for caravans
Information

the “Additional technical information” on the body
builder portal of Volkswagen AG.
5.5 Conversions for municipal vehicles
Practical note
Please note that during more demanding operating

conditions, some servicing work will be necessary
before the next vehicle service is due.
The vehicle has been designed for use under “normal”

operating conditions. Any long-term operation of the
engine at idling speed or with a high share of short-
distance journeys may lead to premature blocking of the
diesel particulate filter and the need for its regeneration.
Please observe the information and notes in the owner’s
manual regarding the regeneration of the diesel
particulate filter. (See the owner’s manual: check!)
Information

the Volkswagen Commercial Vehicles website at:
nutzfahrzeuge.de/de/kundenloesungen/kommunen-und-
behoerden.html
5.6 Tractor unit
Vehicles with ESC* are not suitable for use as tractor units.
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 is not allowed to 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 body builder 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”
Please contact us before starting your conversion (see chap. 1.2.1).
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.
Please contact us before starting your conversion (see chapter 1.2.1).
Please also comply with the following chapters of the Body builder guidelines for your conversion:
 2.2 “Running gear”
5.9 Box bodies (dry freight boxes)
For the construction of dry freight boxes, the following points should be observed:
1. Selection of a suitable base vehicle (gross vehicle weight rating, equipment) (see chapter 1.3.1).
2. The maximum permitted weights and axle loads of the base vehicle must be observed (see chapters 2.2.2, 2.2.1.1 and 8).
3. The body should be constructed so that the forces introduced are evenly distributed.
4. Assembly, maintenance and owner’s manuals specifying the load limits should accompany the modified vehicle.
5. The regulations and standards for load securing must be observed:
 VDI 2700 ff
 StVO or country-specific laws and regulations.
 After all work to the vehicle is complete, remove the drilling chips and implement corrosion protection measures.
(see chapters 2.3.2.10, 2.3.2.13 and 2.3.2.14)
6. The requirements of the body builder guidelines for electrical wiring and fuses must be observed:
 Chapter 2.5.2.1 Electrical wiring and fuses
 Chapter 2.5.2.3 Retrofitting electrical devices
 Chapter 2.5.3 Electrical interface for special vehicles
7. During installation and conversion no electric wires or other components of the base vehicle (e.g. fuel tank, brake lines)
may be damaged.
8. Conversion should only be performed by trained specialist personnel.
9. All of the body brackets provided as factory fittings are to be used for securing box bodies to the vehicle frame.
10. For an even load on the chassis frame, the body shall be attached using an assembly frame (subframe)
(see 4.2 “Chassis frame”).
11. On box bodies, bolted connections with spacer sleeves that are secured against loosening shall be used on the first and second
body brackets in the area behind the cab. The spacer sleeves shall be dimensioned so that they cannot be deformed
(see 2.3.2.1 “Screw connections”).
12. See chapter 4.4 “Subframe (mounting frame)” for the material properties of the subframe.
13. The minimum distance of 20 mm between the rear cab wall and the box body is to be maintained. (see chapter 2.1.6).
14. The wheel clearance on the rear axle must be maintained. (see chapter 2.2.9 “Wings and wheel housings”)
15. Depending on body width, appropriate exterior mirrors and end-outline marker lamps are to be selected (on top of the box).
(see 2.1.6 and 2.5.1.1) It may be necessary to reposition the rear lights (see chapters 4.7 and 2.5.1).
16. Depending on the vehicle length, side marking lights must be provided (see chapter 2.5.1.1).
17. Roof loads must be observed. (see chap. 2.3.1)
Compliance is required with current statutory provisions and legislation, regulations on health and safety and accident prevention,
safety rules, and accident insurance providers’ data sheets. Country specific laws, guidelines and registration conditions must be
observed (see chapter 1.2.9).
5.10 Platform bodies (open boxes)
For the construction of platform bodies, the following points should be observed:
1. Selection of a suitable base vehicle (gross vehicle weight rating, equipment) (see chapter 1.3.1).
2. The maximum permitted weights and axle loads of the base vehicle must be observed
(see chapters 2.2.2, 2.2.1.1 and 8.5).
 VDI 2700 ff
6. Following all work to the vehicle, remove drilling chips and implement corrosion protection measures
(see chapters 2.3.2.10, 2.3.2.13 and 2.3.2.14).
 Chapter 2.5.2.1 Electrical wiring and fuses
 Chapter 2.5.2.3 Retrofitting electrical devices
 Chapter 2.5.3 Electrical interface for special vehicles
8. During body assembly and conversion no electric wires or other components of the base vehicle
(e.g. electrical cables, fuel tank, brake lines) may be damaged.
10. All of the body brackets provided as factory fittings are to be used for securing platform bodies to the vehicle frame.
11. For an even load on the chassis frame, the body shall be attached using an assembly frame (subframe)
(see 4.3.1 “Configuration of the subframe”).
12. For platform bodies, bolted connections protected against loosening with spacer sleeves shall be used on the first and second
body brackets in the area behind the cab. The spacer sleeves shall be dimensioned so that they cannot be deformed
(see 2.3.2.1 “Screw connections”).
13. See chapter 4.3 “Subframe for light commercial vehicles” for the material properties of the subframe.
14. The minimum distance of 20 mm between the rear cab wall and the box body must be maintained (see chapter 2.1.6).
15. The wheel clearance on the rear axle must be maintained (see chapter 2.2.9 “Wings and wheel housings”).
16. Appropriate exterior mirrors must be chosen, depending on the width of the body (see chapters 2.1.6 and 2.5.1.1).
17. It may be necessary to reposition the rear lights (see chapters 2.5)
19. Roof loads must be observed. (see chap. 2.3.1)
20. Compliance is required with current statutory provisions and legislation, regulations on health and safety and accident
prevention, safety rules, and accident insurance providers’ data sheets. Country specific laws, guidelines and registration
conditions must be observed (see chapter 1.2.9).
21. If the standard platform is subjected to point or point-like loading (e.g. transportation of cable drums, coils etc.),
the substructure and platform floor shall be reinforced suitably for the load.
Practical note
If a superstructure has moving attachments, make sure

that there is sufficient clearance from the base vehicle,
otherwise attachments could collide with the base
vehicle causing damage.
5.11 Platform bodies (open boxes)
For the construction of tipper bodies, the following points should be observed:
1. Selection of a suitable base vehicle (gross vehicle weight rating, equipment), see chapter 1.3.1
2. The maximum permitted weights and axle loads of the base vehicle must be observed
(see chapters 2.2.2, 2.2.1.1 and 8.5).
 VDI 2700 ff
6. Following all work to the vehicle, remove drilling chips and implement corrosion protection measures (see chapters 2.3.2.10,
2.3.2.13 and 2.3.2.14).
 Chapter 2.5.2.1 “Electrical wiring and fuses”
 Chapter 2.5.2.3 “Retrofitting electrical devices”
 Chapter 2.5.3 “Electrical interface for special vehicles”
8. During body assembly and conversion no electric wires or other components of the base vehicle
(e.g. electrical cables, fuel tank, brake lines) may be damaged.
10. The minimum distance of 20 mm between the rear cab wall and the box body must be maintained (see chapter 2.1.6).
11. The wheel clearance on the rear axle must be maintained (see chapter 2.2.9 “Wings and wheel housings”).
12. Appropriate exterior mirrors are to be chosen, depending on the width of the body (see chapters 2.1.6 and 2.5.1.1).
13. It may be necessary to reposition the rear lights (see chapter 2.5).
15. Compliance is required with current statutory provisions and legislation, regulations on health and safety and accident
prevention, safety rules, and accident insurance providers’ data sheets. Country specific laws, guidelines and registration
conditions must be observed (see chapter 1.2.9).
16. Tipper bearings
 The rear tipper bearings on three-sided and rear tipper bodies shall be placed as close to the rear as possible.
 The folded down dropside shall not knock against the frame end, the lighting systems or the towing bracket.
 For the front tipper bearings, guide brackets are required to guide the tipper bearings when the tipper is lowered.
17. Safety devices
 A prop (tipper stay) must be incorporated to prevent accidental lowering of the tipper on someone beneath it.
 Secure controls against accidental use.
 A warning device must be incorporated that shows when the tipper is not in rest position (drive position).
18. Tilting press
 The press carrier is secured on cross members in the assembly frame.
 The cross member of the assembly frame and the cross member of the chassis shall be arranged on top of each other
if possible.
 On three-sided tipper bodies, the working point of the tilting press should be in front of the centre of gravity of the body
and payload.
19. Assembly frame
 If chassis are fitted with tipper bodies, sufficient dimensioning of the assembly frame is necessary due to high vehicle
loads.
The following points shall be observed:

a. For an even load on the chassis frame, the body shall be attached using an assembly frame (subframe) (see 4.4 “Subframe
(mounting frame)”).
b. The rear area of the assembly frame is to be closed as a box and, if necessary, stiffened with an inserted diagonal cross or other
suitable measures.
c. At least all of the body brackets provided at the factory are to be used for securing tipper bodies to the vehicle frame.
d. The use of vehicles with tipper bodies is only possible for normal usage conditions. In difficult usage conditions,
we recommend consulting the responsible department (see chapter 1.2.2 “Body builder guidelines and advice”).
e. See chapter 4.4 “Subframe (mounting frame)” for the material properties of the subframe.
Practical note
If a superstructure has moving attachments, make sure

that there is sufficient clearance from the base vehicle,
otherwise attachments could collide with the base
vehicle causing damage.
6 Technical data
6 Technical data
6.1 Build dimension drawings
Please refer to our dimensional drawings for the dimensions of the new Amarok.
They are available for download in DXF, TIFF and PDF format at the body builder portal of Volkswagen AG. All files (except PDFs)
are packed as Zip archives. The files can be unpacked using Winzip (PC) or ZipIt (MAC).
Information
Current build dimension drawings are available for

downloading from the body builder portal of
Volkswagen AG under the “Technical drawings”
menu item.
6 Technical data
6.2 Diagrams (foil templates)
Information
Current diagrams are available for downloading from

the body builder portal of Volkswagen AG under
the “Foil templates” menu item.
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 Technical data
6.3 Circuit diagrams
For detailed information about this topic, refer to the workshop manuals and circuit diagrams of Volkswagen AG.
Information
Volkswagen AG workshop manuals and circuit diagrams

can be downloaded from the Internet at erWin
(Electronic Repair and Workshop Information from
Volkswagen AG):
6 Technical data
6.4 CAD models
On request, body builders can receive 3-D data models in the formats CATIA V.5 / STEP/JT for design purposes.
Information
The available 3-D data can be found on the body

builder portal of Volkswagen AG under the “CAD data”
menu option.
7 Calculations
7 Calculations
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 gross axle weight rating.
 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). Equation (2) should be used to check the results of (3) and (4).
Fig. 1: Determining the position of the vehicle centre of gravity in x-direction
7 Calculations
Determining the total weight of the unladen vehicle with add-ons and body.
𝐺𝐺 = 𝐺𝐻𝐴 + 𝐺𝑉𝐴 (1)
Calculating the position of the overall centre of gravity 𝑆𝐺 in x-direction:
𝐿 = 𝐿𝑉 + 𝐿𝐻 (2)
𝐺𝐻𝐴
𝐿𝑉 = 𝐺𝐺
𝐿 (3)
𝐺𝑉𝐴
𝐿𝐻 = 𝐿 (4)
𝐺𝐺
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
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 Calculations
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 shall be determined with the vehicle in a level state (GFA and GRA) (see 2.1.5. “Determining
the centre of gravity”) and the axle loads on an axle (QHA or QVA) increased by the amount h’.
The raising height h’ should be as high as possible in accordance with the front and rear overhang angles of the vehicle
(also known as front or rear ramp angle). 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 measurements:
– The vehicle must be standing perfectly horizontal for

weighing in level vehicle state. Height differences
between the axles caused by scales should be
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 Calculations
If the vehicle suspension cannot be locked due to the body design or available space, further axle load measurements must be
carried out at different levels (for example, 600 mm, 700 mm and 800 mm). This also allows errors to be limited by averaging.
The centre of gravity height results from the arithmetic average of the individual centre of gravity heights for each raising height.
Example of procedure
1. The vehicle must be weighed without load and with the add-ons or complete body.
2. Inflate the tyres up to the tyre pressure that is specified for the respective gross axle weight rating.
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 by the value h’, but at least by 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
the raised axle and should ideally be identical. 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 axle on the scales.
8. Lower and turn the vehicle around and perform the corresponding measurements on the front axle (first GFA with a level rear
axle and then QFA with a 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. Raise 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 Calculations
Fig. 2: Determining the position of the vehicle centre of gravity in z-direction
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 × tan 𝛼) + 𝑟𝑠𝑡𝑎𝑡 (6)
ℎ′
sin 𝛼 = 𝐿
(6a)
ℎ′
𝛼 = 𝑎𝑟𝑐 sin ( 𝐿 ) (6b)
𝐿 𝑄𝐻𝐴 −𝐺𝐻𝐴
ℎ𝑆 = (ℎ′ × 𝐺𝐺
× √𝐿2 − ℎ′2 ) + 𝑟𝑠𝑡𝑎𝑡 (7)
7 Calculations
Determining the overall centre of gravity 𝑆𝐺 in z-direction for the raised front axle:
𝑄𝑉𝐴 −𝐺𝑉𝐴 1
ℎ𝑆 = ( 𝐺𝐺
× 𝐿 × tan 𝛼) + 𝑟𝑠𝑡𝑎𝑡 (8)
ℎ′
sin 𝛼 = 𝐿
(8a)
ℎ′
𝛼 = 𝑎𝑟𝑐 sin ( ) (8b)
𝐿
𝐿 𝑄𝑉𝐴 −𝐺𝑉𝐴
ℎ𝑆 = (ℎ′ × 𝐺𝐺
× √𝐿2 − ℎ′2 ) + 𝑟𝑠𝑡𝑎𝑡 (9)
Abbreviations and parameters used:

𝑟𝑠𝑡𝑎𝑡 - Static tyre radius
𝑄𝑉𝐴 - Front axle load, rear wheels raised
𝑄𝐻𝐴 - Rear axle load, front wheels raised
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 equipment.
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 Weight tables
8 Weight tables
To guarantee adequate steerability of the vehicle, please observe chapter 2.1.7 “Steerability”.
The kerb weight figures refer to the standard vehicle equipment (including driver, ready to drive, 90% full fuel tank and tools) on the base vehicle.
When ordering your vehicle, please note that the kerb weight increases when additional equipment is selected and the available payload capacity is therefore reduced.
We recommend determining the definitive kerb weight of the entire vehicle by weighing before the conversion.
The superscript numbers in the following chapters mean:

1) Selectable four-wheel drive
2) 2+1 leaf spring (comfort)
3) 3+2 leaf spring (heavy-duty)
4) Torsen permanent
* Version not available for all markets
Gearbox abbreviations: MG = manual gearbox, 4Mo = 4-wheel drive gearbox, A = automatic (DSG)
8 Weight tables
8.1 Weight tables Amarok Double Cab (EU6)
(Kerb weights with driver, ready to drive with 90% tank fill)
Engine Gearbox PR number Perm. weights Unl. weight incl. driver Pay
GVWR [kg] [kg] load
Total weight Front axle load Rear axle load (RA) Total weight (min.) FA RA max.
(FA) [kg]
3.0 l TDI 120 kW 2) Manual 01A 2,900 1,445 1,630 2,024 1,121 903 876
3.0 l TDI 120 kW 3) 01B 3,080 1,445 1,860 2,040 1,121 919 1,040
3.0 l TDI 120 kW 2) 4Mo 01E 2,900 1,445 1,630 2,102 1,191 911 818
3.0 l TDI 120 kW 3) 01B 3,080 1,445 1,860 2,118 1,191 927 962
3.0 l TDI 120 kW 3) 4Mo 01F/B09* 3,200 1,445 1,860 2,118 1,191 927 1,082
3.0 l TDI 150 kW 1) 2) 4Mo + 01E 2,920 1,445 1,630 2,114 1,211 903 806
3.0 l TDI 150 kW 1) 3) MG 01B 3,080 1,445 1,860 2,131 1,211 920 949
Diesel
3.0 l TDI 150 kW 3) 4) 4Mo + A 01E 2,920 1,445 1,630 2,128 1,222 906 792
3.0 l TDI 150 kW 3) 4) 01B 3,080 1,445 1,860 2,145 1,222 923 935
3.0 l TDI 150 kW 1) 3) 4Mo + MG 01F/B09* 3,200 1,445 1,860 2,131 1,211 920 1,069
3.0 l TDI 150 kW 3) 4) 4Mo + A 01C 3,290 1,445 1,930 2,145 1,222 923 1,145
3.0 l TDI 165 kW 2) 4) 4Mo + A 01E 2,920 1,445 1,630 2,078 1,217 861 842
3.0 l TDI 165 kW 3) 4) 01B 3,080 1,445 1,860 2,095 1,217 878 985
3.0 l TDI 165 kW 3) 4) 01C/B09* 3,290 1,445 1,930 2,145 1,222 923 1,145
8 Weight tables
8.2 Weight tables Amarok Double Cab (market: non-EU)
[kg] [kg] load
(FA) [kg]
2.0 l TFSI 118 kW petrol 2) Manual 0WA 2,820 1,310 1,620 1,861 1,040 821 959
Petrol
2.0 l TFSI 118 kW petrol 3) 0WL 3,040 1,310 1,860 1,878 1,040 838 1,162
2.0 l TDI 103 kW 2) Manual 0WA 2,820 1,325 1,620 1,884 1,053 831 936
2.0 l TDI 103 kW 3) 0WL 3,040 1,325 1,860 1,901 1,053 848 1,139
2.0 l TDI 132 kW 2) 0WA 2,820 1,335 1,620 1,904 1,073 831 916
2.0 l TDI 132 kW 3) 0WL 3,040 1,335 1,860 1,921 1,073 848 1,119
2.0 l TDI 132 kW 2) 4) A 0WA 2,820 1,365 1,620 1,908 1,084 824 912
2.0 l TDI 132 kW 3) 4) 0WL 3,040 1,365 1,860 1,925 1,084 841 1,115
2.0 l TDI 103 kW 1) 2) 4Mo 0WA 2,820 1,375 1,620 1,971 1,125 846 849
Diesel
2.0 l TDI 103 kW 1) 3) 0WL 3,040 1,375 1,860 1,998 1,125 863 1,052
2.0 l TDI 132 kW 1) 2) 4Mo 0WA 2,820 1,385 1,620 1,982 1,143 839 838
2.0 l TDI 132 kW 1) 3) 0WL 3,040 1,385 1,860 1,999 1,143 856 1,041
2.0 l TDI 132 kW 2) 4) 4Mo + A 0WA 2,820 1,415 1,620 1,982 1,145 837 838
2.0 l TDI 132 kW 3) 4) 0WL 3,040 1,415 1,860 1,999 1,145 854 1,041
3.0 l TDI 165 kW 1) 2) 4 Mo 01E 2,920 1,445 1,630 2,089 1,209 880 831
3.0 l TDI 165 kW 1) 3) 4 Mo 01B 3,080 1,445 1,860 2,106 1,209 897 974
3.0 l TDI 165 kW 3) 4) 4 Mo + A 01B 3,080 1,445 1,860 2,070 1,215 855 1,010
8 Weight tables
8.3 Weight tables Amarok Double Cab (EU6) cab chassis
GVWR [kg] [kg] load
(FA) [kg]
3.0 l TDI 120 kW 2) Manual 01A 2,900 1,445 1,630 1,906 1,135 771 994
3.0 l TDI 120 kW 3) 01B 3,080 1,445 1,860 1,922 1,135 787 1,158
3.0 l TDI 120 kW 1) 2) 4Mo 01E 2,920 1,445 1,630 1,984 1,205 779 936
3.0 l TDI 120 kW 1) 3) 01B 3,080 1,445 1,860 2,000 1,205 795 1,080
3.0 l TDI 150 kW 1) 2) 4Mo + MG 01E 2,920 1,445 1,630 1,996 1,225 771 924
Diesel
3.0 l TDI 150 kW 2) 4) 4Mo + A 01E 2,920 1,445 1,630 2,010 1,236 774 910
3.0 l TDI 150 kW 1) 3) 4Mo + MG 01B 3,080 1,445 1,860 2,013 1,225 788 1,067
3.0 l TDI 150 kW 3) 4) 4Mo + A 01B 3,080 1,445 1,860 2,027 1,236 791 1,053
3.0 l TDI 165 kW 2) 4) 4Mo + A 01E 2,920 1,445 1,630 1,960 1,231 729 960
3.0 l TDI 165 kW 3) 4) 01B 3,080 1,445 1,860 1,977 1,231 746 1,103
8 Weight tables
8.4 Weight tables Amarok Double Cab (market: non-EU) cab chassis
GVWR [kg] [kg] load
(FA) [kg]
2.0 l TFSI 118 kW petrol 2) Manual 0WA 2,820 1,310 1,620 1,743 1,054 689 1,077
Petrol
2.0 l TFSI 118 kW petrol 3) 0WL 3,040 1,310 1,860 1,760 1,054 706 1,280
2.0 l TDI 103 kW 2) Manual 0WA 2,820 1,325 1,620 1,766 1,067 699 1,054
2.0 l TDI 103 kW 3) 0WL 3,040 1,325 1,860 1,783 1,067 716 1,257
2.0 l TDI 132 kW 2) 0WA 2,820 1,335 1,620 1,786 1,087 699 1,034
2.0 l TDI 132 kW 3) 0WL 3,040 1,335 1,860 1,803 1,087 716 1,237
2.0 l TDI 103 kW 1) 2) 4Mo 0WA 2,820 1,375 1,620 1,853 1,139 714 967
2.0 l TDI 103 kW 1) 3) 0WL 3,040 1,375 1,860 1,870 1,139 731 1,170
Diesel
2.0 l TDI 132 kW 1) 2) 4Mo 0WA 2,820 1,385 1,620 1,864 1,157 707 956
2.0 l TDI 132 kW 1) 3) 0WL 3,040 1,385 1,860 1,881 1,157 724 1,159
2.0 l TDI 132 kW 2) 4) 4Mo + A 0WA 2,820 1,415 1,620 1,864 1,159 705 956
2.0 l TDI 132 kW 3) 4) 0WL 3,040 1,415 1,860 1,881 1,159 722 1,159
3.0 l TDI 165 kW 1) 2) 4Mo 01E 2,920 1,445 1,630 1,971 1,223 748 949
3.0 l TDI 165 kW 1) 3) 01B 3,080 1,445 1,860 1,988 1,223 765 1,092
8 Weight tables
8.5 Weight tables Amarok Single Cab (market: non-EU)
[kg] [kg] load
(FA) [kg]
Petro
2.0 l TFSI 118 kW Manual 0WL 3,040 1,255 1,860 1,775 1,021 754 1,265
l
2.0 l TDI 103 kW Manual 0WL 3,040 1,270 1,860 1,798 1,034 764 1,242
2.0 l TDI 132 kW 0WL 3,040 1,280 1,860 1,818 1,054 764 1,222
2.0 l TDI 132 kW A 0WL 3,040 1,310 1,860 1,822 1,065 757 1,218
Diesel
2.0 l TDI 103 kW 1) 4Mo 0WL 3,040 1,335 1,860 1,885 1,106 779 1,155
2.0 l TDI 132 kW 1) 0WL 3,040 1,345 1,860 1,896 1,124 772 1,144
2.0 l TDI 132 kW 1) 4Mo + A 0WL 3,040 1,375 1,860 1,896 1,126 770 1,144
8 Weight tables
8.6 Weight tables Amarok Single Cab (market: non-EU) cab chassis
[kg] [kg] load
(FA) [kg]
Petro
2.0 l TFSI 118 kW Manual 0WL 3,040 1,255 1,860 1,627 1,026 601 1,413
l
2.0 l TDI 103 kW Manual 0WL 3,040 1,270 1,860 1,650 1,039 611 1,390
2.0 l TDI 132 kW 0WL 3,040 1,280 1,860 1,670 1,059 611 1,370
2.0 l TDI 132 kW A 0WL 3,040 1,310 1,860 1,674 1,070 604 1,366
Diesel
2.0 l TDI 103 kW 1) 4Mo 0WL 3,040 1,335 1,860 1,737 1,111 626 1,303
2.0 l TDI 132 kW 1) 0WL 3,040 1,345 1,860 1,748 1,129 619 1,292
2.0 l TDI 132 kW 1) 4Mo + A 0WL 3,040 1,375 1,860 1,748 1,131 617 1,292
9 Listings
9 Listings
9.1 List of changes
Changes to the body builder guidelines compared to the data status of November 2014
Chapter Section heading Scope of
No. modification
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 Operational safety
1.2 General information
1.2.1 Product and vehicle information for body builders
1.2.1.1 Contact in Germany
1.2.1.2 International contact
1.2.1.3 Electronic repair and workshop information (erWin) Link updated!
1.2.1.4 Genuine parts online ordering portal
1.2.1.5 Online owner’s manual
1.2.1.6 European Type Approval (ETA) and EC Certificate of Conformity (CoC)
1.2.2 Body builder guidelines and consulting
1.2.2.1 Safety certificate Chapter revised
1.2.2.2 Application for the safety certificate Chapter revised
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 Trademarks
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 Chapter revised
1.2.7 Compliance with environmental rules and regulations
1.2.8 Recommendations for inspection, maintenance and repair Chapter revised
1.2.9 Accident prevention
1.2.10 Quality system
1.3 Planning bodies
1.3.1 Selection of base vehicle
1.3.2 Vehicle modifications
1.3.3 Vehicle acceptance
9 Listings

No. modification
1.4 Optional extras
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
2.1.3 Vehicle centre of gravity
2.1.4 Bodies with a high centre of gravity
2.1.4.1 Permissible height of the overall centre of gravity for vehicles with a comfort running gear
2.1.4.2 Extremely high centres of gravity (>800mm)
2.1.4.3 Permissible height of the overall centre of gravity for vehicles with a heavy-duty
running gear
2.1.5 Determining centre of gravity
2.1.6 Maximum dimensions
2.1.7 Steerability
2.2 Running gear
2.2.1 Permitted weights and unladen weights
2.2.1.1 One-sided weight distribution
2.2.2 Turning circle
2.2.3 Authorised tyre sizes
2.2.4 Modifications to axles
2.2.5 Modifications to the steering system
2.2.6 Brake system and brake control system ESC*
2.2.6.1 General information
2.2.6.2 Vehicle stability and ESP*
2.2.6.3 Influence of vehicle conversions Chapter revised
2.2.6.4 Activating the ESP*
2.2.6.5 Downgrading the ESP*
2.2.7 Modification of springs, suspension mounting, dampers
2.2.8 Wheel alignment settings
2.2.9 Wings and wheel houses
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
9 Listings

No. modification
2.3.2 Modifications to the body-in-white
2.3.2.1 Screw 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 Resistance point 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 Rear lid
2.4 Interior
2.4.1 Modifications in the area of airbags
2.4.2 Modifications in the area of seats
2.4.3 Forced ventilation
2.4.4 Acoustic insulation
2.5 Electrics/Electronics
2.5.1 Lights
2.5.1.1 Vehicle lighting devices
2.5.1.1.2 Adjusting headlights New chapter

added
2.5.1.2 Installing 3rd brake light
2.5.1.3 Mounting special lights
2.5.1.4 Additional load compartment light
2.5.2 Vehicle electrical system
2.5.2.1 Electrical wiring/fuses
2.5.2.2 Additional electrical circuits
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)
9 Listings

No. modification
2.5.4 Vehicle battery
2.5.4.1 Installation of additional battery
2.5.5 Digital tachograph (EC monitoring device)
2.5.6 Driver assistance systems New chapter

added
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
2.6.4.1 Exhaust system with SCR system
2.6.5 Selective catalytic reduction (Euro 6)
2.7 Power take-off system, engine/gearbox
2.7.1 Compatibility with base vehicle
2.7.2 Retrofitting an air conditioning system
2.7.3 Specifications for the genuine refrigerant compressor
2.7.4 Assembly and disassembly of the poly V-belt
2.8 Add-ons/units
2.8.1 Roof rack
2.8.2 Towing bracket
2.8.2.1 Maximum trailer weights V6 TDI (market: EU)
2.8.2.2 Maximum trailer weights (market: non-EU)
2.8.2.3 Retrofitting a towing bracket Chapter updated
2.8.2.4 Clearance according to UNECE-R 55 Chapter updated
2.8.3 Styling bar (tubular frame on the cargo box)
2.9 Raising the vehicle
3. Modifications to closed bodies
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 features
3.3 Cargo box
3.3.1 Removal of the cargo box
3.3.2 Weight of the cargo box
3.4 Add-on parts on the cargo box
9 Listings

No. modification
4. Modifications to open bodies
4.1 SCR tank system and fuel filler neck
4.1.1 Fastening the SCR tank system
4.1.2 Fastening the tank filler neck
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 attachment points
4.4 Subframe (mounting frame)
5. Implementation of special bodies
5.1 Conversions for people with disabilities
5.1.1 Notes on installing manual operating devices for the service brake:
5.1.2 Deactivation of airbags Chapter revised
5.2 Refrigerated vehicles
5.3 Shelf installation/workshop vehicles
5.4 Conversions for caravans
5.5 Conversions for municipal vehicles
5.6 Tractor unit Chapter revised
5.7 Elevated work platforms
5.8 Crane superstructures and lift systems
5.9 Box bodies (dry freight boxes) New chapter

added
5.10 Platform bodies New chapter

added
5.11 Tipper bodies New chapter

added
6. Technical data
6.1 Build dimension drawings
6.2 Diagrams (foil templates)
6.3 Current flow diagrams
6.4 CAD models
7. Calculations
7.1 Determining centre of gravity
8. Weight tables
8.1 Weight tables Amarok Double Cab (EU6)
8.2 Weight tables Amarok Double Cab (market: non-EU)
8.3 Weight tables Amarok Double Cab (EU6) cab chassis
8.4 Weight tables Amarok Double Cab (market: non-EU) chassis
9 Listings

No. modification
8.5 Weight tables Amarok Single Cab (market: non-EU)
8.6 Weight tables Amarok Single Cab (market: non-EU) chassis
9. Directories
9.1 List of modifications Updated
Last page Issue date, mailroom slot Updated

Amarok
Subject to change without notice
Edition November 2017
Internet:
volkswagen-nutzfahrzeuge.de
umbauportal.de
bb-database.com
Consulting for body builders in Germany is available from the listed address.
Volkswagen Commercial Vehicles
Brieffach 2992
Postfach 21 05 80
D-30405 Hanover
Fax. +49 (0)511/798-8500

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Table of contents

Body builder guidelines

Body builder guideline

2.3.3 Tailgate .............................................................................................................................................................................. 55

4.2.2 Ladder frame Amarok SC (Single Cab).............................................................................................................................. 118

*Electronic Stability Control

1.1.1 Concept of these guidelines

For more information, see chapter 1.2.1.1 “Contact”,

It is essential that the limit values selected in chapter 2

1.1.2 Means of representation

A danger note draws your attention to possible accident

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

This applies in particular to:

– modifications which change the vehicle type

1.1.4 Operational safety

Incorrect interventions in electronic components

Malfunctions to the electronics can significantly

Have work on or modifications to electronic components

Volkswagen AG recommends a Volkswagen AG customer

Service by a qualified specialist workshop is essential,

Some safety systems only operate when the engine is

1.2 General notes

1.2.1 Product and vehicle information for body builders

1.2.1.1 Contact in Germany

Free hotline 0800-86228836

Contact (email): [email protected]

Personal points of contact: https://umbauportal.de/jctumbau/web/guest/ihre-ansprechpartner

Contact form: https://umbauportal.de/jctumbau/de/web/guest/allgemeine-fragen

1.2.1.2 International contact

Login information: https://bb-database.com/jctumbau/web/international/hilfe#faq_7

1.2.1.3 Electronic repair and workshop information from Volkswagen AG (erWin*)

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

1.2.1.4 Genuine Parts Online Ordering Portal*

1.2.1.5 Online owner’s manuals

1.2.1.6 European Type Approval (ETA) and EC Certificate of Conformity (CoC)

1.2.2 Body builder guidelines and advice

1.2.2.1 Safety certificate

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

 The following assessment results are possible:

The assessment report may also contain “notes/recommendations”.

Country-specific laws, directives and approval

1.2.2.2 Application for the safety certificate

The following details must be included:

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

1.2.6 Recommendations for vehicle storage

Check the battery’s open-circuit voltage:

Battery open-circuit voltage Reading/measure

A maximum charging voltage of 14.8 volt must not be exceeded.