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Volkswagen Amarok Body builder guidelines (Edition May 2013)

Volkswagen Amarok

Volkswagen Amarok Body builder guidelines (Edition May 2013) PDF. 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.

CONTENTS

  • Table of contents
  • 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 notes
      • 1.2.1 Product and vehicle information for body builders
        • 1.2.1.1 Contact
        • 1.2.1.2 Conversion Portal
        • 1.2.1.3 Electronic Repair and Workshop Information from Volkswagen AG (erWin)
        • 1.2.1.4 Genuine parts online ordering portal
      • 1.2.2 Body builder guidelines and consulting
        • 1.2.2.1 Safety certificate
        • 1.2.2.2 Application for the safety certificate
        • 1.2.2.3 Legal entitlements
      • 1.2.3 Warranty and product liability of the body builder
      • 1.2.4 Ensuring traceability
      • 1.2.5 Trademarks
        • 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
      • 1.2.7 Compliance with environmental rules and regulations
      • 1.2.8 Recommendations for inspection, maintenance and repair
      • 1.2.9 Accident prevention
      • 1.2.10 Quality system
    • 1.3 Delivery range
    • 1.4 Advantages of the concept
    • 1.5 Planning bodies
      • 1.5.2 Vehicle modifications
      • 1.5.3 Vehicle approval
  • 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 Extremely high centres of gravity ( >800 mm)
      • 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
        • 2.2.1.2 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 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
      • 2.2.11 Wheelbase modification
    • 2.3 Body-in-white
      • 2.3.1 Roof loads/vehicle roof
      • 2.3.2 Modifications to the body-in-white
      • 2.3.3 Tailgate
    • 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 Lighting
      • 2.5.2 Vehicle electrical system
      • 2.5.3 Electrical interface for special vehicles
      • 2.5.4 Vehicle battery
      • 2.5.5. Digital tachograph (EC monitoring device)
    • 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
    • 2.7 Ancillary drives, engine/gearbox
      • 2.7.2. Driving an ancillary via the 2nd belt track
      • 2.7.3. Specifications of standard refrigerant compressor
      • 2.7.4 Installation and removal of the poly V-belt
    • 2.8 Add-ons/units
      • 2.8.1 Roof rack
      • 2.8.2 Towing bracket
      • 2.8.3 Other accessories
    • 2.9 Lifting 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 equipment
  • 4 Modifications to open bodies
    • 4.1 Removal of the cargo box
      • 4.1.1 Removal of tail lights
      • 4.1.2 Releasing the parking brake cable at the rear
      • 4.1.3 Removal of the wheel housing liner
      • 4.1.4 Removal of the filler neck
      • 4.1.5 Unscrewing securing bolts
      • 4.1.6 Removal of the bumper
      • 4.1.7 Recommendations for attaching the filler neck
      • 4.1.8 Weight of cargo box
    • 4.2 Chassis frame
      • 4.2.1 Ladder frame Amarok DC (Double Cab)
      • 4.2.2 Ladder frame Amarok SC (Single Cab)
      • 4.2.3 Sections, Amarok SC (Single Cab)/Amarok DC (Double Cab)
    • 4.3 Standard mounting points for special bodies
    • 4.4 Subframe (mounting frame)
  • 5 Implementations of special bodies
    • 5.1 Conversions for people with disabilities
    • 5.2 Refrigerated vehicles
    • 5.3 Shelf installation/workshop vehicles
    • 5.4 Conversions for caravans
    • 5.5 Conversions for municipal vehicles
    • 5.6 Articulated vehicles
    • 5.7 Elevated work platforms
    • 5.8 Crane superstructures and lift systems
  • 6 Technical data
    • 6.1 Build dimension drawings
    • 6.2 Diagrams (foil templates)
    • 6.3 Circuit diagrams
    • 6.4 CAD models
    • 6.5 Weight tables
  • 7 Calculation
    • 7.1 Determining the centre of gravity
  • 8 Listings
    • 8.1 List of changes

Language: English
Format: PDF
Pages: 130

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