Volkswagen Amarok 2023

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Body builder guidelines

February 2023 edition

Body builder guidelines

The new Amarok (from model year 2023)

Main Page

Table of Contents2
General Information6
Introduction6
Concept of These Guidelines6
Means of Representation7
Vehicle Safety8
Operational Safety9
Note on Copyright9
General Notes10
Product and Vehicle Information for Body Builders10
Contact in Germany10
International Contact10
Electronic Repair and Workshop Information from Volkswagen AG (Erwin*)11
Genuine Parts Online Ordering Portal11
Online Owner's Manual11
European Type Approval (ETA) and EC Certificate of Conformity (Coc)11
Worldwide Harmonised Light Vehicles Test Procedure (WLTP)12
Manufacturer's Declaration12
Body Builder Guidelines, Consulting13
Letter of Non-Objection13
Application for the Letter of Non-Objection15
Legal Entitlements16
Warranty and Product Liability of the Body Builder16
Ensuring Traceability17
Trademarks17
Positions on Rear of the Vehicle17
Appearance of Overall Vehicle17
Non-Volkswagen Trademarks17
Recommendations for Vehicle Storage17
Compliance with Environmental Rules and Regulations19
Recommendations for Inspection, Maintenance and Repair20
Accident Prevention21
Quality System21
Planning Bodies22
Selecting the Base Vehicle22
Vehicle Modifications23
Vehicle Acceptance23
Special Equipment24
Commercial Aspects25
Restraint System25
Drilling and Welding25
Minimum Requirements for the Brake System25
Road Safety25
Electromagnetic Compatibility (EMC)26
Pickup27
Raising the Vehicle with a Jack28
Vehicle Jacking Points and Axle Stand Positions29
Raising the Vehicle with a Lifting Platform30
Noise, Vibration and Harshness (NVH)31
Vehicle Transport Aids and Vehicle Storage32
Assemblies and Ergonomics34
General Guidelines for Assemblies34
Driver's Operating Area34
Driver's Field of Vision34
Effects of Conversions on Parking Aids34
Aids for Entering and Exiting Vehicles35
Worldwide Harmonised Light Vehicles Test Procedure (WLTP) Calculation Inputs36
Mass of the Finished Vehicle36
Frontal Surface36
Rolling Resistance of Tyres36
Key to Vehicle Dimensions37
Recommended Main Load Range Dimensions38
WLTP Front Area Calculation38
Number Plate40
Assemblies and Ergonomics - Specifications41
Recommended Body Dimensions41
Chassis Cab Body - Basic Dimensions and Weights43
Unladen Mass and Payload44
Gross Vehicle Mass and Axle Load44
Front, Rear and Side Skid Plate45
Rear Skid Plate - Chassis with Cab45
Components - Specifications45
Load Distribution - Specifications46
Load Distribution Calculations - Weight Distribution of Driver and Front Passenger46
Centre of Gravity47
Towing49
Towing Requirements49
Towing Capacities and Specifications49
Chassis50
Running Gear Suspension50
Brake System51
General Information51
Brake Hoses51
Overrun Brake Connection52
Drive Train53
Engine53
Air Flow Areas of the Engine Cooling System53
Engine Selection for Conversions53
Fuel System54
Securing the Fuel Filler Neck During Transport54
Securing the Fuel Filling System55
Breather Hose for Fuel Filling System (Diesel)60
Breather Hose for Axle Venting62
Selective Catalytic Reduction System62
Selective Catalytic Reduction System - Diesel Exhaust Fluid62
Electrics70
Installation and Routing Guidelines for Electrical Wiring70
Wiring Splicing Method70
Wiring through Cab Panel70
Battery and Cables72
Battery Information72
Connecting Auxiliary Loads / Accessories - Vehicles with Factory-Fitted Auxiliary Switches, Wiring and Fuse Box81
Alternator84
Ignition Signal84
Parking Aid85
Sensor Positions88
Engine Management System91
Tachograph91
Vehicle Speed Signal91
Information and Infotainment System92
Reversing Camera92
Exterior Lighting97
Rear Combination Lights98
Rear Fog Light99
Rear Number Plate Lights101
Additional Exterior Lights102
Headlights - Connecting an Additional Main Beam Signal102
Brake Lights105
Side Marker Lights (Parking Lights)105
Reversing Lights, Reversing Camera, Reversing Alarm (Manual Gearbox)106
Towing Mode - Lighting Connections106
Lights - Hazard Warning Lights / Turn Signals108
Electrically Operated Exterior Mirrors109
High-Mounted Centre Brake Light109
Automatic Main Beam110
Glare-Free Main Beam110
Cruise Control System111
Adaptive Cruise Control111
Driver Assist Systems113
Information System Area View Overhead View Camera115
Side View Camera117
Lane Departure Warning System119
Lane Centring Assistant120
Handles, Locks, Catches and Access Systems121
Central Locking System121
Fuses and Relays122
Fuses122
Body and Paint123
Body123
Body Structures - General Information123
Integrated Bodies and Conversions124
Chassis Cab126
Integrity of the Front Section for Cooling, Collision, Aerodynamics and Lighting130
Tipper Bodies130
Tank and Bulk Container Superstructure131
Aerial Cable Routing131
Roof Carriers132
Load Management on the Vehicle Tray133
Front Wing Trim140
Airbag Systems141
Airbags141
Additional Impact Sensors (Front)145
Seat Belt Systems147
Seat Belts - no Drilling Zones147
Corrosion Protection149
General Information149
Touching up Damaged Paintwork149
Underseal and Materials149
Painting Road Wheels149
Galvanic (Bi-Metallic) Corrosion / Contact Corrosion149
Frame and Body Mounting150
Mounting Points and Pipes150
Self-Supporting Body Structure152
Frame Drilling and Tube Reinforcement154
Additional Equipment - Subframe Attachment155
Area for Fitting Additional Body Attachments to the Rear of the Bumper155
Water Tank on Camping Vehicles155
Conversions with an Extended Wheelbase156
Listings161
List of Changes161

Brand	Volkswagen
Model	Amarok 2023
Category	Automobile
Language	English

Volkswagen Amarok 2023 - User Manual

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