Conversion Guideline NEW Movano X62

Transcription

1 Conversion Guideline NEW Movano X62 Part 1 - Chapter 1-27 Version: April 2010 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany

2 CONTENTS CHAPTER DESCRIPTION: PAGE 3 POWER TRAIN RANGE 3 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE 4 6 REFERENCE SYSTEM AND INTERPRETING DIMENSIONS 7 7 MAIN VIEWS AND DIMENSIONS 8 8 PARTITIONS BETWEEN CAB AND LOADING COMPARTMENT 17 9 PANEL VAN STANDARD SECTIONS GLAZING LOADING AREA SECTIONS SLIDING SIDE DOOR ACCESSIBILITY REAR DOOR TRAVEL, DIMENSIONS AND ACCESS LASHING POINTS PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN CHASSIS CAB, POSITION OF BODY BRACKETS REAR UNDERRIDE PROTECTION CROSS SECTION OF REAR WHEEL WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB MODIFYING THE REAR OVERHANG DASH PANEL CROSS MEMBER CAB FLOOR DRILLING AREA DRILLING AREA ON REAR FLOOR OF PANEL VAN CAB ROOF FOR CAMPERVAN 99 up-to-date data on body guidelines (online body guidelines). Data status June 2009

3 3 POWER TRAIN RANGE 1. Engine Front wheel drive Rear wheel drive Type D1 D2 D3 Noncalibrated D3 D1 D2 D3 Noncalibrated D3 Indices Capacity 2,299 cm³ Power 74 kw 92 kw 92 kw 110 kw 74 kw 92 kw 92 kw 110 kw Emission control Euro 4 and 5 Euro 4 and 5 Euro 5 Euro 4 and 5 Euro 4 and 5 Euro 4 and 5 Euro 5 Euro 4 and 5 2. Gearbox Front wheel drive Rear wheel drive Manual gearbox (BVM) PF 6 ZF 4 Robotised gearbox (BVR) PA 0 (optional) ZF 4R (optional) Clutch Control with BVM Hydraulic clutch control Electric clutch control Clutch Control with BVR Electro-hydraulic control (Easytronic) Electric control (ZF module) Drive axle - 2 axles: one for 3.5 t single wheels and one for 4.5 t twin wheels Automatic differential locking - Optional up-to-date data on body guidelines (online body guidelines). Data status June

4 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE To view the chassis number marking (VIN), use a flat-ended tool (e.g. screwdriver) to lift one of the two flaps located above the right-hand cab side sill. The manufacturer s plate is located on the right-hand cab door frame and has two parts: - the regulatory ID plate, - the oval plate showing data primarily intended to facilitate the ordering of spare parts. VEHICLE IDENTIFICATION : Manufacturer s plate 2: VIN marking 3: Weight and dimensions label The vehicle manufacturer s plate must be replaced if it is damaged or moved, as is inevitable during conversion. This means you will have to order a new plate. This request should be addressed to the country s Quality/Service/After-Sales departments. up-to-date data on body guidelines (online body guidelines). Data status June

5 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE MANUFACTURER'S PLATE Information on identification plate 1 ): 1. = Vehicle identification number 2. = Permissible gross vehicle weight rating 3. = Permissible gross combination weight 4. = Maximum permissible front axle load 5. = Maximum permissible rear axle load 6. = Trim code 7. = Technical specifications of vehicle, including: Vehicle paint code, equipment level and vehicle type 8. = Additional equipment specification 9. = Fabrication number 10. = Interior trim code 1 ) The VIN plate on your vehicle may differ from the illustration shown. The combined total of front and rear axle loads must not exceed the permissible gross vehicle weight. For example, if the front axle is bearing its maximum permissible load, the rear axle can only bear a load that is equal to the gross vehicle weight minus the front axle load. The technical data is determined in accordance with European Community standards. We reserve the right to make modifications. Specifications in the vehicle documents always have priority over those given in this manual. Stamped on a machined surface on the rear of the engine block or stamped on a metal plate on the right side of the engine block, depending on variant. up-to-date data on body guidelines (online body guidelines). Data status June

6 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE VIN MARKING : Main VIN engraving 2: Emergency VIN engraving The Vehicle Identification Number is visible through the windscreen. The VIN is also displayed behind a removable plastic cover on the right hand side door step. WEIGHTS AND DIMENSIONS LABEL : Unladen weight 2: Gross authorised train weight 3: Vehicle length 4: Vehicle surface area 5: Vehicle width 6: Gross authorised laden weight up-to-date data on body guidelines (online body guidelines). Data status June

7 6 REFERENCE SYSTEM AND INTERPRETING DIMENSIONS In general, dimensions are expressed as absolute (distance between two points) and positions as relative (location in the reference system). The origin of the reference system is a point situated on the front axle, at the centre of the vehicle, as illustrated on the following view. For laden vehicles, the front axle is fixed at +2 mm along the X axis and mm along the Z axis in relation to the reference system of the unladen vehicle. REFERENCE SYSTEM up-to-date data on body guidelines (online body guidelines). Data status June

8 7 MAIN VIEWS AND DIMENSIONS The figures below show the different versions of the Movano. The main dimensions are given in the tables. 1. Panel van SIDE VIEW PV ED PR LO AERIAL VIEW up-to-date data on body guidelines (online body guidelines). Data status June

9 7 MAIN VIEWS AND DIMENSIONS FRONT VIEW HT VV LA REAR VIEW RV G1 up-to-date data on body guidelines (online body guidelines). Data status June

10 7 MAIN VIEWS AND DIMENSIONS Front Wheel Drive Panel Van Vehicle length L1 L2 L3 Roof height H1 H2 H2 H3 H2 H3 Overall length L0 5,048 5,048 5,548 5,548 6,198 6,198 Overall width without mirror LA 2,070 2,070 2,070 2,070 2,070 2,070 Overall width with mirror G1 2,470 2,470 2,470 2,470 2,470 2,470 Unladen height HT 2,303 2,499 2,502 2,749 2,496 2,747 Wheelbase ED 3,182 3,182 3,682 3,682 4,332 4,332 Front overhang PV Rear overhang PR 1,024 1,024 1,024 1,024 1,024 1,024 Front track VV 1,750 1,750 1,750 1,750 1,750 1,750 Rear track RV 1,730 1,730 1,730 1,730 1,730 1,730 Rear Wheel Drive Panel Van Vehicle length L3, single wheel L3, twin wheels L4, twin wheels Roof height H2 H3 H2 H3 H2 H3 Overall length L0 6,198 6,198 6,198 6,198 6,848 6,848 Overall width without mirror LA 2,070 2,070 2,070 2,070 2,070 2,070 Overall width with mirror G1 2,470 2,470 2,470 2,470 2,470 2,470 Unladen height HT 2,539 2,788 2,556 2,816 2,553 2,803 Wheelbase ED 3,682 3,682 3,682 3,682 4,332 4,332 Front overhang PV Rear overhang PR 1,674 1,674 1,674 1,674 1,674 1,674 Front track VV 1,750 1,750 1,750 1,750 1,750 1,750 Rear track RV 1,730 1,730 1,612 1,612 1,612 1,612 up-to-date data on body guidelines (online body guidelines). Data status June

11 7 MAIN VIEWS AND DIMENSIONS 2. Chassis cab and chassis double cab SIDE VIEW PV ED PR LO AERIAL VIEW up-to-date data on body guidelines (online body guidelines). Data status June

12 7 MAIN VIEWS AND DIMENSIONS FRONT VIEW HT VV LA REAR VIEW RV G1 up-to-date data on body guidelines (online body guidelines). Data status June

13 7 MAIN VIEWS AND DIMENSIONS Single cab Front wheel drive chassis Double cab Vehicle length L2 L3 L2 L3 Overall length L0 5,644 6,294 5,644 6,294 Overall width without mirror LA 2,070 2,070 2,070 2,070 Overall width with mirror G1 2,470 2,470 2,470 2,470 Unladen height HT Wheelbase ED 3,682 4,332 3,682 4,332 Front overhang PV Rear overhang PR 1,120 1,120 1,120 1,120 Front track VV 1,750 1,750 1,750 1,750 Rear track RV 1,730 1,730 1,730 1,730 Single wheel rear drive chassis Single cab Double cab Vehicle length L2 L3 L2 L3 Overall length L0 5,644 6,294 5,644 6,294 Overall width without mirror LA 2,070 2,070 2,070 2,070 Overall width with mirror G1 2,470 2,470 2,470 2,470 Unladen height HT Wheelbase ED 3,682 4,332 3,682 4,332 Front overhang PV Rear overhang PR 1,120 1,120 1,120 1,120 Front track VV 1,750 1,750 1,750 1,750 Rear track RV 1,730 1,730 1,730 1,730 Twin wheel rear drive chassis Single cab Double cab Vehicle length L3 L4 L3 L4 Overall length L0 6,194 6,844 6,194 6,844 Overall width without mirror LA 2,070 2,070 2,070 2,070 Overall width with mirror G1 2,470 2,470 2,470 2,470 Unladen height HT Wheelbase ED 3,682 4,332 3,682 4,332 Front overhang PV Rear overhang PR 1,670 1,670 1,670 1,670 Front track VV 1,750 1,750 1,750 1,750 Rear track RV 1,612 1,612 1,612 1,612 up-to-date data on body guidelines (online body guidelines). Data status June

14 7 MAIN VIEWS AND DIMENSIONS 3. Platform cab SIDE VIEW PV ED PR LO AERIAL VIEW up-to-date data on body guidelines (online body guidelines). Data status June

15 7 MAIN VIEWS AND DIMENSIONS FRONT VIEW HT VV LA REAR VIEW RV G1 up-to-date data on body guidelines (online body guidelines). Data status June

16 7 MAIN VIEWS AND DIMENSIONS Front wheel drive platform cab Vehicle length L1 L2 L3 Roof height H1 H1 H2 H1 H2 Overall length Overall width without mirror Overall width with mirror Unladen height L0 LA 2,070 2,070 2,070 2,070 2,070 G1 2,470 2,470 2,470 2,470 2,470 HT Wheelbase ED 3,182 3,682 3,682 4,332 4,332 Front overhang PV Rear overhang PR Front track VV 1,750 1,750 1,750 1,750 1,750 Rear track RV 1,730 1,730 1,730 1,730 1,730 up-to-date data on body guidelines (online body guidelines). Data status June

17 8 PARTITIONS BETWEEN CAB AND LOADING COMPARTMENT Panel vans and platform cabs may be delivered with partitions. Depending on the version, the partitions may come as standard or be available as an option. The following partitions are available: Full glazed partition. Full sheet-metal partition. These partitions are limited to H1 versions, the free space in H2 versions between the roof panel and the cab trim being reserved for accessing the roof storage area. They are riveted and/or screwed into place. Full partitions are not strictly sealed. These partitions comply with standard DIN and other requirements specific to the different countries. If a partition is included, please refer to the "Sliding side door" sheet for the diagram defining the perfect position for driver's seat clearance and cab ergonomics. It is highly recommended, in case of attack or impact from the rear loading area, to add protection to the partition glazing area. FULL METAL AND GLAZED PARTITION N.B.: Coat hook on partition on the driver's side. Glazed surface area: 14 dm² up-to-date data on body guidelines (online body guidelines). Data status June

18 9 DESIGN OF SUPERSTRUCTURES The various standard sections of the van are shown on the diagram below. N.B.: Throughout this document, INT means vehicle interior and EXT means vehicle exterior. PANEL VAN STANDARD SECTIONS up-to-date data on body guidelines (online body guidelines). Data status June

19 9 DESIGN OF SUPERSTRUCTURES SECTION 1 "DOOR OPENING PILLAR EXT INT 1 up-to-date data on body guidelines (online body guidelines). Data status June

20 9 DESIGN OF SUPERSTRUCTURES SECTION 2 "FRONT DOOR RAIL ROOF-VERSION H1" (X = 1,200) EXT INT 2 up-to-date data on body guidelines (online body guidelines). Data status June

21 9 DESIGN OF SUPERSTRUCTURES SECTION 2 "FRONT DOOR RAIL ROOF-VERSION H2" (X = 1,200) EXT 2 INT up-to-date data on body guidelines (online body guidelines). Data status June

22 9 DESIGN OF SUPERSTRUCTURES SECTION 2 "FRONT DOOR RAIL ROOF-VERSION H3" (X = 1,200) EXT 2 2 INT up-to-date data on body guidelines (online body guidelines). Data status June

23 9 DESIGN OF SUPERSTRUCTURES SECTION 3 REAR CANTRAIL ROOF-VERSION H1 (X = 2,300) EXT INT SECTION 6 "LOWER FRAME CROSS MEMBER 3 up-to-date data on body guidelines (online body guidelines). Data status June

24 9 DESIGN OF SUPERSTRUCTURES SECTION 3 REAR CANTRAIL ROOF-VERSIONS H2 AND H3 (X = 2,300) EXT SECTION 7 3 INT up-to-date data on body guidelines (online body guidelines). Data status June

25 9 DESIGN OF SUPERSTRUCTURES SECTION 4 LOWER SIDE SILL, FIXED SIDE PANEL (X = 2,106.9) EXT INT 4 up-to-date data on body guidelines (online body guidelines). Data status June

26 9 DESIGN OF SUPERSTRUCTURES SECTION 4 LOWER SIDE SILL, SLIDING SIDE DOOR (X = 2,300) INT EXT 4 up-to-date data on body guidelines (online body guidelines). Data status June

27 9 DESIGN OF SUPERSTRUCTURES SECTION 5 FUEL FLAP (X = 1,351) INT EXT 5 up-to-date data on body guidelines (online body guidelines). Data status June

28 9 DESIGN OF SUPERSTRUCTURES SECTION 6 ROOF PANEL VERSION H1 (Y = 0) EXT INT 6 up-to-date data on body guidelines (online body guidelines). Data status June

29 9 DESIGN OF SUPERSTRUCTURES SECTION 6 ROOF PANEL VERSIONS H2 AND H3 (Y = 0) EXT INT 6 up-to-date data on body guidelines (online body guidelines). Data status June

30 9 DESIGN OF SUPERSTRUCTURES SECTION 7 AREA UNDER WINDSCREEN (Y = 0) EXT INT 7 up-to-date data on body guidelines (online body guidelines). Data status June

31 9 DESIGN OF SUPERSTRUCTURES SECTION 8 REAR UPPER CROSS MEMBER (Y = 122) EXT EXT INT INT 8 up-to-date data on body guidelines (online body guidelines). Data status June

32 9 DESIGN OF SUPERSTRUCTURES SECTION 9 REAR LIGHT/DOOR STOP (Z = 740) INT EXT 9 up-to-date data on body guidelines (online body guidelines). Data status June

33 9 DESIGN OF SUPERSTRUCTURES SECTION 10 LOWER RIGHT-HAND REAR DOOR STOP, VERSION L2 FRONT WHEEL DRIVE (Y = 114) INT EXT 10 up-to-date data on body guidelines (online body guidelines). Data status June

34 9 DESIGN OF SUPERSTRUCTURES SECTION 11 SLIDING SIDE DOOR CENTRE RAIL (X = 3,512) INT EXT 11 up-to-date data on body guidelines (online body guidelines). Data status June

35 10 GLAZING To add glazing to a panel van, it is recommended that you: - remove the vertical tensioners, - cut out an opening in the side panel and get close to the insert shape of the glazed versions of the Movano for bonded windows and the window shape for fitted windows. - protect the cut-outs from corrosion. Please refer to the Corrosion Prevention sheet For bonded windows, it is advisable to separate the horizontal centre strut from the vertical members, turn it around and then weld along the bottom of the cut out insert and on the vertical members. Local reinforcement of the frame structure may be required. Warning: Under no circumstances must the vertical seal of the side bodywork panels be cut out. up-to-date data on body guidelines (online body guidelines). Data status June

36 10 GLAZING BASIC SECTIONS : Lower strut 2: Exterior side panel 3: Upper strut 4: Cantrail up-to-date data on body guidelines (online body guidelines). Data status June

37 10 GLAZING DIFFERENCE BETWEEN PANEL VAN AND GLAZED VAN : Lower strut 2: Exterior side panel 3: Bonded window up-to-date data on body guidelines (online body guidelines). Data status June

38 11 LOADING AREA SECTIONS The main dimensions of the loading area (versions H1, H2, H3) are given in the form of superimposed sections. Details of the wheel arches are also given. 1: Loading area 2: Wheel arch 1 2 PANEL VAN H1, FRONT WHEEL DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

39 11 LOADING AREA SECTIONS PANEL VAN H2, FRONT WHEEL DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

40 11 LOADING AREA SECTIONS PANEL VAN H3, FRONT WHEEL DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

41 11 LOADING AREA SECTIONS PANEL VAN H2, SINGLE WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

42 11 LOADING AREA SECTIONS PANEL VAN H3, SINGLE WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

43 11 LOADING AREA SECTIONS PANEL VAN H2, TWIN WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

44 11 LOADING AREA SECTIONS PANEL VAN H3, TWIN WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

45 12 SLIDING DOOR ACCESSIBILITY Access via the sliding door, its clearance and its position along the side of the body are given as overall dimensions. SIDE DOOR DIMENSIONS 1,186 Where a partition is fitted, the diagram below defines the longitudinal travel of the driver s seat. It should be noted that this partition should comply with legislation in the country where the vehicle is marketed. It is highly recommended, in case of attack or impact from the rear loading area, to add protection to the partition glazing area. up-to-date data on body guidelines (online body guidelines). Data status June

46 12 SLIDING DOOR ACCESSIBILITY SLIDING DOOR OPENING 3 C A D B 151 mm 1 2 1: Loading bed 5 4 2: Side door entry 3: Solid partition 4: Position of the backrest as far back as possible 5: Rear seat mounting Vehicle type A (mm) B (mm) C (mm) D (mm) Panel Van L1H1, Front wheel drive 1,581 1, ,050 Panel Van L1H2, Front wheel drive 1,780 1, ,050 Panel Van L2 or L3, Front wheel drive 1,780 1,849 1,147 1,270 Panel Van L3 or L4, Rear wheel drive 1,684 1,849 1,147 1,270 N.B.: A: Useful height of sliding door entry B: Height of sliding door entry above floor C: Useful width of sliding door entry D: Width of sliding door entry 1,100 mm above the floor The tubular partition gives a larger useful width (64 mm) than the solid partition. up-to-date data on body guidelines (online body guidelines). Data status June

47 12 SLIDING DOOR ACCESSIBILITY PIANO SIDE X 1,618 A mini 1 2 1: Solid partition limit 2: Rear wheel arch Wheelbase (mm) A (mm) E1: 3,182 1,150 E2: 3,682 1,650 E3: 4,332 2,300 up-to-date data on body guidelines (online body guidelines). Data status June

48 13 REAR DOOR, DIMENSIONS AND ACCESS 1. Dimensions of rear doors The travel and position along the side of the body are given as overall dimensions and at different heights. The door opening angle is 90 on the first notch and 176 on the second notch. With the 255 opening option, the maximum opening angle is 260 without the sliding side door and 242 with a sliding side door. REAR DOOR TRAVEL up-to-date data on body guidelines (online body guidelines). Data status June

49 13 REAR DOOR, DIMENSIONS AND ACCESS REAR DOOR DIMENSIONS Vehicle length L1 Front wheel drive Roof height H1 H2 MMAC (maximum authorised laden weight) (kg) 2,800 3,300 3,500 2,800 3,300 3,500 1: Door height (mm) 1,815 2,023 2: 3: Minimum height at MMAC (mm) Maximum height at MVODM (mm) ,317 2,317 2,320 2,533 2,533 2,536 up-to-date data on body guidelines (online body guidelines). Data status June

50 13 REAR DOOR, DIMENSIONS AND ACCESS Vehicle length L2 Front wheel drive L3 Front wheel drive Roof height H2 H3 H2 H3 MMAC (maximum authorised laden weight) (kg) 3,300 3,500 3,300 3,500 3,500 1: Door height (mm) 2,023 2: 3: Minimum height at MMAC (mm) Maximum height at MVODM (mm) ,530 2,533 2,529 2,532 2,526 2,524 Vehicle length L3 Rear wheel drive Single wheel L3 Rear wheel drive Twin wheels L4 Rear wheel drive Twin wheels Roof height H2 H3 H2 H3 H2 H3 MMAC (maximum authorised laden weight) 3,500 4,500 3,500 1: Door height (mm) 2,023 2: 3: Minimum height at MMAC (mm) Maximum height at MVODM (mm) ,574 2,572 2,611 2,609 2,600 2,599 MMAC: Maximum authorised laden weight MVODM: Curb weight up-to-date data on body guidelines (online body guidelines). Data status June

51 13 REAR DOOR, DIMENSIONS AND ACCESS 2. Access via the door frame Access via the rear door frame is provided for 3 heights (H1, H2 and H3). REAR DOOR FRAME DIMENSIONS H2 / H3 H1 A A: Maximum height between floor and upper cross member Panel Van H1 Panel Van, Front wheel drive, H2 or H3 Panel Van, Rear wheel drive, H2 or H3 A 1,662 1,847 1,751 N.B.: The rear door frame is the same for versions H2 and H3 up-to-date data on body guidelines (online body guidelines). Data status June

52 14 LASHING POINTS Lashing eyes are mounted in the load compartment to enable cargo to be secured in position using lashing straps or a luggage floor net. The number of lashing points on the floor varies depending on the panel van version: 6 lashing points on the floor and 2 on the far rear pillar for L1 vans 8 lashing points on the floor and 2 on the far rear pillar for L2 vans 10 lashing points on the floor and 2 on the far rear pillar for L3 vans 12 lashing points on the floor and 2 on the far rear pillar for L4 vans These lashing points comply with the requirements of standard DIN (Load per ring: 500 dan with an angle of 30 according to the position of the ring buckle) Their positioning is symmetrical to the body axis (Y = 0). They are attached to the body with M8 x 125 (Art. Nr ) fastening screws, tightening torque: 21 Nm As an option, it is possible to have 8 lashing points on the side panels. up-to-date data on body guidelines (online body guidelines). Data status June

53 14 LASHING POINTS LASHING POINT FASTENING SCREW up-to-date data on body guidelines (online body guidelines). Data status June

54 14 LASHING POINTS PANEL VAN L1, FRONT WHEEL DRIVE C3 C1 C4 C D3 8 D4 6 D2 D1 4 2 PANEL VAN L1 Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 2, on floor 6 2, on floor 7 3, on side panel 8 3, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 3, ,545 on side panel C4 3, on side panel D1 3, ,545 on side panel D2 2, on side panel D3 3, ,545 on side panel D4 3, on side panel up-to-date data on body guidelines (online body guidelines). Data status June

55 14 LASHING POINTS PANEL VAN L2, FRONT WHEEL DRIVE C3 C2 C4 7 5 C D3 10 D4 8 D2 6 D1 2 4 PANEL VAN L2 Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 4, on side panel 10 4, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 4, ,545 on side panel C4 4, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 4, ,545 on side panel D4 4, on side panel up-to-date data on body guidelines (online body guidelines). Data status June

56 14 LASHING POINTS PANEL VAN L3, FRONT WHEEL DRIVE 11 C4 C C1 C D4 D PANEL VAN L3, FRONT WHEEL DRIVE Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 3, on floor 10 3, on floor 11 5, on side panel 12 5, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 5, ,545 on side panel C4 5, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 5, ,545 on side panel D4 5, on side panel 6 D2 D1 4 2 up-to-date data on body guidelines (online body guidelines). Data status June

57 14 LASHING POINTS PANEL VAN L3, REAR WHEEL DRIVE 11 C4 C C2 C D4 D D1 4 2 PANEL VAN L3, REAR WHEEL DRIVE Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 4, on floor 10 4, on floor 11 5, on side panel 12 5, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 5, ,545 on side panel C4 5, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 5, ,545 on side panel D4 5, on side panel D2 up-to-date data on body guidelines (online body guidelines). Data status June

58 14 LASHING POINTS PANEL VAN L4, REAR WHEEL DRIVE C1 1 C2 3 5 C C4 D1 4 2 D3 D D PANEL VAN L4, REAR WHEEL DRIVE Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 3, on floor 10 3, on floor 11 5, on floor 12 5, on floor 13 5, on side panel 14 5, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 5, ,545 on side panel C4 5, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 5, ,545 on side panel D4 5, on side panel up-to-date data on body guidelines (online body guidelines). Data status June

59 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS The cross sections of the floor reinforcement are given for the different vehicle wheelbases. A cross section of the rear lower panel is also available for information. For any modifications to the rear lower panel, please refer to the chapter on rear overhang modifications. It should be noted that the rear skirt performs an important structural function. Details of the main under-floor cross sections are given below. Each overview is an aerial view (floor panel transparent). They show the different side members and cross members in the 3 wheelbase configurations. The principle for going from the L1 wheelbase to the L2 wheelbase chosen for the Movano is elongation behind the exhaust outlet zone (or behind the sliding side door for a panel van). PLATFORM CAB L1 2 E E A B C D 1 A B C D 1: Start of bodywork X = 1,598 2: Vehicle axis Y=0 up-to-date data on body guidelines (online body guidelines). Data status June

60 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION A-A SECTION B-B Distance from start of bodywork = 340 mm Distance from start of bodywork = 840 mm SECTION C-C SECTION D-D Distance from start of bodywork = 1,140 mm Distance from start of bodywork = 2,165 mm SECTION E-E Distance from the vehicle axis Y = 465 mm up-to-date data on body guidelines (online body guidelines). Data status June

61 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS PLATFORM CAB L2 F F 2 A B C D E 1 A B C D E 1: Start of bodywork X = 1,598 2: Vehicle axis Y=0 SECTION A-A SECTION B-B Distance from start of bodywork = 340 mm Distance from start of bodywork = 725 mm up-to-date data on body guidelines (online body guidelines). Data status June

62 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION C-C SECTION D-D Distance from start of bodywork= 1,340 mm Distance from start of bodywork = 1,640 mm SECTION E-E Distance from start of bodywork = 2,665 mm SECTION F-F Distance from the vehicle axis Y = 465 mm up-to-date data on body guidelines (online body guidelines). Data status June

63 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS PLATFORM CAB L3 2 H H A B C D E F G 1 A B C D E F G 1: Start of bodywork X = 1,598 2: Vehicle axis Y=0 SECTION A-A SECTION B-B Distance from start of bodywork = 340 mm Distance from start of bodywork = 725 mm up-to-date data on body guidelines (online body guidelines). Data status June

64 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION C-C SECTION D-D Distance from start of bodywork = 1,340 mm Distance from start of bodywork = 1,640 mm SECTION E-E SECTION F-F Distance from start of bodywork = 1,990 mm Distance from start of bodywork = 2,290 mm SECTION G-G Distance from start of bodywork = 3,315 mm up-to-date data on body guidelines (online body guidelines). Data status June

65 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION H-H Distance from the vehicle axis Y = 465 mm up-to-date data on body guidelines (online body guidelines). Data status June

66 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL On platform cabs, nuts welded onto the side sill closing can be used to attach bodywork connection supports. When manufacturing the rear bodywork, an inertia equivalent to that of the Movano panel van must be recreated. PLATFORM CAB VERSION L2H : Start of bodywork up-to-date data on body guidelines (online body guidelines). Data status June

67 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL POSITION OF NUTS ON SIDE SILL CLOSING PANEL The position of the bolts is given in relation to the vehicle reference system L X 1,720 1,720 2,220 2,220 3,070 3,070 3,720 3,720 4,880 4,880 Y Z L X 1,720 1,720 2,220 2,220 3,070 3,070 4,230 4,230 Y Z L X 1,720 1,720 2,220 2,220 3,730 3,730 Y Z up-to-date data on body guidelines (online body guidelines). Data status June

68 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL SECTION - NUTS 1 AND 2 SECTION - NUTS 5 AND 6 SECTION - NUTS 9 AND 10 up-to-date data on body guidelines (online body guidelines). Data status June

69 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL The absence of side sills on the platform cab version means that the hole at the base of the rear pillar needs to be plugged. The aim is to avoid unwanted noise in the passenger compartment and to prevent pollution getting into the hollow sections. REAR CAB PILLAR 1: 1 1: Zone to be plugged up-to-date data on body guidelines (online body guidelines). Data status June

70 17 PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN Platform cabs H1 and H2 are fitted with a connection rim as standard. To this rim are added 6 brackets welded to the body. The start of bodywork dimension is the same for both the H1 and H2 versions. M8 bolts must be used for attachment to the bodywork. The 6 body brackets must be used. After drilling the body brackets, use a corrosion inhibitor, referring to the Specific Corrosion Guidelines. The location of the body brackets is given for both heights (H1 and H2). As the manufacturing variation is ± 3 mm along the Y and Z axes, it would be prudent to test out any bodywork attachment in practice. PLATFORM CAB REAR RING H H : Upper body brackets H2 (x2) 2 : Upper body brackets H1 (x2) 3 : Side body brackets H2 or H2 (x2) 4 : M8 weld nuts, on rear seat floor cross member (x7) 5 : Loading bed up-to-date data on body guidelines (online body guidelines). Data status June

71 17 PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN PLATFORM CAB H1 B A A B C C SECTION A-A SECTION B-B SECTION C-C 1 1: Start of bodywork up-to-date data on body guidelines (online body guidelines). Data status June

72 17 PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN REAR RIM H1 AND H2 D C D C SECTION C-C SECTION D-D 1 1 1: Start of bodywork up-to-date data on body guidelines (online body guidelines). Data status June

73 18 CHASSIS CAB, POSITION OF BODY BRACKETS The start of bodywork dimension, the locations of the body brackets and the location of the connecting cross members between the side members are given for the different chassis cab versions. For fastening anything to these body brackets, see Body brackets sheet FRONT WHEEL DRIVE CHASSIS CAB, WHEELBASE 2 4,662 3,848 3,266 2,666 2,166 1, ,082 1, ,616 1,901 2,321 2,941 3,442 4,110 4,386 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

74 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS CAB, WHEELBASE 2 5,212 4,602 3,666 2,666 2,166 1, , ,616 1,901 2,321 2,941 3,539 4,110 4,386 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

75 18 CHASSIS CAB, POSITION OF BODY BRACKETS FRONT WHEEL DRIVE CHASSIS CAB, WHEELBASE 3 5,312 4,498 3,916 3,316 2,666 2,166 1, ,082 1, ,616 1,901 2,321 2,941 3,591 4,092 4,760 5,036 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

76 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS CAB, WHEELBASE 3 5,877 5,253 4,316 3,316 2,666 2,166 1, ,926 1,616 1,901 2,321 2,941 3,591 4,189 4, ,036 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

77 18 CHASSIS CAB, POSITION OF BODY BRACKETS FRONT WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 2 4,662 3,848 3,266 2, , , ,381 2,941 3,442 4,110 4,386 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

78 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 2 5,212 4,602 3,666 2, , ,381 2,940 3,539 4,110 4,315 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

79 18 CHASSIS CAB, POSITION OF BODY BRACKETS FRONT WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 3 5,312 4,498 3,916 3,316 2, ,082 1,926 2,381 2,941 3,591 4,092 4, ,036 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

80 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 3 5,862 5,253 4,316 3,316 2, ,926 2,381 2,941 3,591 4,189 4, ,036 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status June

81 20 REAR UNDERRIDE PROTECTION The rear underride protection on chassis cab versions is explained hereafter in situ on a vehicle fitted with a drop-side flat bed. The crossmember which acts as an underride protection device is bolted to the end of the sidemembers and has been designed to provide protection to the rear lamps. CROSSMEMBER POSITION A B A: Max. crossmember height: 550mm for N1 and N2 B: Max. crossmember recess: 450mm for N1 and 300mm for N2 up-to-date data on body guidelines (online body guidelines). Data status June

82 20 REAR UNDERRIDE PROTECTION CROSSMEMBER ATTACHMENTS Ansicht von außen Ansicht von innen 2: Rear underride protection 3: Bolts attaching the underride protection to the sidemembers up-to-date data on body guidelines (online body guidelines). Data status June

83 21 CROSS SECTION OF REAR WHEEL TRAVEL The cross section is given with an asymmetrical travel, with first fit tyres and bump stops pressed down as far as possible. A clearance of 10 mm must be added in relation to the tyre for any bodywork positioning. Additional clearance may be needed for fitting snow chains. FRONT WHEEL DRIVE PLATFORM CAB FRONT WHEEL DRIVE CHASSIS CAB OR CHASSIS DOUBLE CAB up-to-date data on body guidelines (online body guidelines). Data status June

84 21 CROSS SECTION OF REAR WHEEL TRAVEL SINGLE WHEEL REAR DRIVE CHASSIS CAB OR CHASSIS DOUBLE CAB TWIN WHEEL REAR DRIVE CHASSIS CAB OR CHASSIS DOUBLE CAB up-to-date data on body guidelines (online body guidelines). Data status June

85 22 WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB (FWD) Modification of the wheelbase with front wheel drive will alter the distribution of load on the vehicle axles. Full allowance must be made for this before the wheelbase is extended to ensure that the maximum loads per axle are not exceeded. (Also see chapter 79: Maximum authorised load per axle) OPEL/ VAUXHALL forbids any modification to the wheelbase on rear wheel drive vehicles. The transformation must not disrupt the correct operation of the ESP (optional on platform cabs and standard on rear wheel drive vehicles). The connections between the elements of the transformation are the responsibility of the converter. 1. CHASSIS SINGLE CAB AND DOUBLE CAB The recommended splice line has been determined based on considerations of structural soundness (maintenance of the tank and exhaust interfaces) and the location of cross members and struts. CHASSIS SINGLE CAB rear axle 2615 mm X front axle rear axle X = Wheelbase extension up-to-date data on body guidelines (online body guidelines). Data status June

86 22 WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB (FWD) CHASSIS DOUBLE CAB rear axle 2615 mm X front axle rear axle X = Wheelbase extension up-to-date data on body guidelines (online body guidelines). Data status June

87 22 WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB (FWD) 2. PLATFORM CAB The recommended splice line has been determined based on considerations of structural soundness (maintenance of the tank and exhaust interfaces) and the location of crossmembers and struts. For a large extension to the wheelbase, depending on the floor panel used, one or two strengthening crossmembers can be added under the platform between the main sidemembers rear axle 2460 mm X front axle rear axle X = Wheelbase extension up-to-date data on body guidelines (online body guidelines). Data status June

88 23 MODIFYING THE REAR OVERHANG Modification of the rear overhang will alter the distribution of load on the vehicle axles. Make sure that you do not exceed the permissible axle loads. Doing so would prevent the ESP system from functioning correctly on vehicles which are equipped with this feature. Further information regarding permissible weights is contained on the vehicle type identification plates on the vehicle itself. (Also see chapter 79 "Maximum load per axle") The extension to the rear overhang must not exceed the maximum authorized body limit. An extended overhang prevents: - The installation of a lift tailgate - The installation of a platform on this overhang - The assembly of a classic coupling device If installing a new trailer coupling device, ensure validation in accordance with the regulatory requirements. The transformation (load distribution) must not disrupt the correct operation of the ESP. up-to-date data on body guidelines (online body guidelines). Data status June

89 23 MODIFYING THE REAR OVERHANG 1. CHASSIS SINGLE CAB AND DOUBLE CAB The recommended splice line (see 4, view below) has been determined based on considerations of structural soundness (rear leaf spring hangers, etc.) and the location of crossmembers or struts. It is located just in front of the extreme rear crossmember (see 5, view below) which can be removed. The latter must not be cut or modified under any circumstances. REAR CHASSIS: AERIAL VIEW (WITH CLOSURE ELEMENTS REMOVED) : Rear axle front hanger 2: Rear axle + wheel 3: Rear axle rear hanger 4: Splice line 5: Extreme rear crossmember 6: Sidemember internal struts 5 6 It is essential that the extension to the overhang keep or add additional struts to each sidemember (see 6, view above), located in line with the rear leaf spring hangers (see 3, view above). An extension of more than 385mm requires the addition of one or more crossmembers. If the vehicle has a rear tow ring, this must be removed. up-to-date data on body guidelines (online body guidelines). Data status June

90 23 MODIFYING THE REAR OVERHANG CHASSIS SINGLE CAB front axle rear axle F CHASSIS DOUBLE CAB F Initial length 2. Extension of rear overhang 3. Application of the load F 4. Max. rear overhang up-to-date data on body guidelines (online body guidelines). Data status June

91 23 MODIFYING THE REAR OVERHANG CHASSIS CAB Type FRONT WHEEL DRIVE REAR WHEEL DRIVE Single wheel REAR WHEEL DRIVE Twin wheels Length L2 L3 L2 L3 L3 L4 Initial rear overhang (1), 1025 mm 1575 mm Application of the min./max. load (4) (mm) min/max 331 / 905 min/max 294 / 948 min/max -83 / 1007 min/max -160 / 1062 min/max 68 / 578 min/max -21 / 562 Max. body rear overhang (5), 1400 mm 2124 mm 2230 mm 3032 mm 1928 mm 2754 mm CHASSIS DOUBLE CAB Type FRONT WHEEL DRIVE REAR WHEEL DRIVE Single wheel REAR WHEEL DRIVE Twin wheels Length L2 L3 L2 L3 L3 L4 Initial rear overhang (1), 1025 mm 1575 mm Application of the min./max. load (4) (mm) min/max 97 / 483 min/max -58 / 24 min/max -302 / 648 min/max -535 / 152 min/max -131 / 263 min/max -254 / -1 Max. body rear overhang (5), 1119 mm 2078 mm 1917 mm 3032 mm 1669 mm 2471 mm up-to-date data on body guidelines (online body guidelines). Data status June

92 23 MODIFYING THE REAR OVERHANG 2. PLATFORM CAB Under no circumstances must the transformation modify the interfaces with the rear shackle supports. Depending on the size of the extension to the overhang, one or more strengthening crossmembers can be added under the platform between the main sidemembers. front axle rear axle F Initial length 2. Extension of rear overhang 3. Application of the load F 4. Max. rear overhang 4 PLATFORM-CAB Type FRONT WHEEL DRIVE Height H1 H1 H2 H1 H2 Length L1 L2 L2 L3 L3 Initial rear overhang (1) 1006 mm Application of the min./max. load (4) min/max 279 / 851 min/max 418 / 999 min/max 398 / 981 min/max 433 / 1092 min/max 408 / 1068 Max. body rear overhang (5) 1006 mm 1227 mm 1266 mm 1847 mm 1897 mm up-to-date data on body guidelines (online body guidelines). Data status June

93 24 DASH PANEL CROSS MEMBER To feed engine compartment wiring through into the passenger compartment, only the main wiring harness grommet behind the engine interconnection unit may be used. The plastic clamp on the passenger compartment side must be changed (for identical reassembly). The seal must not be damaged. The dash panel may not be drilled. LOCATION OF THE HARNESS GROMMET up-to-date data on body guidelines (online body guidelines). Data status June

94 25 CAB FLOOR DRILLING AREA Points between the driver s seat and the cab partition in right- and left-hand drive vehicles have been identified as drilling areas. Before any drilling is performed, take note of the various elements such as wiring, brake pipes, hand brake cables, the fuel tank, etc. The maximum dimension of the hole to be drilled is 30. After drilling, the filings or shavings must be vacuumed and a corrosion inhibitor used; please refer to the Specific Corrosion Guidelines. Use a grommet for protection and a silicon seal for water tightness. LOCATION OF CAB FLOOR DRILLING AREAS 1: Limit between the cab floor and the loading bed 1 up-to-date data on body guidelines (online body guidelines). Data status June

95 26 DRILLING AREA ON REAR FLOOR OF PANEL VAN Before any drilling is performed (e.g. for fitting a wooden floor), take note of the various elements such as wiring, brake pipes, hand brake cables, the fuel tank, etc. After drilling, the filings or shavings must be vacuumed and a corrosion inhibitor used; please refer to the Specific Corrosion Guidelines. Use a grommet for protection and a silicon seal for water tightness. The different views below show the position of the elements below the floor (fuel tank, exhaust line, muffler and screen, etc). Drilling areas have been identified along with a fastening diagram in case of a location to the right of the under-floor cross member. LOCATION OF LOADING BED DRILLING AREAS (Front wheel drive panel van L1) up-to-date data on body guidelines (online body guidelines). Data status June

96 26 DRILLING AREA ON REAR FLOOR OF PANEL VAN LOCATION OF LOADING BED DRILLING AREAS (Front wheel drive panel van L2) LOCATION OF LOADING BED DRILLING AREAS (Front wheel drive panel van L3) up-to-date data on body guidelines (online body guidelines). Data status June

97 26 DRILLING AREA ON REAR FLOOR OF PANEL VAN LOCATION OF LOADING BED DRILLING AREAS (Single wheel rear drive panel van L3) LOCATION OF LOADING BED DRILLING AREAS (Twin wheel rear drive panel van L3) up-to-date data on body guidelines (online body guidelines). Data status June

98 26 DRILLING AREA ON REAR FLOOR OF PANEL VAN LOCATION OF LOADING BED DRILLING AREAS (Twin wheel rear drive panel van L4) CROSS MEMBER FASTENING DIAGRAM 1: Loading bed 2: Floor reinforcement cross member 3: Reinforcement flange up-to-date data on body guidelines (online body guidelines). Data status June

99 27 CAB ROOF FOR CAMPERVAN Platform cabs and chassis cabs specific to campervans have a specific rear aspect and roof. Due to the presence of additional structural reinforcement, these versions meet regulatory requirements on seatbelt anchor points (ECE14). Therefore a version with a normal roof cannot be cut out to transform it into a version with a shorter roof. It is, however, feasible to manufacture a contremarque (special vehicle order) if large quantities are required. PLATFORM CAB N.B.: The rear section of the upper cantrail can be cut down by 156 mm on platform cab versions. 1, up-to-date data on body guidelines (online body guidelines). Data status June

100 27 CAB ROOF FOR CAMPERVAN CHASSIS CAB 523 1,396 up-to-date data on body guidelines (online body guidelines). Data status June

101 Conversion Guideline NEW Movano X62 Part 2 - Chapter Version: April 2010 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany

102 CONTENTS CHAPTER DESCRIPTION: PAGE 28 MIRRORS 3 29 AIR EXTRACTION 5 30 TYRES AND TURNING CIRCLE 8 31 SPARE WHEEL AIRBAG DEPLOYMENT VOLUME SEATS SEAT BELTS LAMP INSTALLATION EUROPEAN REGULATIONS HEIGHT OF CAB ROOF GROUND CLEARANCE INSTALLATION AND ATTACHMENT OF EQUIPMENT ON DASHBOARD VEHICLE SPEED RESTRICTION TABLE OF WEIGHT ASSEMBLING A SECOND HEATER UNIT INSTALLING ADDITIONAL AIR-CONDITIONING INSTALLING AN ADDITIONAL BOILER 41 up-to-date data on body guidelines (online body guidelines). Data status June 2009

103 28 MIRRORS Chassis cabs and platform cabs come with door mirrors as standard, with 2,170 mm back panelling possibility. Long arm door mirrors can be ordered on option, with back panelling of up to 2,350 mm wide. The mirrors have a built-in side indicator. There are two types of indicator: 5 W or 16 W, depending on the length of the vehicle. The overall width of the vehicle with the standard mirrors is 2,470 mm and 2,654 mm with the long arm mirrors. Important: A 16 W indicator cannot be fitted to a vehicle with 5 W side indicators and vice versa. STANDARD DOOR MIRRORS (Overall width from 2,020 to 2,170 mm) Type Side Steering Reference Manual without defrosting Right Left Steering right R (5 W) / R (16 W) Steering left R (5 W) / R (16 W) Steering right R (5 W) / R (16 W) Steering left R (5 W) / R (16 W) Manual with defrosting Right Left Steering right R (5 W) (S) / R (16 W) (S) Steering left R (5 W) (S) / R (16 W) (S) Steering right R (5 W) / R (16 W) Steering left R (5 W) / R (16 W) (S): with temperature sensor up-to-date data on body guidelines (online body guidelines). Data status June

104 28 MIRRORS LONG ARM DOOR MIRRORS (Overall width from 2,170 to 2,350 mm) Type Side Steering Reference Electric with defrosting Right Left Steering left R (16W) (S) R (16W) Electric with defrosting Right Left Steering right R (16W) (S) R (16W) (S): with temperature sensor up-to-date data on body guidelines (online body guidelines). Data status June

105 29 AIR EXTRACTION Air must be extracted from the interior (cab, loading area, etc.) to achieve satisfactory performance when closing doors (front, side, rear), activating the heating and ventilation systems and in airbag deployment. After any modification to the extraction system, the air extraction surface area must be equivalent to the original system. The modified system must not let water, outside air, dust or mud in. It must also reduce noise levels. It must not compromise the integrity of the vehicle (where necessary, fit vent glass to prevent access to the door opening controls, etc.). It must be protected from potential impacts (stones thrown up from the road, etc.). In the chassis cab and the chassis double cab, the air outlets are located on either side of the cab back panel. The surface area of each air outlet is 10,070 mm². In the panel van, the air outlets are located on either side of the rear bumper. The surface area of each air outlet is 10,679 mm². CHASSIS CAB up-to-date data on body guidelines (online body guidelines). Data status June

106 29 AIR EXTRACTION CHASSIS DOUBLE CAB up-to-date data on body guidelines (online body guidelines). Data status June

107 29 AIR EXTRACTION PANEL VAN up-to-date data on body guidelines (online body guidelines). Data status June

108 30 TYRES AND TURNING CIRCLE The basic tire assembly, except in specific situations, is as follows: VERSION TYRE NAME, LOAD INDEX, SPEED WHEEL RIM MATERIAL COLOURS Panel Van, Combi Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel Panel van, Plcab, Chcab Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel Panel van, Combi Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel Panel van, Plcab, Chcab Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel Panel van, Chcab, Chdbcab, Bus Rear wheel drive/twin wheels Chassis cab Rear wheel drive/single wheel Panel van, Chcab, Chdbcab Rear wheel drive/twin wheels Panel van, Chcab, Chdbcab, Bus Rear wheel drive/twin wheels Chassis cabine Rear wheel drive/single wheel Panel van, Chcab, Chdbcab Rear wheel drive/twin wheels Panel van, Chcab, Chdbcab, Bus Rear wheel drive/twin wheels Chassis cab Rear wheel drive/twin wheels Panel van, Combi Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdcab Front wheel drive/single wheel Panel van, Plcab, Chcab Front wheel drive/single wheel Panel van, Combi, Plcab, Chcab, Chdbcab Front wheel drive/single wheel CONTINENTAL (SUMMER) 215/65 R 16 C 109/107R GOODYEAR (SUMMER) 225/65 R 16 C 112/110R CONTINENTAL (SUMMER) 225/65 R 16 C 112/110R CONTINENTAL (CCAR) 225/65 R 16 C 112/110R CONTINENTAL (ALL WEATHER) 225/65 R 16 C 112/110R CONTINENTAL (SUMMER) 215/65 R 16 C 109/107R GOODYEAR (SUMMER) 225/65 R 16 C 112/110R CONTINENTAL (SUMMER) 225/65 R 16 C 112/110R CONTINENTAL (CCAR) 225/65 R 16 C 112/110R CONTINENTAL (ALL WEATHER) 225/65 R 16 C 112/110R GOODYEAR (SUMMER) 235/65 R 16 C 115/113R CONTINENTAL (CCAR) 235/65 R 16 C 115/113R CONTINENTAL (ALL WEATHER) 235/65 R 16 C 115/113R GOODYEAR (SUMMER) 235/65 R 16 C 115/113R CONTINENTAL (CCAR) 235/65 R 16 C 115/113R CONTINENTAL (ALL WEATHER) 235/65 R 16 C 115/113R CONTINENTAL (SUMMER) 195/75 R 16 C 107/105R CONTINENTAL (CCAR) 195/75 R 16 C 107/105R CONTINENTAL (SUMMER) 215/65 R 16 C 109/107R GOODYEAR (SUMMER) 225/65 R 16 C 112/110R CONTINENTAL (SUMMER) 225/65 R 16 C 112/110R CONTINENTAL (CCAR) 225/65 R 16 C 112/110R CONTINENTAL (ALL WEATHER) 225/65 R 16 C 112/110R GREY 6.5 J 16 H STEEL BLACK GREY 7 J 16 H STEEL BLACK 5.5 J 16 H STEEL GREY 6.5 J 16 H ALUMINIUM GREY up-to-date data on body guidelines (online body guidelines). Data status June

109 30 TYRES AND TURNING CIRCLE Kerb-to-kerb and wall-to-wall turning circle diameters are given for the different wheelbases. Front wheel drive Rear wheel drive L1 L2 L3 L3 L4 Wheelbase (mm) Kerb-to-kerb turning circle diameter (m) Wall-to-wall turning circle diameter (m) TURNING CIRCLE DIAMETERS IN RELATION TO WHEELBASE (m) (mm) Wall-to-wall Kerb-to-kerb up-to-date data on body guidelines (online body guidelines). Data status June

110 31 SPARE WHEEL The spare wheel is held under the vehicle frame using a winch and secured by tightening a cable using the wheel wrench and adapter. Some vehicles are equipped with a tyre repair kit instead of a spare wheel. If the overhang is extended or modified the spare wheel remains in its place. 1. Position of spare wheel in panel van and platform chassis with front wheel drive. POSITION OF SPARE WHEEL 1= front axle, 2 = centre axle Distance between front axle and spare wheel axle by wheelbase: L1 = 3613 mm L2 = 4113 mm L3 = 4763 mm up-to-date data on body guidelines (online body guidelines). Data status June

111 31 SPARE WHEEL 2. Position of spare wheel in chassis cab with front wheel drive. POSITION OF SPARE WHEEL 1= front axle, 2 = centre axle Distance between front axle and spare wheel axle by wheelbase: L2 = 4300 mm L3 = 4950mm 3. Assembly spare wheel with winch up-to-date data on body guidelines (online body guidelines). Data status June

112 31 SPARE WHEEL Spare wheel at single wheel vehicles (without mounting plate) Spare wheel at twin wheel vehicles (with mounting plate) Twin wheel vehicles have an additional mounting plate attached to the spare wheel. Before using the wheel, undo the nut and remove the mounting plate. When reinstalling a spare wheel, attach the mounting plate and secure with the nut. When installing a spare wheel, route the cable from the back and through the centre of the wheel. Attach the retainer and pin, ensuring it is correctly positioned and that the front of the wheel will be facing downwards. Tighten cable using the wheel wrench and adapter until the wheel is secured. up-to-date data on body guidelines (online body guidelines). Data status June

113 32 AIRBAG The airbag system consists of a number of individual systems depending on the scope of equipment. Depending on model and country the vehicle is equipped with various airbags. The passenger airbag is supplied as an option and it may be deactivated. For more information, also see chapter 137, 141 and general conversion recommendations. Note: Warning: Do not make any modifications to the airbag system as this will invalidate the vehicle type approval. If handled improperly the airbag systems can be triggered in an explosive manner. Keep the area in which the airbag inflates clear of obstructions. Do not stick anything on the airbag covers and do not cover them with other materials, also see chapter 41. On no account may any modifications be made to the airbag system or the belt tensioner system. Modifications to or work incorrectly carried out on a restraint system (seat belt and seat belt anchorages, belt tensioner or airbag) or its wiring, can cause the restraint systems to stop functioning correctly, e.g. the airbags or belt tensioners could be triggered inadvertently or could fail in accidents. Vehicle parts that create vibrations must not be secured in the proximity of the airbag control unit or sensor installation locations, nor may modifications be made to the floor structure in the proximity of the airbag control unit or the satellite sensors. Reliable operation of the front airbag, side airbag and belt tensioners is otherwise no longer guaranteed. FRONT AIRBAGS 500 mm 950 mm up-to-date data on body guidelines (online body guidelines). Data status June

114 32 AIRBAG deployment area of the driver airbag 300 mm 550 mm Important: The steering wheel is reach-adjustable up-to-date data on body guidelines (online body guidelines). Data status June

115 32 AIRBAG deployment area of the passenger airbag 350 mm 550 mm 150 mm up-to-date data on body guidelines (online body guidelines). Data status June

116 32 AIRBAG Location of airbag control unit Comment: The ECU is in the same position for both left- and right-hand drive vehicles. Location of airbag and restraint systems components in the vehicle : Driver airbag 2: Passenger airbag 3: Side airbags 4: Warning light (on dashboard) 5: Deactivation light (on roof console) 6: Airbag control unit (ECU) Note: For more information, also see chapter 141. up-to-date data on body guidelines (online body guidelines). Data status June

117 33 SEATS The front seats vary depending on the equipment level, the options and the country of sale. The driver s seat is tilt and height-adjustable and has longitudinal adjustment. As an option, it may have an armrest, heating, lumbar adjustment, a side airbag, etc. A sprung driver s seat is available as an option. The specific campervan versions are fitted with a swivelling driver s seat. Passengers can have a single seat similar to the driver s seat or a 2-seater bench seat. The 2-seater bench seat can have a swivelling table, a storage compartment, etc. The chassis double cab versions are fitted with a rear 4-seater bench seat. Location of R points ( ) X Y Z Single seat 20 1,133 ± Centre bench seat 19 or ,153 ± Side bench seat 19 1,153 ± For the single seat, the R point is given for a position -30 mm from the fully back position (total longitudinal travel of 210 mm) and at mid-height (total vertical travel of 60 mm). On conversion, it may be necessary to remove the seats. Seat anchorages are component elements for vehicle type approval and must not therefore be modified. In particular, it is forbidden to: - modify the original anchorage point positions, - insert other elements into the original assembly. Any modification will require a new type approval. On reassembly, tightening torques must be respected (use of a calibrated torque wrench is recommended). - Attachment of the seat or the 2-seater bench seat to the floor using M10x bolts, tightened to a torque of 44 Nm ± 15%. - Attachment of the chassis double cab 4-seater bench seat to the floor using M12x bolts, tightened to a torque of 62 Nm ± 15%. - Attachment of seat runners to the driver s seat podium using M8x bolts, tightened to a torque of 19.5 Nm ± 10%. up-to-date data on body guidelines (online body guidelines). Data status June

118 33 SEATS N.B.: Disassembly and reassembly must be carried out with the battery disconnected. For seats with the optional side airbag, direct contact between the connectors and the conductive parts must be avoided due to static electricity. Before carrying out any work on the airbags, the airbag ECU must be locked using the Clip diagnostic tool to disable the trigger lines (the airbag dashboard light is on continuously when contact is made). up-to-date data on body guidelines (online body guidelines). Data status June

119 34 SEAT BELTS Seat belts and their anchorages are component elements for vehicle type approval and must not therefore be modified. In particular, it is forbidden to: - modify the original anchorage point positions, - change the original fastening support, - insert other elements into the original assembly. Any modification will require a new type approval. No changes to the seat belt are permitted. On conversion, it may be necessary to remove the seat belts. On reassembly, tightening torques must be respected (use of a calibrated torque wrench is recommended) and the following should be checked: - the correct positioning of the reel indexing before bolting, - that the strap is not twisted between the reel and the final anchoring point, - that no foreign body can come into contact with the strap, - that the strap is not altered by the vehicle conversion. If a floor or floor covering is added, it is essential to make a large enough cut-out so it does not interfere with the seat belt assembly. Fastening Tightening torque Comments Reel M10x bolt (Ref.: ) 21 Nm ± 15% - Same for rows 1 and 2 - Use of a new bolt on reassembly Fitting M10x bolt (Ref.: ) 21 Nm ± 15% - Same for rows 1 and 2 - Use of a new bolt on reassembly Angular member M9 nut for row 1 M10 bolt for row 2 21 Nm ± 15% - Special nut and bolt installed with belt Front stalk Special bolt 27 Nm ± 15% - Attached to front seat and bench seat Rear stalk M12x bolt (Ref.: ) 62 Nm ± 15% - Attached to floor - Use of a new bolt on reassembly up-to-date data on body guidelines (online body guidelines). Data status June

120 36 LAMP INSTALLATION EUROPEAN REGULATIONS FRONT ZONE ALL TYPES A2 - B2 D2 F2 Overall body width (without rearview mirrors) E2 C2 E E1 C D - F A - B D1 F1 C1 A1 - B1 A B C D E F A: Indicator B: Position C: Main Beam FRONT LAMPS D: Dipped Beam E: Fog lamp F: Fixed Bending Lamp* A A1 A2 B B1 B2 C C1 C2 D D1 D2 E E1 E2 F F1 F ** ** ** N.B: * = optional; ** = no value imposed *** = 800 für M1 und N1 **/* ** up-to-date data on body guidelines (online body guidelines). Data status June

121 36 LAMP INSTALLATION EUROPEAN REGULATIONS PANEL VAN REAR ZONE ALL TYPES Overall body width (without rearview mirrors) G2 - H2 - K2 N2 L2- M2 N N1 M1 K G-H L M L1 G1 H1 K1 G H K L M N REAR LAMPS G : Brake H: Position K : Indicator L: Reverse M : Fog N: Reflector G G1 G2 H H1 H2 K K1 K2 L L1 L2 M M1 M2 N N1 N ** ** N.B: ** = no value imposed up-to-date data on body guidelines (online body guidelines). Data status June

122 36 LAMP INSTALLATION EUROPEAN REGULATIONS SIDE ZONE ALL TYPES Overall body width (without rearview mirrors) P2 P3 P1 P Indicator in side mirror SIDE INDICATORS P P1 P2 P * Max N.B: * =350 für M1 und N1 For more information, also see chapter 125 up-to-date data on body guidelines (online body guidelines). Data status June

123 36 LAMP INSTALLATION EUROPEAN REGULATIONS DETAILS OF CHASSIS VERSION ALL TYPES Overall body width (without rearview mirrors) G2 - H2 K2 M2 L2 N2 G H K L M - N G1 - H1 K1 L1 M1 N1 K G H N M L REAR LAMPS Of CHASSIS VERSION G : Brake H : Position K : Indicator L : Reverse M : Fog N : Reflector G G1 G2 H H1 H2 K K1 K2 L L1 L2 M M1 M2 N N1 N ** ** N.B: ** = no value imposed up-to-date data on body guidelines (online body guidelines). Data status June

124 36 LAMP INSTALLATION EUROPEAN REGULATIONS ADDITIONAL INFORMATION If the vehicle overall width > 2,100mm Mandatory use of Vehicle perimeter lamps / front perimeter lamps (2 front, 2 rear). N.B: The rear lights are optional on chassis cabs. If the vehicle overall length < 6,000mm Side position indicator: fitted on the rearview mirror, with the type-approved choice of arm length according to the width of the body. - The indicator is category 5, 5W bulb (type WY5W). If the vehicle overall length > 6,000mm Provide the option for the indicator. The latter must be category 6, 16W bulb (type W16W). Side position indicator: fitted on the rearview mirror, with the type-approved choice of arm length according to the width of the body. Side position lamps and side reflectors are mandatory. Two reverse lamps. N.B: Side position lights are optional on chassis cabs. In after-sales, use mass production rear lamps. National regulations apply to all lamp and turn signal units. up-to-date data on body guidelines (online body guidelines). Data status June

125 37 HEIGHT OF CAB ROOF PLATFORM CAB : Cab roof 2: Loading bed 3: Roof Version H1: 1,747.5 mm ; Roof Version H2: 1,941.7 mm CHASSIS CAB, FRONT OR REAR WHEEL DRIVE : Cab roof 2: Rear side member 3: Version H1: 1,569 mm up-to-date data on body guidelines (online body guidelines). Data status June

126 39 GROUND CLEARANCE The ground clearance is given for a vehicle with a maximum authorized laden weight (MMAC). 1. Panel van Panel van L1, front wheel drive Panel van L2, front wheel drive Panel van L3, front wheel drive Panel van L3, Single wheel rear drive Panel van L3, twin wheel rear drive Panel van L4, twin wheel rear drive Height MMAC (kg) Min. ground clearance (mm) 2, H1 3, , , H2 3, , H2 3, , H3 3, , H ,500 H3 169 H2 H3 3, H2 H3 4, H2 H3 4, Platform cab Platform cab L1 Platform cab L2 Platform cab L3 Height H1 H1 H2 H1 H2 MMAC (kg) Min. ground clearance (mm) 3, up-to-date data on body guidelines (online body guidelines). Data status June

127 39 GROUND CLEARANCE 3. Chassis cab Height MMAC (kg) Min. ground clearance (mm) Chassis cab L2, front wheel drive Chassis cab L2, front wheel drive Chassis cab L2 single wheel rear drive Chassis cab L3 single wheel rear drive H1 3, Chassis cab L3 twin wheel rear drive Chassis cab L4 twin wheel rear drive 4, Chassis double cab Height MMAC (kg) Min. ground clearance (mm) Chassis double cab L2, front wheel drive Chassis double cab L2, front wheel drive Chassis double cab L2 single wheel rear drive Chassis double cab L3 single wheel rear drive H1 3, Chassis double cab L3 twin wheel rear drive Chassis double cab L4 twin wheel rear drive 4, up-to-date data on body guidelines (online body guidelines). Data status June

128 41 INSTALLATION AND ATTACHMENT OF EQUIPMENT ON DASHBOARD Equipment can be installed on the dashboard in the zones indicated below. The vehicle interior must be designed in such a way that airbags can fully deploy without impediment. Please also see chapter 32 Airbag deployment volume. LOCATION OF INSTALLATION AND ATTACHMENT ZONES N.B.: Keep the area in which the airbag inflates clear of obstructions. Do not stick anything on the airbag covers and do not cover them with other materials. Depending on the version and options, the central area may be smaller due to a door or removable shelf being fitted. up-to-date data on body guidelines (online body guidelines). Data status June

129 41 INSTALLATION AND ATTACHMENT OF EQUIPMENT ON DASHBOARD 1. Lateral zones The drilling and attachment depth must not exceed 12 mm. SIZING Zone behind the mobile phone dock The drilling and attachment depth must not exceed 25 mm. SIZING : Prohibited zone 100 up-to-date data on body guidelines (online body guidelines). Data status June

130 41 INSTALLATION AND ATTACHMENT OF EQUIPMENT ON DASHBOARD 3. Central area The drilling and attachment depth must not exceed 25 mm. SIZING : Prohibited zone if folding shelf fitted N.B.: If a cover is fitted, the effective height is restricted to 40 mm. up-to-date data on body guidelines (online body guidelines). Data status June

131 42 VEHICLE SPEED RESTRICTION 1. Cruise control - speed limiter The cruise control - speed limiter is a driving aid and is available as an option depending on the equipment level. Cruise control is a function that maintains the vehicle at a constant speed selected by the driver. The speed limiter is a function that helps the driver to stay below a certain speed previously selected by the driver. The speed setting is left up to the driver whose responsibility it is to stay within speed limits and to remain vigilant. Before use and for any further information on how this function works, please refer to the vehicle s hand book. 2. Client speed restriction This option is more specifically aimed at customers, in particular fleets, who want the vehicle s speed to be limited without the driver being able to disable the restriction. The restriction value is chosen by the customer and is programmed into the engine ECU in the factory. The restriction value can be modified or removed using the TECH2 diagnostic tool. The restriction values are as follows: 90, 100, 110 or 130 km/h. The user must be notified of the status and value of the vehicle s speed restriction. This information must be permanently displayed in the cockpit where it can be seen by the driver. A regulatory sticker corresponding to the selected restriction value must therefore be obtained from the Opel / Vauxhall dealer network. STICKER Part number km/h mph up-to-date data on body guidelines (online body guidelines). Data status June

132 42 VEHICLE SPEED RESTRICTION STICKER POSITION A sticker can be affixed to the rear of the vehicle to inform other road users. 3. Regulatory speed restriction Depending on the category of vehicle and the law in the country where the vehicle is sold, the vehicle s speed can be restricted during manufacture with no option to disable this restriction. The restriction value is programmed into the engine ECU in the factory. The restriction value cannot be modified or removed using the Clip diagnostic tool or by changing the engine ECU. The vehicle s maximum speed must be displayed on the rear of the vehicle. If a vehicle restricted during manufacture is exempt from restriction (for example emergency vehicle, police) or for restriction of a vehicle that was not originally restricted, major vehicle maintenance arranged by the Central Engineering Department can be carried out. up-to-date data on body guidelines (online body guidelines). Data status June

133 9 Driver's seat - Arm rest 1053,0 1,0 0,5 1,6 1,1 0,4 1,6 1,2 0,4 1,6 1,1 0,4 1,6 1,1 0,4 1,6 1,2 0,4 1,6 11 Storage - Roof rack 820,0 1,4 0,5 1,9 1,5 0,4 1,9 1,6 0,4 1,9 1,5 0,4 1,9 1,5 0,4 1,9 1,6 0,4 1,9 14 Panel partition instead of no partition 1498,7 13,2 11,7 24,9 14,8 10,1 24,9 16,3 8,6 24,9 14,8 10,1 24,9 16,3 11,2 27,5 18,0 9,5 27,5 18 Seats - Lumbar adjustment 1053,0 0,1 0,1 0,2 0,1 0,0 0,2 0,1 0,0 0,2 0,1 0,0 0,2 0,1 0,0 0,2 0,1 0,0 0,2 28 Front side airbag (driver) 1053,0 0,6 0,3 0,9 0,6 0,3 0,9 0,7 0,2 0,9 0,6 0,3 0,9 0,6 0,3 0,9 0,7 0,2 0,9 Wheelbase = E1, E2, E3 FRONT WHEEL DRIVE E1P1 E1 = 3182 mm FRONT WHEEL DRIVE E2P1 E2 = 3682 mm FRONT WHEEL DRIVE E3P1 E3 = 4332 mm PANEL VAN SINGLE WHEEL REAR DRIVE E2P2 E2 = 3682 mm TWIN WHEEL REAR DRIVE E2P2 E2 = 3682 mm TWIN WHEEL REAR DRIVE E3P2 E3 = 4332 mm xg Front Rear Total Front Rear Total Front Rear Total Front Rear Total Front Rear Total Front Rear Total 1 Seats - Fixed bench 2 Height-adjustable steering column 3 Two 12V sockets: on instrument panel and on console 4 TEP upholstery 5 Wheels - Wheel centre cover Locking - Electric door control + radio frequency remote control (inc. 2-button key) Electric-window regulator (driver-side onetouch) Electric rearview mirror (PRF included in electric-window regulator) 10 Seats - Fixed shelf bench seat on 1/2 bench seat back rest instead of fixed bench seat 1275,0 0,7 0,5 1,2 0,8 0,4 1,2 0,8 0,4 1,2 0,8 0,4 1,2 0,8 0,4 1,2 0,8 0,4 1,2 12 Rev counter 13 Fabric upholstery Wheels - Bolt cover instead of wheel centre cover One-touch electric-window regulator (driver and passenger) Locking - 3-button key (involves electric door control or SUPCPE) 0,4 0,4 0,7 0,4 0,4 0,7 0,4 0,4 0,7 0,4 0,4 0,7 19 Seats - Rotating shelf bench seat on 1/2 bench seat back rest, storage tray under bench seat and tilting seat cushion instead of fixed shelf 1147,5 5,4 3,0 8,4 5,8 2,6 8,4 6,2 2,2 8,4 5,8 2,6 8,4 5,8 2,6 8,4 6,2 2,2 8,4 20 Wheels - Integral covers instead of bolt covers 0,7 0,7 1,5 0,7 0,7 1,5 0,7 0,7 1,5 0,7 0,7 1,5 21 Instrument panel: upper storage and 1 DIN collapsible shelf 1245,0 1,2 0,8 2,0 1,3 0,7 2,0 1,4 0,6 2,0 1,3 0,7 2,0 1,3 0,7 2,0 1,4 0,6 2,0 22 Sunglasses holder 23 Cab step lighting 24 Additional 12V socket loading space (closed transport only) 25 Fabric upholstery 2 26 ADAC (onboard computer) 27 Parking aid/rear parking sensor

134 30 Passenger airbag 400,0 1,5 0,2 1,7 1,5 0,2 1,7 1,5 0,2 1,7 1,5 0,2 1,7 1,5 0,2 1,7 1,5 0,2 1,7 32 Trailer tow bar -6,4 31,4 25,0-5,5 30,6 25,0-4,7 29,7 25,0-10,3 36,5 26,1-10,3 36,5 26,1-4,6 30,7 26,1 33 Mud flaps (FR + RR) 0,7 0,7 1,4 0,7 0,7 1,4 0,7 0,7 1,4 0,7 0,7 1,4 1,0 1,0 1,9 1,0 1,0 1,9 37 Manual CA -420,0 18,0-2,1 15,9 17,7-1,8 15,9 17,4-1,5 15,9 17,7-1,8 15,9 17,7-1,8 15,9 17,4-1,5 15,9 38 Regulated CA -420,0 18,5-2,2 16,3 18,2-1,9 16,3 17,9-1,6 16,3 18,2-1,9 16,3 18,2-1,9 16,3 17,9-1,6 16,3 44 Glass partition instead of panel partition 1549,0 0,8 0,7 1,5 0,9 0,6 1,5 1,0 0,5 1,5 0,9 0,6 1,5 0,9 0,6 1,5 1,0 0,5 1,5 49 Tachograph 854,0 1,0 0,4 1,4 1,0 0,3 1,4 1,1 0,3 1,4 1,0 0,3 1,4 1,0 0,3 1,4 1,1 0,3 1,4 51 Grilled half partition instead of no partition 1425,0 6,0 4,9 10,9 6,7 4,2 10,9 7,3 3,6 10,9 6,7 4,2 10,9 6,7 4,2 10,9 7,3 3,6 10,9 56 Half-height wood trim 0,8 2,3 3,1 1,1 2,6 3,7 2,3 2,4 4,7 0,7 3,2 3,9 0,7 3,2 3,9 1,0 3,6 4,6 29 Wheelbase = E1, E2, E3 Front side airbag (passenger) - not compatible with bench seat FRONT WHEEL DRIVE E1P1 E1 = 3182 mm FRONT WHEEL DRIVE E2P1 E2 = 3682 mm FRONT WHEEL DRIVE E3P1 E3 = 4332 mm PANEL VAN SINGLE WHEEL REAR DRIVE E2P2 E2 = 3682 mm TWIN WHEEL REAR DRIVE E2P2 E2 = 3682 mm TWIN WHEEL REAR DRIVE E3P2 E3 = 4332 mm xg Front Rear Total Front Rear Total Front Rear Total Front Rear Total Front Rear Total Front Rear Total 1053,0 0,6 0,3 0,9 0,6 0,3 0,9 0,7 0,2 0,9 0,6 0,3 0,9 0,6 0,3 0,9 0,7 0,2 0,9 31 Alarm (Parts and Accessories Dept. accessory) 34 Differential locking (RWD only) 35 Robotized gearbox (available on 125 bhp and150 bhp FWD and RWD) -301,3 7,0-0,6 6,4 7,0-0,5 6,4 6,9-0,4 6,4 7,9 1,1 9,0 7,9 1,1 9,0 8,0 0,9 9,0 36 Additional CA (combi and bus only) Semi-glazed body 1 fixed window PLC instead of metal body 1 metal PLC Semi-glazed body 2 fixed window PLC instead of metal body 1 metal PLC Glazed body 1 fixed window sliding side door instead of metal body 1 metal sliding side door Glazed body 2 fixed window sliding side door instead of metal body 1 metal sliding side door 43 Rain/light sensor 2,8 4,6 7,4 3,8 4,3 8,1 5,0 3,1 8,1 4,3 3,9 8,1 4,3 3,9 8,1 5,1 3,0 8,1 12,4 22,8 35,2 18,1 21,5 39,6 24,2 15,4 39,6 20,9 19,0 39,9 20,9 19,0 39,9 25,3 15,0 40,3 1,1 11,4 12,5 2,8 10,5 13,4 5,0 10,4 15,4 0,9 16,3 17,3 0,9 16,3 17,3 4,5 17,6 22,1 10,3 28,7 38,9 15,5 29,6 45,2 24,2 24,3 48,4 16,9 31,7 48,5 16,9 31,7 48,5 23,6 28,6 52,2 45 Locking - Hands Free Access (involves 2-button key) 46 Locking - Super locking (SUPCPE) 1211,0 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 47 C-Box connectivity (option in R2 radio, involved via navigation) 48 Trajectory control - ESP + ASR -6,0 0,5 0,0 0,5 0,5 0,0 0,5 0,5 0,0 0,5 50 Puncture - Puncture kit (no spare wheel - jack and crank maintained) 5,7-31,3-25,6 5,2-30,9-25,6 4,8-30,5-25,6 9,5-37,4-27,8 8,4-33,0-24,6 7,5-32,1-24,6 52 Lighting - FBL (Fixed bending light as on Modus) - INVOLVES ESP 53 Lighting - Front fog lamps 54 Lighting - Follow me home 55 Complete wood trim 0,9 18,2 19,1 2,8 18,3 21,1

135 57 Trim for panel partition 1499,0 1,3 1,2 2,5 1,5 1,0 2,5 1,6 0,9 2,5 1,5 1,0 2,5 1,5 1,0 2,5 1,6 0,9 2,5 58 Trim for glass partition 1499,0 1,3 1,1 2,4 1,4 1,0 2,4 1,6 0,8 2,4 1,4 1,0 2,4 1,4 1,0 2,4 1,6 0,8 2,4 63 Wooden floor (all types for conso 3 variant) 5,1 25,7 30,8 8,0 29,5 37,5 10,8 35,4 46,2 5,5 37,5 43,0 4,0 37,1 41,1 8,1 41,7 49,8 70 Trunk lids 270 instead of 180-0,2 0,7 0,5-0,2 0,7 0,5-0,2 0,7 0,5-0,2 0,7 0,5-0,2 0,7 0,5 71 Glazed trunk lids 4173,0-1,4 5,9 4,5-1,2 5,7 4,5-1,0 5,5 4,5-2,0 6,5 4,5-2,0 6,5 4,5-1,7 6,2 4,5 72 Power take-off on gearbox (RWD) 350,0 6,8 0,7 7,5 6,8 0,7 7,5 6,9 0,6 7,5 74 Bluetooth mp3 CD radio (R2-08 v2) 509,0 1,4 0,3 1,7 1,4 0,2 1,7 1,5 0,2 1,7 1,4 0,2 1,7 1,4 0,2 1,7 1,5 0,2 1, l instead of 80l tank 1370,0 10,1 7,6 17,7 11,1 6,6 17,7 12,1 5,6 17,7 11,1 6,6 17,7 11,1 6,6 17,7 12,1 5,6 17,7 79 No RR running board (RWD) 5,3-17,7-12,4 5,3-17,7-12,4 4,5-16,9-12,4 81 Heated seat 1053,0 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 0,2 0,1 0,3 Wheelbase = E1, E2, E3 FRONT WHEEL DRIVE E1P1 E1 = 3182 mm FRONT WHEEL DRIVE E2P1 E2 = 3682 mm FRONT WHEEL DRIVE E3P1 E3 = 4332 mm PANEL VAN SINGLE WHEEL REAR DRIVE E2P2 E2 = 3682 mm TWIN WHEEL REAR DRIVE E2P2 E2 = 3682 mm TWIN WHEEL REAR DRIVE E3P2 E3 = 4332 mm xg Front Rear Total Front Rear Total Front Rear Total Front Rear Total Front Rear Total Front Rear Total Smoker's kit (portable ashtray + cigarette lighter) RR running board (FWD) - option on Panel vans, Combis and Buses NFA navigation (involves R1 or R2+C BOX radios) -0,4 10,9 10,5-0,3 10,8 10,5-0,3 10,8 10,5 506,0 2,1 0,4 2,5 2,1 0,3 2,5 2,2 0,3 2,5 2,1 0,3 2,5 2,1 0,3 2,5 2,2 0,3 2,5 62 Metal paint Right-hand sheet-metal sliding side door instead of no sliding side door Right-hand glass sliding side door instead of no sliding side door Right-hand sliding side door with fixed window instead of no sliding side door Left-hand sheet-metal sliding side door instead of no sliding side door Left-hand glass sliding side door instead of no sliding side door Left-hand sliding side door with fixed window instead of no sliding side door 11,4 18,3 29,7 14,8 16,4 31,2 18,7 12,5 31,2 17,6 14,0 31,6 17,6 14,0 31,6 21,3 10,6 32,0 14,2 22,8 37,0 19,5 21,5 41,0 24,6 16,4 41,0 22,9 18,1 41,0 22,9 18,1 41,0 27,3 13,7 41,0 12,6 20,2 32,8 16,9 18,7 35,6 21,4 14,2 35,6 19,9 15,7 35,6 19,9 15,7 35,6 23,7 11,9 35,6 11,4 18,3 29,7 14,8 16,4 31,2 18,7 12,5 31,2 17,6 14,0 31,6 17,6 14,0 31,6 21,3 10,6 32,0 14,2 22,8 37,0 19,5 21,5 41,0 24,6 16,4 41,0 22,9 18,1 41,0 22,9 18,1 41,0 27,3 13,7 41,0 12,6 20,2 32,8 16,9 18,7 35,6 21,4 14,2 35,6 19,9 15,7 35,6 19,9 15,7 35,6 23,7 11,9 35,6 72 Power take-off instead of none (FWD and RWD, incompatible with CA) -432,0 0,2 0,0 0,2 0,2 0,0 0,2 0,2 0,0 0,2 0,2 0,0 0,2 0,2 0,0 0,2 0,2 0,0 0,2 73 Mp3 CD radio with remote display and RCA (R1-08 v2) 509,0 1,4 0,3 1,7 1,4 0,2 1,7 1,5 0,2 1,7 1,4 0,2 1,7 1,4 0,2 1,7 1,5 0,2 1, Radio tuner only, with in jack line on fascia (R0-07) Cruise control and speed limiter (involves ADAC) 509,0 1,4 0,3 1,7 1,4 0,2 1,7 1,5 0,2 1,7 1,4 0,2 1,7 1,4 0,2 1,7 1,5 0,2 1, aluminium wheels instead of steel wheels (FWD only) -0,9-0,9-1,8-0,9-0,9-1,8-0,9-0,9-1,8 80 Underslung driver's seat instead of driver's seat - Arm rest 992,0 16,1 7,3 23,4 17,1 6,3 23,4 18,1 5,4 23,4 17,1 6,3 23,4 17,1 6,3 23,4 18,1 5,4 23,4 82 Individual passenger seats instead of fixed shelf bench seat on 1/2 bench seat back rest 2093,0-1,1-2,1-3,2-1,4-1,8-3,2-1,6-1,5-3,2-1,4-1,8-3,2-1,4-1,8-3,2-1,6-1,5-3,2 83 Pneumatic Suspension (FWD only) 1,0 27,2 28,2 0,9 27,3 28,2 0,8 27,5 28,2

136 47 ASSEMBLING A SECOND HEATER UNIT 1. Definition A second heater unit can be assembled in mass production. It is supplied via the heater housing's inlet tube (2). This supply is provided using branching pipes, a solenoid valve and an electric water pump to ensure a sufficient flow rate to both heater units. 2. Cooling system 2.1. Coolant system diagram Heater housing 2 Radiator inlet pipe 3 Solenoid valve 4 Electric water pump 5 Secondary heater unit up-to-date data on body guidelines (online body guidelines). Data status June

137 47 ASSEMBLING A SECOND HEATER UNIT 2.2. Connection to supply the additional circuit 2.3. The recommended zone for applying the two T-shaped branching pipes to supply the second heater unit with water is on the heater housing's inlet pipe (2) Recommendations for assembly For starting the vehicle, it is recommended to assemble the additional heating unit (5), as close as possible to the main heating unit. Additional drains must be added to the extra circuit. Important: If there is poor drainage, there is a risk of engine breakage. 3. General recommendations - Disconnect the battery. - Corrosion-proof the holes each time you drill into the sheet-metal. - Do not attach anything to the braking circuit or other piping. - Fill with coolant after the modification to the cooling system, checking the level again after the heater unit has been operated for the first time. - Leave sufficient clearance for the electric harness and solenoid valve to pass; 10mm from fixed parts, 20mm from mobile parts and 150mm from a source of heat. - Follow the start-up procedure to drain the air which could form in any of the pipes. - The water pipes must be held in place on the ends; spring clamps or elastic reserve screw clamps must be used for this. - Provide anti-gritting protection for the water pipes, either by protecting them or by using special reinforced pipes under the body. - Provide thermal protection for the water pipes as they pass near to the exhaust. - Install the water pipes' attachment lugs on existing holes if possible, avoiding contact between the pipes and the sharp corners of the attachment lugs. up-to-date data on body guidelines (online body guidelines). Data status June

138 48 INSTALLING ADDITIONAL AIR-CONDITIONING 1. Definition The assembly of additional air-conditioning can only be possible if the standard vehicle is fitted with mass production air-conditioning. 2. Mass production air-conditioning 2.1. Air-conditioning system diagram : Cabin evaporator 4: High pressure line from condenser to relief valve 2: Air-conditioning compressor 5: Low pressure line at relief valve outlet 3: Condenser 6: Line from compressor to condenser up-to-date data on body guidelines (online body guidelines). Data status June

139 48 INSTALLING ADDITIONAL AIR-CONDITIONING 3. Additional air-conditioning 3.1. Air-conditioning system diagram : * Cabin evaporator 8: ** High pressure line from secondary compressor to condenser 2: * Air conditioning compressor 9: ** Line from secondary condenser to condenser 3: * Condenser 10: ** High pressure line from condenser to secondary condenser 4: * High pressure line from condenser to relief valve 11: ** Low-pressure line from cabin evaporator to secondary evaporator 5: * Low pressure line at relief valve outlet 12: ** Evaporator strut/compressor high pressure line 6: ** Secondary condenser + ventilator(s) 13: ** Secondary evaporator strut/condenser high pressure line 7: ** Evaporator/Secondary relief valve *= Parts on mass production vehicle; ** = Additional air conditioning parts up-to-date data on body guidelines (online body guidelines). Data status June

140 49 INSTALLING AN ADDITIONAL BOILER 1. Definition An additional boiler can be associated with a secondary heater unit. It must be assembled as close as possible to the cabin heater housing's inlet pipe using branching pipes. An electric water pump is required to ensure a sufficient flow rate to the additional system. 2. Cooling system 2.1. Diagram showing additional boiler only : Heater housing 2: Radiator inlet pipe 3: Additional boiler 4: Water pump up-to-date data on body guidelines (online body guidelines). Data status June

141 49 INSTALLING AN ADDITIONAL BOILER 2.2. Diagram showing additional boiler + heater unit : Heater housing 2: Radiator inlet pipe 3: Additional boiler 4: Water pump 5: 3-way solenoid valve 6: Secondary heater unit up-to-date data on body guidelines (online body guidelines). Data status June

142 49 INSTALLING AN ADDITIONAL BOILER 2.3. Connection to supply the additional circuit The recommended zone for creating the connection is the radiator's inlet pipe (2) Recommendations for assembly For starting the vehicle, it is recommended to assemble the additional boiler (4) as close as possible to the main heater unit. Additional drains must be added to the extra circuit. Important: If there is poor drainage, there is a risk of engine breakage Recommendations on the cooling system - Disconnect the battery. - Corrosion-proof the holes each time you drill into the sheet-metal. - Do not attach anything to the braking circuit or other piping. - Fill with coolant after the modification to the cooling system, checking the level again after the heater unit has been operated for the first time. - Leave sufficient clearance for the electric harness and solenoid valve to pass; 10mm from fixed parts, 20mm from mobile parts and 150mm from a source of heat. - Follow the startup procedure to drain the air which could form in any of the pipes. - The water pipes must be held in place on the ends; spring clamps or elastic reserve screw clamps must be used for this. - Provide anti-gritting protection for the water pipes, either by protecting them or by using special reinforced pipes under the body. - Provide thermal protection for the water pipes as they pass near to the exhaust. - Install the water pipes' attachment lugs on existing holes if possible, avoiding contact between the pipes and the sharp corners of the attachment lugs. up-to-date data on body guidelines (online body guidelines). Data status June

143 49 INSTALLING AN ADDITIONAL BOILER 3 Connection on the cooling system The connection must be made on the fuel pipe between the tank and the manual repriming pump General recommendations on the fuel system It is prohibited to pierce the fuel tank. The connection to supply the boiler must be fitted with a non-return valve. 3. Boiler exhaust The boiler exhaust must not pass near to parts sensitive to the heat emitted by this exhaust. up-to-date data on body guidelines (online body guidelines). Data status June

144 Conversion Guideline NEW Movano X62 Part 3 - Chapter Version: April 2010 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany

145 CONTENTS CHAPTER DESCRIPTION: PAGE 53 FOLDING PARKING BRAKE 3 56 ROOF RACKS AND ROOF BARS TRAILER HITCH INTEGRATED STEP IN REAR BUMPER TACHOGRAPH SUNROOF AND EMERGENCY EXIT REAR AND FRONT SUSPENSION POWER TAKE-OFF, FRONT WHEEL DRIVE POWER TAKE-OFF, REAR WHEEL DRIVE POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE FUEL SUPPLY SYSTEM EXHAUST SYSTEM BRAKE SYSTEM TRANSLATION OF THE FUEL TANK FILLER PIPE MAXIMUM AUTHORIZED LOAD PER AXLE 46 up-to-date data on body guidelines (online body guidelines). Data status June 2009

146 53 FOLDING PARKING BRAKE The platform cab and chassis cab versions specific to campervans may be fitted with a folding parking brake as an option. The parking brake on all vehicles can be replaced by a folding model. The folding parking brake reference for ordering from the Opel dealer network is Upon replacement, the main cable must also be changed. FOLDING PARKING BRAKE 1 2 1: Parking brake 2: Main cable (under body) Operating the folding parking brake: - To engage: pull the lever up and then release. It goes back down into horizontal position. - To release: while holding down the push button, pull the lever up before returning it to a horizontal position. up-to-date data on body guidelines (online body guidelines). Data status June

147 56 ROOF RACKS AND ROOF BARS Fixing points for roof rack systems Movano vehicles are prepared for the fitting of a roof rack, except on models with an H3 high roof. The use of roof rack fixing points requires an inside connection and reinforcement plate between the roof and roof strut reinforcement. For safety reasons and to avoid damage to the roof, the vehicle approved roof rack system is recommended. Follow the installation instructions and remove the roof rack when not in use. Driving with a roof load increases the sensitivity of the vehicle to cross-winds and has a detrimental effect on vehicle handling due to the vehicle's higher centre of gravity. Distribute the load evenly and secure it properly with retaining straps. Adjust the tyre pressure and vehicle speed according to the load conditions. N.B: For passenger transport vehicles fitted with emergency exits in the roof, it is forbidden to block or even partially obstruct these openings when installing roof racks or roof bars. The following specified fixing points must be used. L1H1 / L1H L2H L1H1 L1H2 L2H2 X Y (+/-) Z X Y (+/-) Z X Y (+/-) Z N.B: The values are in mm and start from the axis of the front axle for the dimensions along X. up-to-date data on body guidelines (online body guidelines). Data status June

148 56 ROOF RACKS AND ROOF BARS L3H L4H L3H2 L4H2 X Y (+/-) Z X Y (+/-) Z N.B: The values are in mm and start from the axis of the front axle for the dimensions along X. up-to-date data on body guidelines (online body guidelines). Data status June

149 56 ROOF RACKS AND ROOF BARS Roof bars VEHICLE TYPE MAX. NUMBER OF BARS LENGTH * MASS OF ONE BAR * MAX. PERMISSIBLE LOAD ON THE ROOF (All fixing points must be used) L1H1 L1H2 3 approx mm approx. 2.4 kg 150 kg L2H2 4 L3H2 5 approx mm approx. 2.3 kg 200 kg L4H2 6 ATENTION: - The maximum permissible mass per bar on the roof is 50kg. - The maximum permissible mass on the roof is 200kg. *= Weight and length may vary depending on version. Roof racks VEHICLE TYPE NUMBER OF MOUNTINGS MASS OF THE ROOF RACK * MAX. PERMISSIBLE LOAD ON THE ROOF (All fixing points must be used) L1H1 approx. 22,7 kg 2 x 3 L1H2 approx. 22,0 kg L2H2 2 x 4 approx. 30,5 kg L3H2 2 x 5 approx. 34,5 kg L4H2 2 x 6 approx. 43,0 kg 200 kg 200 kg *= Weight may vary depending on version. up-to-date data on body guidelines (online body guidelines). Data status June

150 57.1 TRAILER HITCH A trailer hitch is available as an option for the panel van, combi models und chassis cabs; a tow bar can also be obtained as an accessory from your Opel dealer (all models, including chassis cab). The fitted tow bar must comply with European standard 94/20. The maximum permitted laden weight: of a braked trailer is 2500 kg, vehicles with a GVW of 3500 kg only of a braked trailer is 3000 kg, vehicles with a GWV of 4500 kg only of an unbraked trailer is 750 kg The permissible trailer loads are specified in the vehicle documents. In general, they are valid for gradients up to max. 12 %. The maximum permitted vertical coupling load is 100 kg. (vertical force allowable on the ball/towing system). Mounting points and fabrication tolerances are given as follows; it is essential that all these mounting points are used. The wiring diagram for this trailer hitch is given in chapter Tow bars on panel vans up-to-date data on body guidelines (online body guidelines). Data status June

151 57.1 TRAILER HITCH View from the bottom assembly, left side. 6 1 : Rear left suspension 2 : SCREW: HM12X : Rear section of the rear left sidemember 4 : Rear crossmember and skirt 5 : trailer hitch 6 : support trailer hitch 1.1. Front wheel drive version (Towing weight 2,5 t) : trailer hitch 2 : support left side 3 : support right side up-to-date data on body guidelines (online body guidelines). Data status June

152 57.1 TRAILER HITCH 1.2. Single wheel rear drive version (Towing weight 2,5 t) : trailer hitch 2 : support left side 3 : support right side 1.3. Twin wheel rear drive version (Towing weight 3 t) : trailer hitch 2 : support left side 3 : support right side up-to-date data on body guidelines (online body guidelines). Data status June

153 57.1 TRAILER HITCH 2. Tow bars on chassis cabs and chassis double cabs View from the bottom assembly, left side. 6 1 : Rear section of the rear left sidemember 2 : Trailer hitch 3 : Rear left suspension 4 : Support trailer hitch 5 : SCREW: HM12X : Extreme rear crossmember up-to-date data on body guidelines (online body guidelines). Data status June

154 57.1 TRAILER HITCH 2.1. Front wheel drive version (Towing weight 2,5 t) up-to-date data on body guidelines (online body guidelines). Data status June

155 57.1 TRAILER HITCH 2.2. Twin wheel rear drive version (Towing weight 3 t) up-to-date data on body guidelines (online body guidelines). Data status June

156 57.1 TRAILER HITCH 1. Dimensions trailer hitch ball trailer hitch ball type approved at 2.5t for vehicles with a maximum permissible laden mass of 3.5t GVW 3.0t for vehicles with a maximum permissible laden mass of 4.5t GVW Version 2,5 t oder oder 1.2. Version 3 t min = minimum up-to-date data on body guidelines (online body guidelines). Data status June

157 57.2 INTEGRATED STEP IN REAR BUMPER Integrated step in rear bumper for panel vans are available as an option or in after-sales. They are compatible with tow bars. Parts A, B and C must be installed for versions without tow bars Front wheel drive version A 1.2. Single wheel rear drive version B up-to-date data on body guidelines (online body guidelines). Data status June

158 57.2 INTEGRATED STEP IN REAR BUMPER 1.3. Twin wheel rear drive version C Example for integrated step in rear bumper for rear wheel drive version (the rear parking distance sensors is available as an option) up-to-date data on body guidelines (online body guidelines). Data status June

159 58 TACHOGRAPH Depending on the type of vehicle and the country where it is sold, the vehicle may be fitted with a digital tachograph as standard. It is also possible, on a vehicle not fitted with a tachograph as standard and depending on what the vehicle will be used for, to order the tachograph as an option. This is particularly the case in Europe for goods vehicles with a gross train weight of more than 3.5 t. It is therefore highly recommended to offer the chronotacygraph option for vehicles ordered with the trailer coupling option. If the customer is exempt from the use of a tachograph, it is prudent to get him to mention this on the order stating that he is lawfully exempt from tachograph use. N.B.: Fitting after manufacture is not possible. TACHOGRAPH POSITION IN THE ROOF CONSOLE up-to-date data on body guidelines (online body guidelines). Data status June

160 59 SUNROOF AND EMERGENCY EXIT The roofs of some bodywork versions are marked out for cutting out and installing a sunroof and/or an emergency exit. SUNROOF (Panel vans L1H1) (L2H2 Chassis double cab) SUNROOF AND EMERGENCY EXIT (Panel vans L2H2, L3H2 and L4H2) Sunroof Emergency Exit up-to-date data on body guidelines (online body guidelines). Data status June

161 59 SUNROOF AND EMERGENCY EXIT DIMENSIONS (Sunroof cut-out) (Emergency exit cut-out) N.B: For passenger transport vehicles fitted with emergency exits in the roof, it is forbidden to block or even partially obstruct these openings when installing roof racks or roof bars. up-to-date data on body guidelines (online body guidelines). Data status June

162 60 REAR AND FRONT SUSPENSION 1. Rear suspension The vehicle s rear suspension is created by leaf springs coupled to hydraulic shock absorbers. All rear wheel drive vehicles and some front wheel drive versions also have an anti-roll bar. The definition of the leaf springs varies depending on the type of vehicle and the maximum authorised laden weight (MMAC). N.B.: The polyurethane bump stops are in constant contact with the axle and therefore contribute to the stiffness of the rear suspension. REAR SUSPENSION FRONT and WHEEL DRIVE REAR SUSPENSION and REAR WHEEL DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

163 60 REAR AND FRONT SUSPENSION 1.1. Front wheel drive vehicles All front wheel drive vehicles are fitted with a single steel leaf spring. The leaf spring rate, flanged in the centre and with no articulation, is 71.7 N/mm with the exception of special campervan versions with wider tracks for which the rate is N/mm Single wheel rear drive vehicles All single wheel rear drive vehicles are fitted with two steel leaf springs. The rate of the single spring, flanged in the centre and with no articulation, is N/mm for a deflection of 0 to 80 mm and N/mm for a deflection of 80 to 180 mm. The origin of the travel corresponds to the spring in free state Twin wheel rear drive vehicles All twin wheel rear drive vehicles are fitted with three steel leaf springs. The rate of the single spring, flanged in the centre and with no articulation, is N/mm for a deflection of 0 to 100 mm and N/mm for a deflection of 100 to 200 mm. The origin of the travel corresponds to the spring in free state. 2. Front suspension The front suspension is a Macpherson strut type suspension. All rear wheel drive vehicles and some front wheel drive versions also have an anti-roll bar. The coil spring rate is 56 N/mm. FRONT AXLE up-to-date data on body guidelines (online body guidelines). Data status June

164 63.1 POWER TAKE-OFF, FRONT WHEEL DRIVE 1. Option V66 Power take-off is available as an option on front wheel drive versions. The option consists mainly of a free pulley attached to a support in place of the air-conditioning compressor and an automatic idler pulley. Power take-off on rear wheel drive see also chapter 63.2 and 63.3 The power take-off option is incompatible with the robotized gearbox. The power take-off option is incompatible with air conditioning. If a piece of equipment is not installed in place of the free pulley immediately, the free pulley can be left as it is. Its operation has been validated for normal use of the vehicle with no change to the belt changing frequencies. N.B.: It is not possible to fit power take-off to the vehicle at a later stage. However, a space is provided at the top of the engine to fit an additional piece of equipment driven by a second belt. FREE PULLEY : Alternator 2: Accessory belt 3: Free pulley 4: Crankshaft damper pulley 5: Water pump 6: Power-assisted steering pump up-to-date data on body guidelines (online body guidelines). Data status June

165 63.1 POWER TAKE-OFF, FRONT WHEEL DRIVE Care must be taken to comply with the following points for assembly minimizing the impact on engine reliability. - The weight of the equipment to be fitted in place of the free pulley must not exceed 7.5 kg. - The equipment must use the existing fastening points on the accessory support. - The pitch diameter of the equipment s drive pulley must be the same as that of the original pulley. The pitch diameter of the engine s free pulley is between mm and mm. - The position of the equipment s drive pulley must match the spatial coordinates of the free pulley. - The alignment of the belt s grooves must be the same as they were to start with. - The maximum power absorbed by the equipment replacing the engine s free pulley should not exceed 6 kw. - Characteristics of the original belt: Type Poly-V to 7 V, width: mm, length: 1,970 4 mm These criteria allow the use of the original accessory belt. The belt replacement frequency must be reassessed according to the vehicle's use cycle and may differ from that stated in the vehicle maintenance log book. Driving a piece of equipment may call for the use of the accelerated idle. 2. After-sales assembly This allows equipment to be fitted to a vehicle with air conditioning or to a vehicle without the power takeoff option. An additional pulley (ref ) can be fitted to the crankshaft damper pulley to operate an additional belt. Assembly of the additional crankshaft damper pulley means the original strut needs to be removed and a new fastening screw used (ref ). The tightening torque is 50 Nm, plus angular tightening of The additional belt can vary from 5 to 7 V and may be elastic for which a dynamic tensioner need not be used. Check that the additional belt is correctly lined up. The changing frequency for the additional belt should be assessed and the user notified. A space at the top of the engine is provided for fitting additional equipment. The fastenings for the additional equipment support should take into account its weight. The maximum power absorbed by the additional equipment should not exceed 6 kw. This type of assembly is incompatible with the robotised gearbox. Driving a piece of equipment may call for the use of the accelerated idle. up-to-date data on body guidelines (online body guidelines). Data status June

166 63.1 POWER TAKE-OFF, FRONT WHEEL DRIVE ADDITIONAL CRANKSHAFT DAMPER PULLEY ASSEMBLY : Alternator 2: Accessory belt 3: Air-conditioning compressor 4: Strut (to be removed) 5: Additional crankshaft damper pulley 6: Mounting bolt 7: Crankshaft damper pulley 8: Water pump 9: Power-assisted steering pump up-to-date data on body guidelines (online body guidelines). Data status June

167 63.1 POWER TAKE-OFF, FRONT WHEEL DRIVE ASSEMBLY EXAMPLE : Additional equipment 2 : Additional belt 3 : Additional crankshaft damper pulley 4 : Idler roller 5 : Additional equipment support up-to-date data on body guidelines (online body guidelines). Data status June

168 63.2 POWER TAKE-OFF, REAR WHEEL DRIVE 1. Option V66 Power take-off is available as an option on rear wheel drive versions. The option is comprised only of an additional pulley attached to the crankshaft pulley. Power take-off on front wheel drive see also chapter 63.1 and The power take-off option is incompatible with the robotised gearbox. Assembly of the additional crankshaft pulley is independent of the equipment fitted to the accessory face. The additional crankshaft pulley may be left as it is without any particular effect. ASSEMBLY EXAMPLE : Crankshaft pulley 2: Additional crankshaft pulley 3: Mounting bolt 4: Additional belt 5: Cooling compressor 6: Support up-to-date data on body guidelines (online body guidelines). Data status June

169 63.2 POWER TAKE-OFF, REAR WHEEL DRIVE Care must be taken to comply with the following points for assembly minimising the impact on engine reliability. - The weight of the equipment must not exceed 7.5 kg. - The equipment must use the existing mounting points on the engine block. - The equipment pulley and the additional crankshaft pulley must be aligned. - The maximum power absorbed by the equipment should not exceed 6 kw. - The additional belt can vary from 5 to 7 V and may be elastic for which a dynamic tensioner need not be used. - Check that the additional belt is correctly lined up. - The changing frequency for the additional belt should be assessed and the user notified. With this type of assembly, the whole equipment and support should be tested for vibratory resistance and the additional belt for slippage, jump and longevity. Driving a piece of equipment may call for the use of the accelerated idle. N.B.: There is no free pulley on rear wheel drive versions. DETAIL OF THE ADDITIONAL CRANKSHAFT PULLEY up-to-date data on body guidelines (online body guidelines). Data status June

170 63.2 POWER TAKE-OFF, REAR WHEEL DRIVE POSITION OF THE ADDITIONAL CRANKSHAFT PULLEY IN RELATION TO THE SUPPORT S MOUNTING POINTS up-to-date data on body guidelines (online body guidelines). Data status June

171 63.2 POWER TAKE-OFF, REAR WHEEL DRIVE N.B.: The three holes are threaded to a depth of 19 mm; M8 x 1.25 tapping 2. After-sales assembly The additional crankshaft pulley (ref ) can be fitted post-process. Assembly of the additional crankshaft pulley means the original strut needs to be removed and a new mounting bolt used (ref ). The tightening torque is 50 Nm, plus angular tightening of up-to-date data on body guidelines (online body guidelines). Data status June

172 63.3 POWER TAKE-OFF ON GEARBOX, 1. power take-off on gearbox option is available on rear wheel drive vehicles The option consists of the power take-off, assembled on the gearbox, an activation button on the instrument panel and an ECU. The power take-off on gearbox option is incompatible with the robotized gearbox. Power take-off on gearbox POWER TAKE-OFF ON GEARBOX Power take-off (PTO) for M9T engines is a production option which must be specified by the converter when the vehicle is ordered. 2. Power take-off production option assembly PTO requires a ZF4*001 type gearbox and cannot be ordered with a robotized gearbox. up-to-date data on body guidelines (online body guidelines). Data status June

173 63.3 POWER TAKE-OFF ON GEARBOX, 3. Power take-off/unit interface 1: Power take-off on ZF4 gearbox Nebenantrieb an Getriebe ZF4 2: Kit to mount a unit to the power take-off. A B 1 2 E C 3.1. Assembly flowchart Clean mating surface (1) Screw the studs (A) to the power take-off Tighten to a torque of 20 ± 3 N.m Put the sleeve into place (B) Put into place the joint (C), unit (pump, etc.), washers (D) and nuts (E) M10x150 Tighten the nuts (E) Torque of 50 ± 8 N.m D 3.2. Mechanical properties Maximum resulting torque 180 N.m PTO weight 6.3kg Drive/Engine rotation speed ratio 1.1 up-to-date data on body guidelines (online body guidelines). Data status June

174 67 FUEL SUPPLY SYSTEM Fuel tank capacity The mass production vehicle is delivered with an 80 litre fuel tank. A fuel tank with a capacity of 100 litres is available as an option. From the outside, the two tanks are identical. It is not possible to modify the capacity of the fuel tank. Any modification to the fuel tank will require the converter to apply for a new type approval. Precaution If disassembling and re-assembling the fuel tank, it is essential to maintain the assembly order of the fuel tank straps on the front zone. The vertical strap must be positioned above the strap that holds the fuel tank in place. Retaining straps Vertical strap up-to-date data on body guidelines (online body guidelines). Data status June

175 67 FUEL SUPPLY SYSTEM 100 and 80 litre fuel tank - REAR WHEEL DRIVE - Left-hand drive and 80 litre fuel tank - REAR WHEEL DRIVE - Right-hand drive : Filler pipe 2: Tank 3: Engine supply pipe 4: Diesel filter 5: Vapour absorber pipe 6: Intake assembly up-to-date data on body guidelines (online body guidelines). Data status June

176 67 FUEL SUPPLY SYSTEM 100 and 80 litre fuel tank - FRONT WHEEL DRIVE - Left-hand drive and 80 litre fuel tank - FRONT WHEEL DRIVE - Right-hand drive : Filler pipe 2: Tank 3: Engine supply pipe 4: Diesel filter 5: Vapour absorber pipe 6: Intake assembly up-to-date data on body guidelines (online body guidelines). Data status June

177 68 EXHAUST SYSTEM Transformation of the exhaust line Any transformation to the exhaust line can modify the vehicle's technical characteristics. This transformation can affect the correct operation of the engine and/or require new type approvals. (Power, noise, smoke emissions, etc.). up-to-date data on body guidelines (online body guidelines). Data status June

178 68 EXHAUST SYSTEM Front and rear wheel drive version. EXHAUST LINE ENGINE M9T 74 / 92 / 110 KW Euro 4 up-to-date data on body guidelines (online body guidelines). Data status June

179 68 EXHAUST SYSTEM Front and rear wheel drive version. EXHAUST LINE ENGINE M9T 74 / 92 / 110 KW Euro 5 up-to-date data on body guidelines (online body guidelines). Data status June

180 69 BRAKE SYSTEM Irrespective of the version, there is only one power brake system of 10 inches. The power brake system is located on the left for left-hand drive vehicles and on the right for right-hand drive vehicles. ESP is available as an option on front wheel drive versions. For more information, see also Chapter A sufficient distance must be maintained between brake lines and heat sources, sharp-edged or moving parts. - If the routing of the brake hoses, lines and cables has to be altered, avoid routing across sharp edges and through narrow cavities or near moving components - No other lines may be attached to brake hoses. - The brake cables must be routed without kinks. - Cover plastic lines, brake hoses and brake cables before carrying out any welding, drilling and grinding work or before working with cutting discs. If necessary, the plastic lines, brake hoses and brake cables should be removed. N.B: On no account should modifications be made to brake callipers, discs, sensors etc. Any modifications to brake components may result in these systems not functioning correctly and ultimately failing. The ESP option is not compatible with large-scale bodywork modifications and prohibits any major modifications to the vehicle's load distributions or centre of gravity. Work carried out incorrectly on the brake hoses, lines and cables may impair their function. This may lead to the failure of components or parts relevant to safety. up-to-date data on body guidelines (online body guidelines). Data status June

181 69 BRAKE SYSTEM LEFT-HAND FRONT WHEEL DRIVE / ABS / ESP* * RIGHT-HAND FRONT WHEEL DRIVE / ABS / ESP* 7* : Master cylinder and ESP/Emergency brake assist booster M/CYL 10/ : Left power brake system pipe 3 : Primary master cylinder rigid tube - ABS 4 : Secondary master cylinder rigid tube - ABS 5 : ABS / ASR / ESP* Hydraulic Block 6 : ABS / ASR / ESP*Hydraulic block support 7: ESP - sensor * 6 *= Vehicles with ESP only up-to-date data on body guidelines (online body guidelines). Data status June

182 69 BRAKE SYSTEM Engine cover All types version 1: FR RH WHEEL ABS BRAKE RIGID TUBE 2: FR LH WHEEL ABS BRAKE RIGID TUBE 3: RR LH SENSOR ABS BRAKE RIGID TUBE RR RH SENSOR ABS BRAKE RIGID TUBE 4: BRAKE RETAINER Under-body circuit Wheelbase 1, front wheel drive panel van version RR LH SENSOR ABS BRAKE RIGID TUBE RR RH SENSOR ABS BRAKE RIGID TUBE 2. RR LH INTM BRAKE RIGID TUBE RR RH INTM BRAKE RIGID TUBE 3. RR LH WHEEL SENSOR BRAKE RIGID TUBE 4. RR RH WHEEL SENSOR BRAKE RIGID TUBE 5. BRAKE RETAINER 3 up-to-date data on body guidelines (online body guidelines). Data status June

183 69 BRAKE SYSTEM Under-body circuit Wheelbase 2, front wheel drive panel van version RR LH SENSOR ABS BRAKE RIGID TUBE RR RH SENSOR ABS BRAKE RIGID TUBE 2. RR LH INTM BRAKE RIGID TUBE RR RH INTM BRAKE RIGID TUBE 3. RR LH WHEEL SENSOR BRAKE RIGID TUBE 4. RR RH WHEEL SENSOR BRAKE RIGID TUBE 5. BRAKE RETAINER 34 5 Under-body circuit Wheelbase 3, front wheel drive panel van version 1. RR LH SENSOR ABS BRAKE RIGID TUBE RR RH SENSOR ABS BRAKE RIGID TUBE 2. RR LH INTM BRAKE RIGID TUBE RR RH INTM BRAKE RIGID TUBE 3. RR LH WHEEL SENSOR BRAKE RIGID TUBE 4. RR RH WHEEL SENSOR BRAKE RIGID TUBE 5. BRAKE RETAINER up-to-date data on body guidelines (online body guidelines). Data status June

184 69 BRAKE SYSTEM Under-body circuit Wheelbase 2, front wheel drive chassis cab version RR LH SENSOR ABS BRAKE RIGID TUBE RR RH SENSOR ABS BRAKE RIGID TUBE 2. RR LH INTM BRAKE RIGID TUBE RR RH INTM BRAKE RIGID TUBE 3. RR LH WHEEL SENSOR BRAKE RIGID TUBE 4. RR RH WHEEL SENSOR BRAKE RIGID TUBE 5. BRAKE RETAINER 3 5 Under-body circuit Wheelbase 3, front wheel drive chassis cab version RR LH SENSOR ABS BRAKE RIGID TUBE RR RH SENSOR ABS BRAKE RIGID TUBE 2. RR LH INTM BRAKE RIGID TUBE RR RH INTM BRAKE RIGID TUBE 3. RR LH WHEEL SENSOR BRAKE RIGID TUBE 4. RR RH WHEEL SENSOR BRAKE RIGID TUBE 5. BRAKE RETAINER up-to-date data on body guidelines (online body guidelines). Data status June

185 69 BRAKE SYSTEM Front left-hand wheel sensor calliper All types version 1 2 1: FRONT WHEEL SPEED SENSOR 2: FR BRAKE HOSE 3: FR RH BRAKE DISC DIAM 48/48 DSQ 302x28 3 Front right-hand wheel sensor calliper All types version : FRONT WHEEL SPEED SENSOR 2: FR BRAKE HOSE 3: FR RH BRAKE DISC DIAM 48/48 DSQ 302x28 up-to-date data on body guidelines (online body guidelines). Data status June

186 69 BRAKE SYSTEM Rear left-hand wheel sensor calliper All types version 1: RR LH BRAKE DISC DIAM 48 DSQ 305/12 2: RR WHEEL SPEED SENSOR 3: HOSE SUPPORT LUG 4: RR BRAKE HOSE Rear right hand wheel sensor calliper All types version 1: RR LH BRAKE DISC DIAM 48 DSQ 305/12 2: RR WHEEL SPEED SENSOR 3: HOSE SUPPORT LUG 4: RR BRAKE HOSE up-to-date data on body guidelines (online body guidelines). Data status June

187 78 TRANSLATION OF THE FUEL TANK FILLER PIPE Some conversions require translation of the fuel tank filler pipe. The following recommendations can be used to offset, by up to 150 mm, the position of the filler pipe along the Y axis. However, the position along the X and Z axes cannot be modified. To carry out the translation, the standard connecting sleeve between the tank and the filler pipe needs to be replaced with a special sleeve. EXAMPLE OF SLEEVE 388 MAX 188 L A A-A A 1: Fuel tank side 2: Filler pipe side L: From 0 to 150 mm The sleeve material must be compatible with its use. The sleeve must be held in place on the filler pipe and on the fuel tank by elastic reserve clamps. Assembly must comply with legislation in force, in particular Directive 70/221/EEC and Directive 2000/8/EC for Europe: For two minutes, the fuel system (tank, pipe, sleeve) fixed as on the vehicle, must be exposed to flame. There must be no leakage of fuel. Three tests must be carried out on three different tanks half filled with fuel. It may be possible to thermally protect the filler sleeve to avoid the need for the flame test. When fitted, the sleeve must not be twisted or trapped in such a way that might hinder filling. The filler pipe must be held in place and the place where it passes through the floor must be sealed. For translations of more than 60 mm, the body needs to be cut. After cutting, the filings or shavings must be vacuumed and a corrosion inhibitor used; please refer to the Specific Corrosion Guidelines. up-to-date data on body guidelines (online body guidelines). Data status June

188 78 TRANSLATION OF THE FUEL TANK FILLER PIPE STANDARD ASSEMBLY TRANSLATION OF THE FILLER PIPE : Fuel tank 2: Filler pipe 3: Sleeve 4: Area of body to be modified up-to-date data on body guidelines (online body guidelines). Data status June

189 79 MAXIMUM AUTHORIZED LOAD PER AXLE The maximum authorized load per axle depends on the version and the maximum authorized laden weight (MMAC). The values are given in the table. Front axle (kg) Rear axle (kg) Front wheel drive, MMAC 2,800 kg 1,550 1,650 Front wheel drive, MMAC 3,300 kg 1,650 1,900 Front wheel drive, MMAC 3,500 kg 1,790 2,100 Single wheel rear drive, MMAC 3,500 kg 1,790 2,300 Twin wheel rear drive, MMAC 4,500 kg 1,790 3,200 After vehicle conversion, the weight per axle must be lower than the maximum authorised loads and the vehicle weight must be lower than the maximum authorised laden weight. N.B.: The maximum authorised loads per axle and the maximum authorized laden weight are shown on the manufacturer s plate. up-to-date data on body guidelines (online body guidelines). Data status June

190 Conversion Guideline NEW Movano X62 Part 4 - Chapter Version: April 2010 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany

191 CONTENTS CHAPTER DESCRIPTION: PAGE 101 POSITION OF ELECTRICAL GROUNDS BATTERY LOCATION ELECTRICAL CURRENTS AVAILABLE ADAPTATION CONNECTOR, KPD OPTION CONVERSION UNIT, KC6 OPTION CELL WIRING CONNECTION, ADPCNC OPTION ELECTRICAL CONNECTIONS V CURRENT DISTRIBUTION ENGINE RUNNING INFORMATION ACCELERATED IDLE, UF3 OPTION PARKING BRAKE INFORMATION POSITION OF WIRING INSTALLATION ABS WIRING INSTALLATION INSTALLATION OF ELECTRICAL COMPONENTS ENGINE INTERCONNECTIONS UNIT PASSENGER COMPARTMENT FUSE-RELAY BOX MULTIPLEXED CAN NETWORK LIGHTS AND SIGNALLING LIGHT INFORMATION DAYTIME RUNNING LIGHTS SWITCH INSTALLATION WATT SIDE INDICATORS INSTALLATION OF AN ADDITIONAL BATTERY DRIVER S AUDIBLE SEAT BELT WARNING EXTENDED REAR WIRING, UNF OPTION MODIFIABLE ECU SETTINGS INTERIOR LIGHTING ELECTRIC PLUG FOR TRAILERHITCH REMOTE ENGINE START AND STOP DEACTIVATION OF AIRBAGS AND SEAT BELT PRETENSIONERS CONNECTION TO THE NEGATIVE BATTERY TERMINAL CONNECTION TO THE POSITIVE BATTERY TERMINAL ROUTING AIRBAG AND PRE-TENSIONER WIRING 73 up-to-date data on body guidelines (online body guidelines). Data status June 2009

192 101 POSITIONS OF ELECTRICAL GROUNDS The vehicle has several electrical and electronic grounds. Before working on the vehicle, refer to the Electrical Connections sheet. The electricity sheets of the General Technical Conversion Guide must also be consulted before any modifications are made to the vehicle. An electrical ground, on a welded stud, is recommended for each additional piece of electrical equipment. The tightening torque for the grounding nuts on the M6 studs is 8 Nm ± 15% (use of a calibrated torque wrench is recommended). LOCATION OF THE ELECTRICAL GROUNDS N.B.: Electronic grounds may not be used. up-to-date data on body guidelines (online body guidelines). Data status June

193 101 POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON DASHBOARD CROSS MEMBER : Ground MAM-32 2: Ground MAN-32 3: Do not use up-to-date data on body guidelines (online body guidelines). Data status June

194 101 POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS IN THE ENGINE COMPARTMENT : Ground MW-32 2: Ground MAJ-12 3: Ground MAS-32 4: Do not use up-to-date data on body guidelines (online body guidelines). Data status June

195 101 POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON THE PANEL VAN EXTREME REAR PILLAR 1 2 1: Ground MGA-7 2: Do not use up-to-date data on body guidelines (online body guidelines). Data status June

196 101 POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON THE CHASSIS : Ground MAE 2: Do not use up-to-date data on body guidelines (online body guidelines). Data status June

197 102 BATTERY LOCATION The battery is located in the left-hand side door sill. To get to the battery, the plastic door sill trim needs to be removed. The battery is an L6 110 Ah battery. BATTERY LOCATION To connect anything to the battery, please refer to the Connection to the positive battery terminal and Connection to the negative battery terminal sheets. up-to-date data on body guidelines (online body guidelines). Data status June

198 OPEL MOVANO 103 ELECTRICAL CURRENTS AVAILABLE The tables below show the different electrical currents available (in amps) depending on engine type and options. The vehicles come with a 110 Ah battery and a 180 A alternator. Warning: The value given is the worst-case-scenario average value available when the engine is running. The electrical equipment added is given priority over the vehicle s basic additional electric heating (thermoplunger) and may thus jeopardise the vehicle s comfort level. Note: Any electrical equipment added must be fused. These fuses must have a value appropriate to the equipment s consumption and the cross section of the wiring. For the electrical assessment calculation method, please refer to the Energy Management sheet. To find out how the accelerated idle works, please refer to the Accelerated idle sheet. CURRENTS AVAILABLE FOR FRONT WHEEL DRIVE VERSIONS Engine M9T (74 kw) M9T (92 kw) M9T (110 kw) Base CA Base CA Base CA Version With accelerated idle (rpm) Without acc. idle DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL: Day Running Lights (Automatic operation of lights) CA: Air conditioning up-to-date data on body guidelines (online body guidelines). Data status June

199 OPEL MOVANO 103 ELECTRICAL CURRENTS AVAILABLE CURRENTS AVAILABLE FOR REAR WHEEL DRIVE VERSIONS Engine M9T (74 kw) M9T (92 kw) M9T (110 kw) Base CA Base CA Base CA Version Without acc. With accelerated idle (rpm) idle DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL* Without DRL* DRL: Day Running Lights (Automatic operation of lights) CA: Air conditioning up-to-date data on body guidelines (online body guidelines). Data status June

200 104 6 PIN- and 2 PIN-CONNECTOR Before working on the vehicle, refer to the Electrical Connections sheet. This option provides: - A stand-by connector in the dashboard area. - A stand-by connector in the right-hand B pillar (lateral zone). These connectors provide engine running information, activate the accelerated idler and provide power supplies. 1. Dashboard area connector The connector is located on the left-hand side near to the panel feed-through ring, the passenger compartment fuse and relay box and the bonnet opening lever. It is secured on the dashboard wiring using a link. An excess length is provided for the connection. The connector is in the same position for both left-hand and right-hand drive vehicles. LOCATION 1 1: Connector position 2: Passenger compartment relay and fuse box 2 up-to-date data on body guidelines (online body guidelines). Data status June

201 104 6 PIN- and 2 PIN-CONNECTOR ASSIGNMENT OF CONNECTOR WAYS Way number Way 1 (3ADJ) Way 2 (BMT1) Way 3 (SBP4) Way 4 (MAN32) Way 5 Way 6 Assignment Accelerated idle control (wire cross section 0.5 mm²) Engine running information Shared 10 A fuse Power supply + 12 V offloaded current (wire cross section 1 mm²) distribution Ground (wire cross section 1.5 mm² large enough to adapt to the +12V offloaded current distribution) Reserve Reserve The counterpart to this connector is available from the Opel dealer network under part number CONNECTION KIT N.B.: The permanent accumulated currents of the following 2 ways must not exceed 8 A: - Way 2: "Running Engine" information - Way 3: + 12 V current distribution. (activated from the +ACC (+ accessory) position, 1 st notch on the ignition key). These ways are protected by 10 A fuse F28 in the passenger compartment fuse and relay box (BFRH). For more power, ways 2 and 3 need to be relayed. When the engine is off, the energy management system can offload these functions to save enough battery power to start the vehicle. up-to-date data on body guidelines (online body guidelines). Data status June

202 104 6 PIN- and 2 PIN-CONNECTOR 2. B pillar connector The connector is located in the right-hand B pillar behind the plastic trim. LOCATION ASSIGNMENT OF CONNECTOR WAYS N.B.: Way number Way 1 (BP23) Way 2 (MAN32) Assignment +12 V direct battery power supply for maximum consumption of 40 A (wire cross section 7 mm²). 50 A fuse protection. Ground (wire cross section 7 mm² large enough to adapt to the current of the +12V battery). The maximum permanent current of this power supply must not exceed 40 A. This line is protected by 50 A fuse F9 in the engine interconnections unit. up-to-date data on body guidelines (online body guidelines). Data status June

203 104 6 PIN- and 2 PIN-CONNECTOR Important: This power supply is connected directly to the battery. The vehicle is therefore not protected by the energy management system. Risk of battery draining. The counterpart to this connector is already fitted to the wiring but it is still necessary to obtain the contacts for this connector (reference: ) Connector Wire cross section Contact part number Supplier reference Supplier 3 to 6 mm² P TYCO 7 to 10 mm² P TYCO 3. Location of grounds associated with the KPD option The grounds (MAN32-A and MAN32-B) for the 6-way and 2-way connectors are grouped together on a single stud on the right-hand support of the dashboard cross member. MAN32-A MAN32-B GROUNDS 4. Activation of the accelerated idle To activate the accelerated idle speed, way 1 of the 6-way connector must be grounded. up-to-date data on body guidelines (online body guidelines). Data status June

204 104 6 PIN- and 2 PIN-CONNECTOR EXAMPLE OF CONNECTION (ACCESSORY CONTROL) A + 12V ACC C D E B A: +12 V accessory relay power supply B: Accessory control of the accelerated idle C: Way 1 of the 6-way connector D: Switch E: Relay with a freewheel diode N.B.: The following 20 A relay can be used: RENAULT part number: ; (Cartier supplier reference: ) up-to-date data on body guidelines (online body guidelines). Data status June

205 OPEL MOVANO 105 CAN BUS- INTERFACE MODULE, KC6 OPTION Before working on the vehicle, refer to the Electrical Connections sheet. The interface module is available as an option on all versions. This module can be used to recover certain information that is available on the multiplexed network. The module is attached on the right-hand side of the central dashboard console for both left- and righthand drive vehicles. To recover the information from the interface module, the connection kit (part number ) needs to be obtained (harness length: 600 mm). CONNECTION KIT For left-hand drive, the connection requires the storage box to be removed. UNIT LOCATION 1 2 N.B.: 1: Interface module 2: Connection kit To make sure that each wire in the connection kit is correctly assigned, it is advisable to check the electrical continuity of the wiring before connection. The unused wires should be insulated separately using a heat-shrinkable sleeve. up-to-date data on body guidelines (online body guidelines). Data status June

206 106 CELL WIRING CONNECTION FOR CHASSIS CAB AND PLATFORM CAB Before working on the vehicle, refer to the Electrical Connections sheet. This option, which is available for the chassis cab and the platform cab, provides 2 stand-by connectors in the right-hand B pillar behind the plastic trim. These connectors provide engine running information, can be used to recreate the electrical functions of the van in a separate cell and provide power supplies. LOCATION 2-way connector 16-way connector up-to-date data on body guidelines (online body guidelines). Data status June

207 106 CELL WIRING CONNECTION FOR CHASSIS CAB AND PLATFORM CAB ASSIGNMENT OF 2-WAY CONNECTOR WAYS Way number Way 1 (BP23) Way 2 (MAN32) Assignment +12 V direct battery power supply for maximum consumption of 40 A (wire cross section 7 mm²). 50 A fuse protection. Ground (wire cross section 7 mm² large enough to adapt to the current of the +12 V battery). N.B.: The maximum permanent current of this power supply must not exceed 40 A. This line is protected by 50 A fuse F9 in the engine interconnections unit. Important: This power supply is connected directly to the battery. The vehicle is therefore not protected by the energy management system. Risk of battery draining. The counterpart to this connector is already fitted to the wiring but it is still necessary to obtain the contacts for this connector (reference: ) Connector Wire cross section Contact part number Supplier reference Supplier to 6 mm² P TYCO 7 to 10 mm² P TYCO up-to-date data on body guidelines (online body guidelines). Data status June

208 106 CELL WIRING CONNECTION FOR CHASSIS CAB AND PLATFORM CAB ASSIGNMENT OF 16-WAY CONNECTOR WAYS N.B.: The width of the contact for ways 1, 8, 9 and 16 is 2.8 mm; the width for the other ways is 1.5 mm. Way number Way 1 (20BK) Way 2 (87T) Way 3 (BPT2) Way 4 (LPG) Way 5 (34D) Way 6 (34B) Way 7 (BMT1) Way 8 (SBP4) Way 9 (142K) Way 10 (65A) Way 11 (13M) Way 12 (LPD) Way 13 (34C) Way 14 (34A) Way 15 Way 16 (20W) Assignment Analogue door closing control signal (wire cross section 2 mm²) Logical boot lock switch information signal (wire cross section 0.35 mm²) Delayed +12 V 2 A power supply for courtesy lights, controlled by the passenger compartment ECU (UCH) (wire cross section 0.5 mm²) 3 A left-hand side light power supply (wire cross section 0.5 mm²) + right-hand rear speaker (wire cross section 1 mm²) - left-hand rear speaker (wire cross section 1 mm²) Engine running information, 10 A fuse shared by ways 7 and 8 (wire cross section 1.5 mm²) +12 V offloaded current distribution power supply, 10 A fuse shared by ways 7 and 8 (wire cross section 1.5 mm²) Analogue door closing control signal (wire cross section 2 mm²) 5 A 3 rd brake light power supply (wire cross section 0.5 mm²) Progressive ground for 2 A courtesy lights, controlled by the passenger compartment ECU (UCH) (wire cross section 0.35 mm²) 3 A right-hand side light power supply (wire cross section 0.5 mm²) - right-hand rear speaker (wire cross section 1 mm²) + left-hand rear speaker (wire cross section 1 mm²) Reserve Analogue door super lock signal (wire cross section 2 mm²) up-to-date data on body guidelines (online body guidelines). Data status June

209 106 CELL WIRING CONNECTION FOR CHASSIS CAB AND PLATFORM CAB Important: The signals for ways 1, 2, 9 and 16 can only be used to control standard locking (panel van locks) and are only suitable for 3 locks. For any other use, a relay has to be used. For ways 11 and 13, if a relay is used, a panel switch should be added to replace the 13M link. (See courtesy light sheet). Ways 7 and 8 are protected by a single 10 A fuse (F28). The accumulated currents of the 2 lines must not exceed 8 A. Above 8 A, a relay has to be used. When the engine is off, the energy management system can offload these functions to save enough battery power to start the vehicle. The counterpart to this connector is already fitted to the wiring but it is still necessary to obtain the contacts for this connector (reference: ) Connector Wire cross section Contact part number Supplier reference Supplier 1,5 : 0.35 to 0.75 mm² CL2S1160 FCI 1,5 : 1 to 2 mm² CL2S2160 FCI ,8 : 0.35 to 0.75 mm² CL3S1160 FCI 2,8 : 1 to 2.5 mm² CL3S2160 FCI 2,8 : 2.5 to 5 mm² CL3S3120 FCI up-to-date data on body guidelines (online body guidelines). Data status June

210 107 ELECTRICAL CONNECTIONS 1. General Overview Before carrying out any operations, it is imperative that the battery s negative terminal be disconnected. The negative terminal should only be reconnected after ensuring that all the disconnected elements have been reconnected (especially the steering wheel controls). As the vehicle is multiplexed, any change to the wiring may cause the vehicle to malfunction or to break down. It is therefore strongly advised not to make any changes to the original wiring. Modification of the CAN network wiring is prohibited. If any devices are added, the power consumption requirements must be compared with the authorised values given in the table in the Available currents sheet. Use of electrical options, such as KC6, KPD and KC5, is recommended. Please see the corresponding sheets. The rating of a fuse is a wiring protection value and not an available energy value. It is therefore forbidden to change the fuse ratings. The covering protecting the wires must be preserved and maintain its effectiveness after modification. The electricity pages of the General Technical Conversion Guide must also be consulted before any modifications are made to the vehicle. Failure to follow these recommendations will invalidate the manufacturer s warranty. 2. Electrical power Any electrical power greater than 10 Ah sampled on the main vehicle battery must be sampled with the engine running (unless there is a multi-battery with coupling device architecture). With the engine off, up to 10 Ah may be sampled on the main battery, e.g. 20 A for 30 minutes, 5 A for 2 hours, etc. Comment: The vehicle has an energy management system that alerts the driver if the battery load reaches an abnormal level. Any electrical sampling that is too big with the engine running is likely to result in misunderstandings and customer complaints (Alert message repeatedly displayed on the dashboard). Any electrical power sampled on the vehicle battery must be sampled on the battery terminal block. Please refer to the Connection to battery terminal sheets. All power supplies must be fused. up-to-date data on body guidelines (online body guidelines). Data status June

211 107 ELECTRICAL CONNECTIONS 3. Anti-lock braking system (ABS) Under no circumstances may a power cable be fitted less than 100 mm from any component of the ABS system (ABS unit, ECU, wiring and sensors). In addition, for the anti-lock braking system (ABS) to function correctly, notwithstanding any specific agreement, we advise against servicing the brake contactor on the pedal assembly. The ABS wiring may not be extended. 4. Alternator The connection of the alternator to the vehicle s electrical systems is multiplexed. Any servicing of electrical connections on the alternator will lead to malfunction of the alternator and/or an electronic ECU, which may result in the destruction of these systems and/or cause the vehicle to break down. As a result, any connection on the alternator is prohibited. The alternator communicates with the vehicle s electronic ECUs. Therefore, the alternator cannot be changed unless it is changed for an alternator that is exactly the same as the original. Failure to follow this rule will lead to malfunction of the alternator and/or an electronic ECU, which may result in the destruction of these systems and/or cause the vehicle to break down. up-to-date data on body guidelines (online body guidelines). Data status June

212 V CURRENT DISTRIBUTION Before working on the vehicle, refer to the Electrical Connections sheet. The +12 V current distribution power supply is a power supply that can be temporarily unavailable to save the battery. An energy management system constantly checks the battery charge status. Connecting electrical accessories while the engine is off will discharge the battery. Do not exceed the maximum power consumption. Electrical accessories that are connected must comply with requirements laid down in DIN VDE the electromagnetic compatibility This +12 V current distribution power supply is available on the connectors of the KPD and KC5 options but also through the accessory sockets. Please refer to the sheets dealing with the KPD and KC5 options for further information. A +12 V current distribution fused power supply can be obtained by using the accessory sockets (or cigar lighter). Two accessory sockets are available on the dashboard. - Upper accessory socket (10 A fuse F2 and F3 in the passenger compartment fuse and relay box), - Lower accessory socket (10 A fuse F4 in the passenger compartment fuse and relay box), Depending on the version and options, an accessory socket is possible in the panel van s loading area. The socket is located on the left-hand extreme rear pillar. - - Rear accessory socket (10 A fuse F4 in the passenger compartment fuse and relay box), Important: This +12 V current distribution supply is temporarily cut off when the starter motor is activated. Do not connect any current-delivering accessories, e.g. electrical charging devices or batteries. up-to-date data on body guidelines (online body guidelines). Data status June

213 V CURRENT DISTRIBUTION LOCATION OF ACCESSORY SOCKETS ON THE DASHBOARD LOCATION OF ACCESSORY SOCKETS ON THE LOAD COMPARTMENT up-to-date data on body guidelines (online body guidelines). Data status June

214 110 ENGINE RUNNING INFORMATION Before working on the vehicle, refer to the Electrical Connections sheet. In the event of a lot of electrical power being taken, the electrical assessment may have an adverse effect on the battery charge. The power take-off therefore needs to be conditioned with the engine running information. This information can be accessed inside the vehicle in four different ways depending on the vehicle s equipment level: - for all vehicles using a specific electrical wire, - with the KPD option (adaptation connector) - see corresponding sheet. - with the KC5 option (cell connector adaptation) - see corresponding sheet. - with the KC6 option (conversion unit) - see corresponding sheet. A violet 0.5 mm² idle cable is located underneath the dashboard and can be used to recover the engine running information. This cable can be found behind the passenger compartment fuse and relay box in the KPD connector location. This cable is directly connected to the engine ECU. When the engine is running, it is connected to the ground but otherwise the circuit is open. Care therefore needs to be taken when connecting this cable: - Follow the wiring instructions in the General Technical Conversion Guide. - Never connect a consumer or relay greater than 400 ma to this cable. - Use a relay with a free wheel diode to control the system that has been added. CONNECTION DIAGRAM A +12 V D C B 1 3 A: +12 V circuit distribution power supply B: Engine running information available on the idle cable (connection 48D) C: Additional equipment D: Relay with a free wheel diode E: +12 V battery power supply +12 V E up-to-date data on body guidelines (online body guidelines). Data status June

215 111 ACCELERATED IDLE, UF3 OPTION The accelerated idle function is used to increase the vehicle s idle speed to give more power and/or electrical energy. The standard vehicle idle is 800 rpm. The accelerated idle s default value is 1,000 rpm. This value may be set to between 1,000 and 2,000 rpm in 100 rpm increments. This is done using the Clip diagnostics tool in the Opel dealer network. For an idle value between 1,000 and 1,300 rpm, the vehicle can be running (except for vehicles with a robotized gearbox in which case the vehicle must be stopped). Above this, the vehicle must be stopped. It is also possible to have the accelerated idle function with the KPD option. Please refer to the relevant sheet. N.B.: The accelerated idle function is not possible on a vehicle that does not have the UF3 option or the KPD option. 1. Operation and safety The driver controls operation of the accelerated idle by pressing a button on the dashboard. The accelerated idle is activated approximately 4 seconds after engine start-up, even if the button is on when the engine is started. The function is deactivated if the water temperature warning light or any other warning light highlighting an engine risk comes on. For vehicles with a mechanical gearbox: - Deactivation possible at a vehicle speed of between 0 and 30 km/h (idle between 1,000 and 1,300 rpm). - Deactivation possible at zero vehicle speed (idle greater than 1,300 rpm). - Disengaging the clutch deactivates the accelerated idle. - Above an idle speed of 1,300 rpm, pressing the accelerator pedal deactivates the accelerated idle. For vehicles with a robotized gearbox: - Activation in neutral gear. - Pressing the accelerator pedal deactivates the accelerated idle. - Deactivation for any speed above zero. up-to-date data on body guidelines (online body guidelines). Data status June

216 112 PARKING BRAKE INFORMATION Before working on the vehicle, refer to the Electrical Connections sheet. The parking brake information is grounded when the brake is applied. This connection can be accessed on the handbrake. HANDBRAKE 1 1: Handbrake 2: Handbrake cable 3: Handbrake cable (disconnected) up-to-date data on body guidelines (online body guidelines). Data status June

217 112 PARKING BRAKE INFORMATION To recover this information, it must be sent using a relay with a free wheel diode. For example, the following OPEL parts may be used: 40 Amp relay, Cartier Reference: Amp relay, Cartier Reference: CONNECTION DIAGRAM +ACC B A B A: Handbrake information B: Dry contact to recover handbrake information +ACC: accessory power supply, 1 st notch on the ignition key Important: The relay s power supply must not be taken directly from the battery +terminal. up-to-date data on body guidelines (online body guidelines). Data status June

218 113 WIRING INSTALLATION Before working on the vehicle, refer to the Electrical Connections sheet. PANEL VAN WIRING LOCATIONS up-to-date data on body guidelines (online body guidelines). Data status June

219 113 WIRING INSTALLATION CHASSIS CAB WIRING LOCATIONS N DESCRIPTION 1 Front bumper wiring 2 Door sill light wiring 3 Engine wiring 4 Dashboard wiring 5 Multimedia wiring 6 Front door, sliding door wiring 7 Additional side light wiring 8 Rear pad wear indicator wiring 9 Right and left-hand side swing door wiring 10 Coupling and bumper wiring 11 Under-body wiring 12 Rear wiring 13 Front pad wear indicator wiring Wiring locations for platform cabs are similar to those for chassis cabs. up-to-date data on body guidelines (online body guidelines). Data status June

220 114 ABS WIRING INSTALLATION Additional power cables may not be installed less than 100 mm from any ABS system components (ECU, wiring and sensors), electronic units or ECUs. For more information, see also Chapter 69 ROUTING OF WIRING AND BRAKE PIPES (wiring in green, pipes and others in blue) : Central and rear section ABS wiring (in green) 2: Front section ABS wiring (in green) 3: ABS unit and ECU 4: ABS sensors N.B.: Modifications are not permitted to ABS wiring up-to-date data on body guidelines (online body guidelines). Data status June

221 115 INSTALLATION OF ELECTRICAL COMPONENTS MARKING DESCRIPTION 1 BFRH (passenger compartment fuse-relay box) 2 BIM (engine interconnections unit) 3 Thermoplunger unit USM (Undercoat Switching Module) 4 Control unit: voltage power supply control 5 Injection computer 6 (option) BVR ECU (robotised gearbox) Front wheel drive 7 ABS/ESP hydraulic unit 8 (option) BVR ECU (robotised gearbox) Rear wheel drive 9 Airbag detection unit 10 (option) Parking assistance computer 11 (bus option) BFRH (passenger compartment fuse-relay box) 12 (option) KC6 (Conversion Unit) 13 UCH (Passenger Compartment Unit) up-to-date data on body guidelines (online body guidelines). Data status June

222 117 ENGINE INTERCONNECTIONS UNIT (BIM) The engine interconnections unit can be found to the left of the engine compartment in front of the shock absorber mounting. This unit contains the power supply fuse board and the protection and switching unit (UPC). POSITION OF UNIT IN THE ENGINE COMPARTMENT Warning: These indications are given for information purposes only. Changing a fuse or connecting electrically to a UPC connection is prohibited. up-to-date data on body guidelines (online body guidelines). Data status June

223 117 ENGINE INTERCONNECTIONS UNIT (BIM) INTERIOR OF THE ENGINE INTERCONNECTIONS UNIT Fuse Type Rating Connection Function F F F F4 Maxi Fuse 40 A BP8 ABS ECU F5 Maxi Fuse 50 A BP23 Conversion F6 Maxi Fuse 50 A BP9 Additional heating relay 1 F7 Maxi Fuse 70 A BP91 Additional heating relay 2 F8 Maxi Fuse 70 A BP11 Rear lights, passenger compartment fuse-relay box, diesel heater resistance F9 Maxi Fuse 70 A BP12 Passenger compartment relay and fuse box F10 F10 Maxi Fuse Maxi Fuse 50 A 40 A BP71 Motor fan relay 3, motor fan relays (rating depending on vehicle spec.) F11 Maxi Fuse 40 A F11 Maxi Fuse 50 A F11 Maxi Fuse 60 A BP7 Motor fan speed relay 1, Motor fan speed relay 2 (rating depending on vehicle spec.) F12 Maxi Fuse 40 A BP1C Starter motor F13 Maxi Fuse 60 A BP9E Heating interface unit F14 Maxi Fuse 60 A BP9J Heating interface unit F15 Maxi Fuse 70 A BP17 Diesel glow plug relay unit F16 Maxi Fuse 40 A BP36 Gearbox electro pump unit relay F16 Maxi Fuse 50 A Fuse box 2 up-to-date data on body guidelines (online body guidelines). Data status June

224 117 ENGINE INTERCONNECTIONS UNIT (BIM) PROTECTION AND SWITCHING UNIT Fuse Type Rating Conn. Function F1 Min. Fuse 7.5 A LPD LPDA Right side light F2 Min. Fuse 7.5 A LPG LPGA Left side light F3 Min. Fuse 10 A CPDB CPD Right dipped beam lights F4 Min. Fuse 10 A CPG Left dipped beam lights F5 Min. Fuse 20 A 8E 8F Fog lamps F6 Min. Fuse 10 A RPG Left main beam light F7 Min. Fuse 10 A RPD Right main beam light up-to-date data on body guidelines (online body guidelines). Data status June

225 117 ENGINE INTERCONNECTIONS UNIT (BIM) Fuse Type Rating Conn. Function F8 Min. Fuse 25 A BP14 ABS power supply F9 Min. Fuse 30 A 14L 14K Windscreen wiper F10 Min. Fuse 10 A AP25 Airbag PIS (primary ignition supply) F F12 Min. Fuse 20 A BP42 Gearbox ECU power supply (Front wheel drive) F F F F16 Min. Fuse 5 A AP4 Gearbox PIS (primary ignition supply) F17 Min. Fuse 7.5 A AP43 Passenger compartment PIS (primary ignition supply) F18 Min. Fuse 5 A AP15 Injection ECU/diesel heater relay F19 Min. Fuse 10 A AP11 Rear running lights PIS (primary ignition supply) F F F22 Min. Fuse 10 A 38R Air conditioning (compressor) F23 Min. Fuse 5 A 15LP Defrosting (relay control) up-to-date data on body guidelines (online body guidelines). Data status June

226 118 PASSENGER COMPARTMENT FUSE-RELAY BOX (BFRH) Before working on the vehicle, refer to the Electrical Connections sheet. This fuse-relay box is located under the dashboard, on the left above the driver s feet (left-hand drive vehicles) or above the passenger s feet (right-hand drive vehicles). To access it, the access flap must be removed. POSITION OF THE PASSENGER COMPARTMENT FUSE-RELAY BOX Depending on the version and the options, some fuses may not be present. DETAILS OF LEFT PASSENGER COMPARTMENT FUSE-RELAY BOX COMPONENTS Fuse Type Rating 1 Mini Fuse 10 A 2 Mini Fuse 10 A 3 Mini Fuse 10 A 4 Mini Fuse 10 A Connection E1 S1 E2 S2 E3 S3 E4 S4 Function << SP2 >>Relais servitude 1. Relais moteur tournant, relais alimentation siège chauffant, Radio << SP4 >> Socket Accessories premier rang << SP4G >> cigarette lighter premier rang << SP4 >> Prise Accessoires second rang up-to-date data on body guidelines (online body guidelines). Data status June

227 118 PASSENGER COMPARTMENT FUSE-RELAY BOX (BFRH) Fuse Type Rating 5 Mini Fuse 5 A 6 Mini Fuse 30 A 7 Mini Fuse 25 A 8 Mini Fuse 5 A 9 Mini Fuse 10 Mini Fuse 5 A 11 Mini Fuse 10 A 12 Mini Fuse 5 A 13 Mini Fuse 15 A 14 Mini Fuse 5 A 15 Mini Fuse 20 A 16 Mini Fuse 20 A 17 Mini Fuse 15 A 18 Mini Fuse 5 A 19 Mini Fuse 15 A 20 Mini Fuse 21 Mini Fuse 10 A 22 Mini Fuse 10 A 23 Mini Fuse 5 A 24 Mini Fuse 10 A 25 Mini Fuse 26 Mini Fuse 27 Mini Fuse 40 A 28 Mini Fuse 10 A 29 Mini Fuse 40 A Connection E5 S5 E6 S6 E7 S7 E8 S8 E9 S9 E10 S10 E11 S11 E12 S12 E13 S13 E14 S14 E15 S15 E16 S16 E17 S17 E18 S18 E19 S19 E20 S20 E21 S21 E22 S22 E23 S23 E24 S24 E25 S25 E26 S26 AE1 AS1 AE2 AS2 AE3 AS3 << BP 69 >> dashboard Function << BP 3 >> UCE Habitacle (CPE, SUPCPE), BFR << BP 77 >> UCE Habitacle + Bat sécurité << BP 75 >> diagnostic outlet not used << BP 97 >> UCE Habitacle + BAT ABS << BP 80 >> control panel air conditioning, UCE Habitacle << DP >> UCE Habitacle << SP17 >> Relais allumage brake light, Contacteur Stop << SP22 >> Relais electrically operated windows, UCE Habitacle, control panel air conditioning << 15K >> Custode arrière gauche dégivrante << 15K >> Custode arrière droite dégivrante << AP7 >> Commandes sous volant << AP51 >> Bague Transpondeur, UCE Habitacle << BP79 >> BFRH2, ADPCNC, adaptation complémentaire, siège chauffant not used << AP10 >> UC fixed bending light, code virage << BCP4 >> UCE Radio, Afficheur multifonctions, Avertisseur alarme, UCE alarme << BP3A >> UCE Accès mains libres << BCP3 >> Contrôlographe not used (emplacement diode) not used (emplacement diode) << SP3 >> Dispositif de Soufflage d'air << BP98 >> BFRH2, relais ACC délesté, adaptation complémentaire, relais servitude 1 << BP70 >> relais electrically operated windows, UCE Habitacle ( LVAVEI ) It is necessary to add a supply for the empty fuse locations (reserve). Locations 25 and 26 can be fitted with a diode in place of a fuse. up-to-date data on body guidelines (online body guidelines). Data status June

228 120 MULTIPLEXED CAN NETWORK (CONTROLLER AREA NETWORK) The multiplexed network enables the ECUs to exchange their data. It complies with the CAN protocol and is connected to the diagnostic socket. Modifications to the multiplexed network are not permitted. CAN ARCHITECTURE Splice - A Splice - B USM 1337 Cockpit ECU 645 TDB 247 Airbag ECU 756 Aircon TBD 319 BOIADP 1664 ABR/ESP 118 Inj. ECU 120 Diag. socket 247 Display 653 BIC 1714 Splice - C Cpt ESP 1175 BVA4 119 AML ECU 2883 ENGINE Splice - D Radio 261 CMDE SSVOLANT 1519 MAIN CAN SECONDARY CAN MULTIMEDIA CAN EQX STANDARD EQX OPTION TERMINAL IMPEDANCE N.B.: PRIVATE CAN Control of the multiplexed network is only possible using the Clip diagnostics tool in the OPEL / VAUXHALL network. If one of the ECUs is replaced, configuration needs to be carried out using the Clip diagnostics tool in the OPEL / VAUXHALL network. up-to-date data on body guidelines (online body guidelines). Data status June

229 122 LIGHTS AND SIGNALLING LIGHT INFORMATION Before working on the vehicle, refer to the Electrical Connections sheet. 1. Right or left front lamps The information is available directly on the front lamp connectors in the engine compartment. ASSIGNMENT OF CONNECTOR WAYS Way number Way 1 Way 2 Way 3 Way 4 Way 5 Way 6 Way 7 Way 8 Way 9 Way 10 Assignment Dipped beam light Main beam light Side light Indicator Fixed bending light Ground for side light, indicator and fixed bending light Ground for main beam and dipped beam lights Important: Each of these connections must only be used to control one single automotive relay; no power available. up-to-date data on body guidelines (online body guidelines). Data status June

230 122 LIGHTS AND SIGNALLING LIGHT INFORMATION 2. Front fog lamps The information is available on the connection located under the bumper. CONNECTOR POSITION ASSIGNMENT OF CONNECTOR WAYS Way number Way 1 Way 2 Way 3 Right fog lamp Left fog lamp Ground Assignment Important: Each of these connections must only be used to control one single automotive relay; no power available. up-to-date data on body guidelines (online body guidelines). Data status June

231 122 LIGHTS AND SIGNALLING LIGHT INFORMATION 3. Right or left tail lights 3.1. Panel van The information is available directly on the tail light connectors in the loading area. CONNECTOR POSITION ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Way 1 Way 2 Way 3 Way 4 Way 5 Way 6 Turn signal light Side light Brake lamp Ground Fog lamp Reversing lamp N.B.: A consumer with the same power as the trailer bulbs can be connected to each of the connections. up-to-date data on body guidelines (online body guidelines). Data status June

232 122 LIGHTS AND SIGNALLING LIGHT INFORMATION 3.2. Chassis cab, chassis double cab and platform cab The information is available directly on the tail light connectors on the extreme rear cross member. CONNECTOR POSITION ASSIGNMENT OF CONNECTOR WAYS Way number Way 1 Way 2 Way 3 Way 4 Way 5 Way 6 Ground Side light Reversing lamp Turn signal light Brake lamp Fog lamp Assignment N.B.: A consumer with the same power as the trailer bulbs can be connected to each of the connections. up-to-date data on body guidelines (online body guidelines). Data status June

233 122 LIGHTS AND SIGNALLING LIGHT INFORMATION 3.3. Versions with trailer coupling connector All chassis cabs and panel vans with the trailer coupling option ( VR2 option) have this connector. POSITION OF THE CONNECTOR ON PANEL VANS ASSIGNMENT OF CONNECTOR WAYS up-to-date data on body guidelines (online body guidelines). Data status June

234 122 LIGHTS AND SIGNALLING LIGHT INFORMATION Way number Way 1 Trailer presence information Way 2 Reverse lamp (21 W) Way 3 Left side light (5 W) Way 4 Left turn signal light (21 W) Way 5 Brake lamp (42 W) Way 6 Right turn signal light (21 W) Way 7 Right side light (5 W) Way 8 Vehicle fog lamp feedback Way 9 Ground Way 10 Fog lamp (21 W) Assignment Way 1: Detection of a turn signal fault (audible alarm if bulb out). Connect to ground for addition of any consumer on ways 4 and 6. Way 8: Vehicle fog lamp power supply if vehicle pre-fitted with trailer coupling ( VR2 option). Remove pin 8 on the coupling side if consumer added to way 10. WAY 8 CONNECTION DIAGRAM brouillard adaptation 10 brouillard adaptation ok 1: Original connection diagram with VR2 option 2: Connection diagram with VR2 option and addition of a consumer on way 10 Nok Currents available on the trailer coupling connector: - Vehicle with coupling: Each of these connections must only be used to control one single automotive relay; no power available. - Vehicle without coupling: A consumer with the same power as the trailer bulbs can be connected to each of the connections. up-to-date data on body guidelines (online body guidelines). Data status June

235 123 DAYTIME RUNNING LIGHTS Option T3W Daytime running lights increase visibility of the vehicle during daylight. The running lights option automatically switches on the dipped beam lights when the vehicle starts up, depending on legislation in the country where the vehicle is sold. When the ignition is on, the headlights come on and instrument illumination is subdued. The daytime running lights switch off when the ignition is switched off. The running lights function can be activated or deactivated using the Opel diagnostics tool in the Opel dealer network. up-to-date data on body guidelines (online body guidelines). Data status June

236 124 SWITCH INSTALLATION Before working on the vehicle, refer to the Electrical Connections sheet. Depending on the version, one or more spaces for switches may be provided on the side part and/or the centre left of the dashboard. A B A: Left side switch support 1: Electric headlamp height adjustment 2: ESP dynamic driving control (*) 3: Parking assistance (*) B: Left centre switch support (**) 4: Cruise control-speed limiter (*) 5: Snow position for MTA transmission (*) 6: Accelerated idle (*) (*) Presence and position dependent on version (**) Presence of a storage box, dependent on version up-to-date data on body guidelines (online body guidelines). Data status June

237 WATT SIDE INDICATORS Vehicles (shorter than 6 metres) are fitted with side indicators with 5 W bulbs as standard. All complete vehicles with a total length of over six metres must be equipped with side marker lamps and 16 W side indicators in compliance with EU Directive 76 / 756 / EEC. Vehicles with this equipment have side indicators and a special Passenger Compartment Control Unit (UCH). The side indicators are located at the bottom of the door mirrors. For more information, see also Chapter 36. SIDE INDICATORS 1 2 1: Right side indicator 2: Left side indicator SIDE MARKER LAMPS length > 6000 m Important: The indicators are not controlled by a flashing light unit but by the Passenger Compartment Control Unit. It is not possible to change from 5 W indicators to 16 W indicators, or vice versa, after vehicle manufacture. It is prohibited to fit indicators with more than 16 W power on the door mirrors. up-to-date data on body guidelines (online body guidelines). Data status June

238 126 INSTALLATION OF AN ADDITIONAL BATTERY A space is set aside under the right-hand cab side sill. A special battery tray should be used according to the size of the battery. It is to be attached under the body. It is recommended that a model be taken on the mountings of the main battery tray on the left-hand side. The battery will therefore be fitted from underneath the body. The side sill panel may be cut out to allow access to the positive and negative terminals. The maximum authorized cut-out must follow the stamped part. The side sill cut-out must be sealed (water, air, noise). The right-hand plastic side sill is not intended for this use. LOCATION 1: Main battery access area in the left-hand cab side sill 1 2 2: Zone to be cut out for access to the additional battery terminals in the right-hand cab side sill After cutting out the side sill, the filings or shavings must be vacuumed and a corrosion inhibitor used, referring to the Specific Corrosion Guidelines. To install the additional battery and its mountings, please refer to the Battery sheet. For battery coupling, please refer to the Battery coupling sheet. N.B.: The additional battery must be disconnected during installation. Warning: The batteries may not be directly coupled in parallel. up-to-date data on body guidelines (online body guidelines). Data status June

239 127 DRIVER S SEAT BELT WARNING The vehicle comes with an audible seat belt warning as standard for the driver s seat. If the driver's seat is changed, this feature can be replaced or potentially neutralized. The seat belt stalk has a mechanical contact switch that reads the presence of the seat belt buckle. This contact switch is directly connected to the airbag ECU. The contact connections are on the 6-way connector under the seat. POSITION OF THE DRIVER S SEAT CONNECTOR Way number Way 1 (60DU) Way 2 (60DV) Way 3 (SP8) Way 4 (SP8) Way 5 (MAM) Way 6 (LPG) Assignment Seat belt buckle connection (wire cross section 0.5 mm²) Seat belt buckle connection (wire cross section 0.5 mm²) Protected +12 V circuit distribution supply for heated seat (wire cross section 1 mm²) Protected +12 V circuit distribution supply for heated seat (wire cross section 2 mm²) Ground (wire cross section 0.5 mm²) Protected left-hand side light supply (wire cross section 0.75 mm²) up-to-date data on body guidelines (online body guidelines). Data status June

240 127 DRIVER S SEAT BELT WARNING To activate the audible seat belt warning, a stalk fitted with an opening contact switch should be used, which should be connected to the connector using ways 1 and 2 of the 6-way connector. The presence of the seat belt is detected when the contact switch is open. To deactivate the audible seat belt warning, ways 1 and 2 of the 6-way connector need to be connected by a shunt. Comment: In cases where the audible seat belt warning is deactivated, it is advisable to inform the end customer, for example through the instruction manual and/or with a sticker. up-to-date data on body guidelines (online body guidelines). Data status June

241 128 EXTENDED REAR WIRING, UNF OPTION The UNF option provides special rear wiring that is 650 mm longer, which is necessary for extension of the rear overhang. This excess length is wound on the chassis. The additional length enables extension of the overhang depending on the version: - Platform cab: 1,690 mm - Single wheel chassis cab: 1,500 mm - Twin wheel chassis cab: 950 mm COIL LOCATION ON THE CHASSIS up-to-date data on body guidelines (online body guidelines). Data status June

242 129 MODIFIABLE ECU SETTINGS Some ECU settings can be changed using the diagnostics tool in the Opel dealer network. Prior to any modification, the ECU in question must be fully reconfigured. After modification, the vehicle must still comply with the legislation and standards in force in the country of sale. ECU Modifiable function Settings that can be modified using CLIP Vehicle locking and unlocking Side doors Rear doors Boot opening 2-button key 3-button key (boot = rear doors - PAR) 3-button key (boot = side PL + rear doors PAR) Passenger Compart-ment Control Unit (UCH) Front left door Front right door Left side door Right side door Rear door(s) Automatic locking of doors after 2 minutes of no activity Deadlocking (internal and external handles inactive) (In line with legislation) Front fog lamp Vehicle light cut-off (In line with legislation/depending on country) Rain and light sensor, function presence Automatic headlight illumination and rain sensor. Absent Present Absent Present Absent Swing door Sliding door Absent Swing door Sliding door Absent Swing doors Tailgate Active Inactive Present Not present With Without Lights go out when the engine stops and when the doors are opened. Lights go out when the engine stops. With Without Function active (as standard) Function inactive up-to-date data on body guidelines (online body guidelines). Data status June

243 129 MODIFIABLE ECU SETTINGS ECU Passenger Compartment Control Unit (UCH) Dashboard Parking assistance Modifiable function Rain/light sensor detection threshold: - Northern countries and Great Britain - Other countries (In line with legislation in the country of sale) Emergency Brake Assist with or without warning (In line with legislation) Retrofit alarm Consumption unit (ADAC) (In line with legislation) Odometer unit (In line with legislation) Seat belt unfastened warning Language (dashboard display) Vehicle service range Overspeed warning signal (In line with legislation/depending on country) Beep volume Tone adjustment Settings that can be modified using CLIP North South No light Light With Without Litres/100 kilometres Miles/Gallon Kilometres/1 litre Kilometres Miles Active Inactive By country Without Configured Free Active Inactive None Low Medium High Maximum 800 Hz 1,000 Hz 2,000 Hz Engine Accelerated idle From 1,000 to 2,000 rpm in 100 rpm increments ABS/ESP Brake light illumination if ESP operating (In line with legislation) Active Inactive up-to-date data on body guidelines (online body guidelines). Data status June

244 129 MODIFIABLE ECU SETTINGS ECU Modifiable function Settings that can be modified using CLIP Passenger-side front airbag Active Inactive Side airbag for driver Active Inactive Passenger-side side airbag Active Inactive Driver s front pretensioner Active Inactive Driver s front pretensioner Active Inactive Driver s 2 nd row pretensioner Active Inactive Passenger s 2 nd row pretensioner Active Inactive Airbags For some of the functions, please refer to the relevant sheet. up-to-date data on body guidelines (online body guidelines). Data status June

245 131 INTERIOR LIGHTING Before working on the vehicle, refer to the Electrical Connections sheet. 1. Energy recovery conditions The progressive ground on connectors is a delayed analogue signal. Under no circumstances may this signal be relayed. Excess consumption of no more than 2 A (24 W) may be taken from the rear zone and double cab lighting. No excess consumption is feasible for front and right-hand side courtesy lights (sliding side door). Follow the procedure for consumption greater than 2 A. If consumption is greater than 2 A (24 W) for the rear and double cab lighting and on the front or right-hand side lighting: - the delayed power supply should control a relay which will control another power supply. - a specific ground should be used (the progressive ground will no longer be usable). If the open door information is required, a panel switch should be added. N.B.: For wires with a cross section of 0.5 mm², it is possible to bypass these wires by using a crimp adaptor. However, for wires with a cross section of 0.35 mm², use of the crimp adaptor is very delicate and it is strongly recommended to recover this information on the roof connector. up-to-date data on body guidelines (online body guidelines). Data status June

246 131 INTERIOR LIGHTING 2. Location of lighting and connector way assignments DRIVER'S SEAT LIGHTING ASSIGNMENT OF CONNECTOR WAYS Way number Way 1 (BPT2) Way 2 (13L) Way 3 (NAM) Assignment Delayed +12 V power supply (wire cross section 0.5 mm²) Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.5 mm²) Ground (wire cross section 0.5 mm²) up-to-date data on body guidelines (online body guidelines). Data status June

247 131 INTERIOR LIGHTING REAR PANEL VAN LIGHTING AND DOUBLE CAB LIGHTING Van Chassis Cab ASSIGNMENT OF CONNECTOR WAYS Way number Way 2 (13M) Way 3 (MG) Way 4 (BPT2) Assignment Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.35 mm²) Permanent ground (wire cross section 0.35 mm²) Delayed +12 V power supply (wire cross section 0.35 mm²) up-to-date data on body guidelines (online body guidelines). Data status June

248 131 INTERIOR LIGHTING ROOF CONNECTOR Van Chassis Cab ASSIGNMENT OF CONNECTOR WAYS Way number Way C5 (13M) Way B7 (BPT2) Assignment Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.35 mm²) Delayed +12 V power supply (wire cross section 0.35 mm²) up-to-date data on body guidelines (online body guidelines). Data status June

249 131 INTERIOR LIGHTING RIGHT-HAND SIDE DOOR LIGHTING ASSIGNMENT OF CONNECTOR WAYS Way number Way 2 (13M) Way 3 (NAM) Way 4 (BPT2) Assignment Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.35 mm²) Permanent ground (wire cross section 0.35 mm²) Delayed +12 V power supply (wire cross section 0.35 mm²) Warning: The wires cannot be retrieved in the connector as there is no double exit. up-to-date data on body guidelines (online body guidelines). Data status June

250 132 ELECTRIC PLUG FOR COUPLING The first-fit electric plug for the coupling and the one available from after-sales are 13-pin type. Assignment of the pins is standardised. Electrical switches are built into the plug. They are activated depending on the opening or closing of the coupling plug hood. The SW1 switch indicates the presence or absence of the trailer to the vehicle ECUs. The SW2 switch enables the vehicle ECUs to automatically disconnect the rear fog lamp. The coupling wiring can be connected to the vehicle in three ways. - On panel vans with coupling equipment pre-fitted or the VR2 option: special 10-way intermediate connector fitted in the rear left pillar. The trailer coupling wiring is available in the Opel dealer network under part number for vehicles fitted with a rear parking sensor or under part number for vehicles not fitted with a rear parking sensor. - On panel vans without coupling equipment pre-fitted or the VR2 option, pick-offs need to be created at the vehicle s tail light location. Please refer to the Lights Information sheet - On chassis cabs and platform cabs: special 10-way intermediate connector on the rear left of the chassis. The trailer coupling wiring is available in the Opel dealer network under part number R. Comment: Connecting the coupling plug maintains the service monitoring operation of the vehicle s indicators and also allows the rear parking sensor to be disabled. up-to-date data on body guidelines (online body guidelines). Data status June

251 132 ELECTRIC PLUG FOR COUPLING ASSIGNMENT OF CONNECTOR TRACKS SW SW Way number Way 1 Way 2 Way 3 Way 4 Way 5 Way 6 Way 7 Way 8 Way 9 Way 10 Way 11 Way 12 Way 13 SW1 SW1 Left turn signal light Rear fog lamp Ground (10 A max) Right turn signal light Right side light Brake lights Left side light Reversing lamp Not wired Not wired Not wired Not wired Ground (10 A max) Trailer presence Rear fog lamp disconnection Assignment up-to-date data on body guidelines (online body guidelines). Data status June

252 132 ELECTRIC PLUG FOR COUPLING SW1 ELECTRICAL DIAGRAM 1 UCH 151I : Passenger Compartment Control Unit (UCH) 2: SW1 switch 3: Coupling plug, track 3 4: Ground 1 SW2 ELECTRICAL DIAGRAM 9Q UCH 9P : Passenger Compartment Control Unit (UCH) 2: SW2 switch 3: Coupling plug, track 2 up-to-date data on body guidelines (online body guidelines). Data status June

253 135 REMOTE ENGINE START AND STOP It is possible to double the engine start and stop control. It is the job of the converter to take into account all the aspects associated with safe operation and to ensure: - the quality of the connections. - that the wires added have the same cross sections as the original wires; or even larger if called for by the length of the wires added. - that relays closed at rest are used if the cut-offs in these lines are executed via relays. Please also see the Wiring and Electrical Connections sheets. This installation operation must be done with the battery disconnected. To effect the remote engine stop or start function, the function of the ignition switch on start-up needs to be recreated. POSITION OF THE IGNITION SWITCH up-to-date data on body guidelines (online body guidelines). Data status June

254 135 REMOTE ENGINE START AND STOP ASSIGNMENT OF CONNECTOR WAYS 104AA Way number Way 1 (BP12) Assignment Protected 12 V power supply, red wire with cross section 5 mm² Way 2 - Way 3 (D) Way 4 (A) Start-up, beige wire with cross section 5 mm² Primary ignition supply, yellow wire with cross section 5 mm² Way 5 - Way 6 (S) Current distribution power supply, yellow wire with cross section 5 mm² To start the engine (starter solenoid control), activate way 3 with the protected 12 V power supply. Way 4 to be activated to start the engine and to be cut off to stop it. Way 6 to be cut off momentarily during starter activation. LOCATION OF CORRESPONDING FUSES +ser S F21 F9 BP12 + APC A F13 + Dém D F : Engine interconnections unit (BIM) power supply board 2: Passenger compartment fuse-relay box (BFRH) up-to-date data on body guidelines (online body guidelines). Data status June

255 137 DEACTIVATION OF AIRBAGS AND SEAT BELT PRETENSIONERS Depending on the customer s requirements, an airbag or seat belt pretensioner may need to be deactivated. This can be done using the Opel diagnostics tool in the Opel dealer network. An airbag or pretensioner that has been deactivated can be reactivated at any time. After modification, the vehicle must still comply with the legislation and standards in force in the country of sale. The customer must be notified of any modifications. Temporary deactivation of the passenger airbag Front airbag and side airbag systems for the front passenger seat have to be deactivated if a child restraint system is to be fitted on this seat. The belt pretensioners and all driver airbag systems will remain active. The front passenger airbag system can be deactivated via a switch on the side of the instrument panel. With the front passenger door open, press switch in and rotate anticlockwise to the OFF position. Front passenger seat airbags are deactivated and will not inflate in the event of a collision. Control indicator illuminates continuously in the information display. Switsch to deaktivate the passenger airbag Note: Airbags and pretensioners cannot be added after vehicle manufacture. The front airbag system is triggered in the event of a front-end impact of a certain severity. The ignition needs to be switched on. For more information, also see Chapter 32, 141 and the General conversion recommendations up-to-date data on body guidelines (online body guidelines). Data status June

256 139 CONNECTION TO THE NEGATIVE BATTERY TERMINAL Before working on the vehicle, refer to the Electrical Connections sheet. 1. General recommendations The wiring used must allow the negative battery terminal block to be removed (tightening torque 8 Nm ± 15%). Tighten at the recommended torque of 8 Nm ± 15%. Leave threading of at least one thread free after tightening. NEGATIVE BATTERY TERMINAL 1 1: Additional wiring (must be black) connected to the negative battery terminal 2. Wiring protection Use a category 3 resin, lightweight felt or tape-type protection in the engine compartment and in the under-body and category 1 to 3 for the other sections not subjected to high temperatures (see electrical chapter of the General Conversion Guide). Since the annular sheathing type protection (Split Annular Sheath) is abrasive and may cause corrosion (paint wear) and noise (in hollow bodies), it must be immobilised. There must be no contact between the wiring and the brake or fuel pipes. If the original wiring is near to an annular sheath, a spacer (double finger clip grip) must be added in order to avoid any contact (risk of wear and short circuit). up-to-date data on body guidelines (online body guidelines). Data status June

257 139 CONNECTION TO THE NEGATIVE BATTERY TERMINAL 3. Wiring duct WIRING PATH IN BATTERY TRAY 1 2 1: Additional wiring 2: Cable duct (diameter 40), grommet to be fitted UNDER-BODY WIRING PATH : Cable duct (diameter 40), grommet to be fitted 2: Brake pipes 3: Additional wiring 4: Under-body electrical wiring up-to-date data on body guidelines (online body guidelines). Data status June

258 140 CONNECTION TO THE POSITIVE BATTERY TERMINAL Before working on the vehicle, refer to the Electrical Connections sheet. Depending on the electrical assessment, the power take-off may be conditioned with the engine running information. 1. General recommendations The wiring used must allow the positive battery terminal block to be removed (tightening torque 8 Nm ± 15%). The wiring must be red and supported inside the battery tray and as close to the terminal block as possible in order to avoid any vibration that could lead to damage of a terminal block or loosening of the nut. A red insulating sleeve is necessary for the terminal. The wiring must be protected by a fuse which will be sized depending on the cross section of the wire and on the consumer. There are two options for connecting to the positive battery terminal, depending on the power consumed. Any other connection to the positive terminal is prohibited. POSITIVE BATTERY TERMINAL 1 2 1: Locations provided for midi-type fuses for power supply of less than 40 A 2: M6 stud for power supplies greater than 40 A Note: It is also possible to connect directly to the battery using the 2-way connector located in the B pillar, which is available with the KPD and KC5 options. Please refer to the relevant sheets for more information. up-to-date data on body guidelines (online body guidelines). Data status June

259 140 CONNECTION TO THE POSITIVE BATTERY TERMINAL 2. Connection to M6 stud Make sure there is good contact (flatness) with the terminal. Crimping must be done in accordance with terminal manufacturer guidelines. Tighten at the recommended torque of 8 Nm ± 15% and leave at least one spare thread after tightening. The fuse holder should be properly attached to avoid any vibrations and damage to its surroundings (e.g. risk of noise, corrosion). EXAMPLE OF FUSE AND FUSE HOLDER For information: MTA fuse kit, part number up-to-date data on body guidelines (online body guidelines). Data status June

260 140 CONNECTION TO THE POSITIVE BATTERY TERMINAL 3. Connection using the midi fuse locations Two locations are provided for midi-type fuses. For this, special M5 studs from the supplier MTA must be used. The following fuses may be used: 30 A midi fuse; 40 A midi fuse. Tighten at the recommended torque of 5 Nm ± 15% for the M5 studs and leave at least one spare thread after tightening. POSITIVE BATTERY TERMINAL 1 2 1: Locations provided for midi-type fuses 2: Locations provided for M5 studs EXAMPLE OF: M5 STUD MIDI FUSE N.B.: Tightening torque for M8 nuts on the positive terminal: 12 Nm ± 15% up-to-date data on body guidelines (online body guidelines). Data status June

261 140 CONNECTION TO THE POSITIVE BATTERY TERMINAL 4. Wiring protection Use a category 3 resin, lightweight felt or tape-type protection in the engine compartment and in the under-body and category 1 to 3 for the other sections not subjected to high temperatures (see Wiring sheet). Since the split annular sheathing type protection is abrasive and may cause corrosion (paint wear) and noise (in hollow bodies) it must be immobilised. There must be no contact between the wiring and the brake or fuel pipes. If the original wiring is near to a split annular sheath, a spacer (double finger clip grip) must be added in order to avoid any contact (risk of wear and short circuit). up-to-date data on body guidelines (online body guidelines). Data status June

262 141 ROUTING AIRBAG AND PRE-TENSIONER WIRING No intervention or modification must be made to elements relating to the vehicle's passive safety. The airbag and seatbelt pre-tensioner wire is an integral part of the vehicle's passive safety system units. Particular attention must therefore be paid before any transformation which may affect their integrity and generate a customer effect which potentially affects safety (example: unwanted and/or untimely triggering of the airbags, lack of triggering or delayed triggering in the event of an impact (airbags and pre-tensioners), untimely triggering of the pyrotechnic restraint systems with the vehicle moving or at a stop). The routing for this wiring must be identified on the vehicle. If necessary, before any intervention, install protection on these sensitive units to preserve their integrity under all circumstances. Location of the wiring in question: In blue, the wiring for the sensitive units which make up the vehicle's passive safety system: Left-hand drive version up-to-date data on body guidelines (online body guidelines). Data status June

263 141 ROUTING AIRBAG AND PRE-TENSIONER WIRING In blue, the wiring and sensitive units which make up the vehicle's passive safety system: Right-hand drive version Note: For more information, also see Chapter 32, 137 and the General conversion recommendations up-to-date data on body guidelines (online body guidelines). Data status June