Conversion Guideline Opel Movano [ X62 ]

Transcription

1 Conversion Guideline Opel Movano [ X62 ] Part 3 - Chapter and Edition: August 2013 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany

2 CONTENTS Conversion Guideline - Part 3 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 PREPARING FOR COLD COUNTRIES FUEL SUPPLY SYSTEM EXHAUST SYSTEM BRAKE SYSTEM TRANSLATION OF THE FUEL TANK FILLER PIPE MAXIMUM AUTHORIZED LOAD PER AXLE AERIAL WORK PLATFORM (CHERRY PICKER) ON PANEL VAN * PROHIBITED CONVERSION TYPES LIFT TAILGATE DETERMINING THE CENTRE OF GRAVITY 59 * = This chapter is new or was modified after the last edition of November up-to-date data on body guidelines (online body guidelines).

3 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

4 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 January

5 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 January

6 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 150kg for a Van L1H1 and L1H2. - The maximum permissible mass on the roof is 200kg for a Van L2H2, L3H2 and L4H2. - The H3-roof is made of plastic. This roof is not intended for attaching a roof rack Roof rack *= Weight and length may vary depending on version. Example of roof bars 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. Example of roof rack up-to-date data on body guidelines (online body guidelines). Data status January

7 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 permissible maximum towable, unless otherwise noted: of a braked trailer is 2500 kg, vehicles with a GVW of 3500kg and single wheels only. The maximum nose weight is 100kg (vertical force allowable on the ball/towing system). of a braked trailer is 3000 kg, vehicles with a GWV of 4500kg, RWD and twin wheels only. The maximum nose weight is 120kg (vertical force allowable on the ball/towing system). of a braked trailer is 3500 kg, chassis cab with a GWV of 3500kg, RWD and twin wheels only. The maximum nose weight is 140kg (vertical force allowable on the ball/towing system). of an unbraked trailer is 750kg The permissible trailer loads are specified in the vehicle documents. In general, they are valid for gradients up to max. 12 %. GVW = gross vehicle weight; RWD = rear wheel drive 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 October

8 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 October

9 57.1 TRAILER HITCH 1.2. Single wheel rear drive version (Towing weight 2,5 t) outside : trailer hitch 2 : support left side 3 : support right side 1.3. Twin wheel rear drive version (Towing weight 3 t and 3,5 t) inside : trailer hitch 2 : support left side 3 : support right side up-to-date data on body guidelines (online body guidelines). Data status October

10 57.1 TRAILER HITCH 2. Tow bars on chassis cabs and chassis double cabs View from the bottom assembly, left side. 1 : Rear left suspension 2 : Rear section of the rear left sidemember 3 : Extreme rear crossmember 4 : Support trailer hitch 5 : Trailer hitch up-to-date data on body guidelines (online body guidelines). Data status October

11 57.1 TRAILER HITCH 2.1. Front wheel drive version single wheel (Towing weight 2,5 t) S1 single wheel S2 single wheel up-to-date data on body guidelines (online body guidelines). Data status October

12 57.1 TRAILER HITCH 2.2. Twin wheel rear drive version twin wheels (Towing weight 3 t and 3,5 t) S1 twin wheels S2 twin wheels S1 twin wheels S2 twin wheels < S1 single wheel < S2 single wheel Note: The short overhang chassis cab version is not compatible with the coupling devices described above. In the case of a change in the rear overhang, reinforcing brackets must be added if a coupling device is fitted. These reinforcing brackets will ensure the soundness of the vehicle's side member when towing. It may be necessary to check compliance with the regulations. up-to-date data on body guidelines (online body guidelines). Data status October

13 57.1 TRAILER HITCH 3. 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 and 3,5t for vehicles with a maximum permissible laden mass of 3,5 and 4.5t GVW (Only for RWD with twin wheels) Version 2,5 t oder oder 3.2. Version 3 t and 3,5 t min = minimum up-to-date data on body guidelines (online body guidelines). Data status October

14 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. Rrear drive version B - Single wheel C - Twin wheel up-to-date data on body guidelines (online body guidelines). Data status Mai

15 57.2 INTEGRATED STEP IN REAR BUMPER Van overall length in mm Vehicle length wheelbase drive without integrated step with integrated step L FWD L FWD L FWD RWD L RWD Example for integrated step in rear bumper for rear wheel drive version (the rear parking distance sensors are available as an option) up-to-date data on body guidelines (online body guidelines). Data status Mai

16 58 DIGITAL 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. A vehicle fitted with a digital tachygraph (standard or optional) is also fitted with an CAN BUS- Interface module (refer to chapter105- CAN BUS- INTERFACE MODULE) for reduncancy of vehicle speed information. 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 October

17 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

18 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

19 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 gross vehicle weight (GVW). Regardless of the suspension type, it is prohibited to add an additional air cushion in the bump stop area and between the side members. A host structure, sized to withstand the cushion / body interface forces, must be used. Regardless of the vehicle, do not touch the original bump stops, which are suspension parts with two functions: - bump stop - suspension function : Bump stop of the vehicle 2 : air bellows 3 : frame longitudinal member N.B.: The polyurethane bump stops are in constant contact with the axle and therefore contribute to the stiffness of the rear suspension. up-to-date data on body guidelines (online body guidelines). Data status August

20 60 REAR AND FRONT SUSPENSION 2. Front wheel drive vehicles All front wheel drive vehicles are fitted with one single steel leaf spring Rear axle for panel van and chassis cabs The rate of the single spring, flanged in the centre and with no articulation, is 71.7 N/mm 2.2. Rear axle for camper vans (with normal and widened tracks) Special campervan versions with widened tracks for which the rate is N/mm. Note: The widened track is strictly reserved for camper vans. It is prohibited to fit this axle to any other conversion Rear Axle with Pneumatic suspension It is available for panel vans and chassis up-to-date data on body guidelines (online body guidelines). Data status August

21 60 REAR AND FRONT SUSPENSION 3. Rear wheel drive vehicles 3.1. Rear axle with single wheels 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 Rear axle with twin wheels 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. 4. Front suspension The front suspension is a McPherson 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 August

22 60 REAR AND FRONT SUSPENSION 5. If the anti-roll bar is absent 5.1. Front axle MOVANO [X62] WITHOUT ANTI-ROLL BAR ON REAR AXLE Front wheel drive Rear wheel drive Wheelbase [mm] Roof height Twinwheels ESP GVW [kg] PANEL VAN X 3182 H1, H2 No 2800 PANEL VAN X Rear axle MOVANO [X62] WITHOUT ANTI-ROLL BAR ON REAR AXLE Front wheel drive Rear wheel drive Wheelbase [mm] Roof height Twinwheels ESP GVW [kg] PANEL VAN X 3182 H1 No PANEL VAN X 3682 H2, H3 No X 3500 PANEL VAN X 3182 H2 No PANEL VAN X 3682 H2 No 3300 COMBI X 3682 H2 No 3300 COMBI X 3182 H1 No X 2800 up-to-date data on body guidelines (online body guidelines). Data status August

23 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 September

24 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 (Kat.-No ) 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 (Kat.-No ). 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 September

25 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 September

26 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 September

27 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 September

28 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 September

29 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 September

30 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 (Kat.-No ) 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 (Kat.-No ). The tightening torque is 50 Nm, plus angular tightening of up-to-date data on body guidelines (online body guidelines). Data status September

31 63.3 POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE 1. Power take-off (PTO) on gearbox option is available on rear wheel drive vehicles only. 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 (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 (Easytronic). up-to-date data on body guidelines (online body guidelines). Data status August

32 63.3 POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE 3. Power take-off/unit interface 1: Power take-off on ZF4 gearbox 2: Kit to mount a unit to the power take-off. A B 1 2 E C 3.1. Assembly flowchart D 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 3.2. Mechanical properties Maximum resulting torque 150 N.m between 1,000 and 2,000 rpm PTO weight 7,4 kg Drive/Engine rotation speed ratio Max. permissible power at idle 22 kw up-to-date data on body guidelines (online body guidelines). Data status August

33 63.3 POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE 4. Positioning of the PTO on vehicle (±2mm). Distance Description (mm) D PTO mounting face / front axle 369,5 E PTO mounting face / partition wall of the Panel van 1482 F PTO mounting face / rear panel of the Chassis Cab 1615 G PTO mounting face / rear panel of the Chassis Crew Cab 2366 Part Description Part Description 1 left front side member 5 partition wall of the Panel van 2 motor 6 rear panel of the Chassis Cab 3 gearbox 7 rear panel of the Chassis Crew Cab 4 Power take-off D E F G up-to-date data on body guidelines (online body guidelines). Data status August

34 63.3 POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE Distance Description (mm) A Middle axle shaft PTO / vehicle longitudinal axis (X- axis) 176 B Middle axle shaft PTO / left front side members 285,5 C Middle axle shaft PTO / left front side members 61,5 Part Description 1 left front side member 3 gearbox 4 Power take-off 3 A 1 C B 4 PTO mounting face Middle axle shaft PTO up-to-date data on body guidelines (online body guidelines). Data status August

35 63.3 POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE 5. Position from the PTO and its control unit Part Description 1 Power take-off 2 control unit (ECU) of Power take-off 3 engine interconnections unit (= BIM can be found to the left of the engine compartment) up-to-date data on body guidelines (online body guidelines). Data status August

36 65 PREPARING FOR COLD REGIONS The vehicle is adapted to extreme cold configuration by modifying or adding the following elements: - Coolant - Windscreen wash - Addition of protective parts Engine coolant Drain the circuit and refill with a mixture of 5.5 litres of coolant and 5.5 litres of demineralised water. Windscreen wash Vehicles manufactured between April 1 and July 31 are delivered with a screen wash composed of 20% washer liquid and 80% demineralised water. Outside of these dates, the vehicles are delivered in extreme cold (-20 C) configuration (45% Antifreeze & clear view liquid and 55% demineralised water). Front brake disc protection Front brake disc protection must be added for extreme cold vehicles: Front left: Front right: The addition of disc protection also protects the steering ball joint cover. up-to-date data on body guidelines (online body guidelines). Data status November

37 67 FUEL SUPPLY SYSTEM 1. 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 December

38 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 December

39 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 December

40 67 FUEL SUPPLY SYSTEM 2. Precautions for assembly and disassembly 2-1 Fuel tank 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 (1) must be positioned above the strap (2) that holds the fuel tank in place : Vertical strap 2: Front support strap 3: Rear support strap up-to-date data on body guidelines (online body guidelines). Data status December

41 67 FUEL SUPPLY SYSTEM 2-2 Regulatory tank guard This protective guard around the tank is subject to Regulation ECE 34 and concerns the fire resistance of the fuel circuit. Any modification or removal of this guard must comply with this directive. For information: On all the CHASSIS CAB vehicles (except the double cab), carry-over of the fuel tank guard element. This measure is identical for TRACTION HEADS when the standard fuel tank is carried over onto a specific chassis developed by a coach-builder. Fuel tank guard up-to-date data on body guidelines (online body guidelines). Data status December

42 68 EXHAUST SYSTEM Modification of the exhaust pipe: The exhaust lines for the MOVANO versions are designed for output below the vehicle. The architecture of the MOVANO has been designed to maintain the vehicle's ground clearance and to direct the exhaust gases downwards. Any modification may result in alteration of the vehicle's type approval (engine power, noise or exhaust emissions). The body builder is entirely responsible for carrying out this type approval. A B C A = B = C = Rear attachment of the silencers Front attachment of the silencers Connection clamp up-to-date data on body guidelines (online body guidelines). Data status March

43 68 EXHAUST SYSTEM D On the A and B attachments: - Respect the parallelism between the 2 hooks (body and line), see reference D. - Check that the internal clearances of the 2 flexible exhaust mounts are indeed identical, see reference E. Exhaust clamp: The exhaust clamp must be changed for a new one. Depending on the tooling used for tightening the connection clamp, apply the following procedure: - with an automatic screw driving machine (plant type and not impact type tooling) tighten to 21 Nm - during manual tightening, it must be carried out as linear as possible, without sudden pickup. Tightening stops when the X clearance between the clamp ends is between 3.6 mm and 6.3 mm (which correspond to a torque of approximately 18 Nm). E X up-to-date data on body guidelines (online body guidelines). Data status March

44 68 EXHAUST SYSTEM EXHAUST LINE ENGINE M9T 74 / 92 / 110 KW Euro 4 Front and rear wheel drive version. up-to-date data on body guidelines (online body guidelines). Data status March

45 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 March

46 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

47 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

48 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

49 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

50 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

51 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

52 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

53 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

54 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

55 79 MAXIMUM AUTHORIZED LOAD PER AXLE The maximum authorized load per axle depends on the version and the gross vehicle weight (GVW). The values are given in the table. GVW (kg) Front axle (kg) Rear axle (kg) Front wheel drive Front wheel drive Front wheel drive Single wheel rear drive Twin wheel rear drive Twin wheel rear drive 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 gross vehicle weight are shown on the manufacturer s plate. In order to ensure the directional stability and traction of the vehicle, Opel/Vauxhall recommends a weight ratio (minimum weight on front axle) / (total converted vehicle weight when laden) in excess of: - 30% for rear-wheel drive vehicles - 40% for front-wheel drive vehicles These conditions can be more restrictive than the maximum regulatory technical axle values in the table above. For more information on the compliance with the Centre of Gravity position, refer to the chapter Determining the Centre of Gravity and chapter 40 - Limit of conversions with ESP. up-to-date data on body guidelines (online body guidelines). Data status September

56 142 AERIAL WORK PLATFORM ( CHERRY PICKER ) ON PANEL VAN Without stabiliser jacks The conversion of type aerial work platform is permitted without stabilizers on chassis cab and panel van. With two side stabiliser jacks For an aerial work platform conversion on panel van, it may be necessary to equip the vehicle with two side stabiliser jacks.. The stabiliser jacks must under no circumstances be able to lift the vehicle with the wheels in suspended position. During the stabilization and horizontal adjustment phase, the relief for the suspension system must be limited to the minimum. For an aerial work platform conversions on FWD and RWD Chassis Cabs and Chassis Double Cabs, see Chapter 143-prohibited conversion types-x62. up-to-date data on body guidelines (online body guidelines). Data status August

57 143 PROHIBITED CONVERSION TYPES The following conversions are not allowed: 1. Aerial Work Platform (Cherry picker) conversion with stabilisers on Chassis Cabs and Chassis Crew Cabs with FWD and RWD. For conversion on panel vans, see chapter Cherry picker -X Transformation allowing the lifting of vehicle (Unballasting of axles) For the adaptation of type : stabilizers and jacks. 3. Cooling components conversion (kinematic chain) The components are sized for vehicles with a GVW of 3.5t or 4.5t. The authorised GTW cannot be used as a basis for future GVW certification. The Opel warranty will not apply if the basic vehicle's GVW is exceeded. 4. Additional heating on water heater unit circuit The use of branching pipes on the water circuit is prohibited on Start/Stop versions. Additional pressure drops affect the engine's temperature, which jeopardises its reliability. up-to-date data on body guidelines (online body guidelines). Data status August

58 146 LIFT TAILGATE The Movano can be fitted with a lift tailgate. Fitting a tailgate precludes the fitting of a Opel/Vauxhall towing system. When installing a new coupling, it is necessary to plan for a validation, in compliance with regulatory requirements. Permitted masses The maximum load + tailgate mass can vary between the vehicles in the range. The maximum lifting capacity of the tailgate must not exceed 500kg. It depends on the type of vehicle and the type of tailgate bearing structure. In all cases, and particularly in the case of vehicles without an additional chassis, the loading gate mounting system must include a structure that allows forces to be distributed over the vehicle s chassis. Lift tailgate maximum lifting capacity Lift tailgate maximum lifting capacity + Tailgate mass Panel Van 500 kg 700 kg ChassisCab Platform Cab Max. load to be determined by the coachbuilder according to the type of mounting. Mounting on a built-on structure is advised. Max. load to be determined by the coachbuilder according to the type of mounting. The absence of an upper structure (rear ring) limits the maximum permissible load on the tailgate NB: The converter shall be solely responsible for any changes made. For all versions, the converter shall ensure that the lifting tailgate does not adversely affect the integrity or reliability of the basic vehicle. up-to-date data on body guidelines (online body guidelines). Data status September

59 148 DETERMINING THE CENTRE OF GRAVITY The vehicle's centre of gravity after conversion can be determined: - by measurement - by calculation. 1. DETERMINING THE CENTRE OF GRAVITY POSITION BY MEASUREMENT 1.1. X and Y position The x and y position of the centre of gravity is determined by measuring the mass on each wheel and calculating the barycentre. S Gv1 Gh1 H R sc Xv1 Xh1 ES1 S = centre of gravity E = Wheelbase v = Front axle h = Rear axle H = Height of centre of gravity R sc = Loaded radius of the tyre, axle not raised (in m) up-to-date data on body guidelines (online body guidelines). Data status June

60 148 DETERMINING THE CENTRE OF GRAVITY 1.2. Z position The Z position of the centre of gravity is determined by measuring the variation in mass on one axle. The vehicle is weighed horizontally, and then inclined at an angle. H = Height of the centre of gravity in relation to the floor (in m) Rsc = Loaded radius of the tyre, axle not raised (in m) E = Wheelbase (in m) M = Radial force variation measured on the axle (in kg) Mtot = Total vehicle mass (in kg) = Vehicle lift angle (in rad) Gv2 S Gh2 XV2 Xh2 ES2 up-to-date data on body guidelines (online body guidelines). Data status June

61 148 DETERMINING THE CENTRE OF GRAVITY The measurement requires the following precautions to be taken: - no moving fluids => tank completely empty or completely full - Tyres overinflated to the maximum permitted level (to minimise loaded radius variations) - Front and rear suspensions locked - the brakes (service and handbrake) MUST NOT be applied - in order to obtain a reliable measurement, the vehicle must be lifted at an angle of at least 20 - either the front or rear axle may be lifted 2. DETERMINING THE CENTRE OF GRAVITY POSITION BY CALCULATION The converted vehicle's centre of gravity is determined by calculating the barycentre between the centre of gravity positions of the basic and converted vehicles. Comments on the information in the table below: - The centre of gravity position is given in the vehicle reference guide and in relation to the floor where the Z dimension is concerned (indicated as Z (mm)/floor' in the table) - The positions are given for the extremes (vehicle with no options and with all options). It will be necessary to interpolate for an intermediate vehicle. Glossary: - TRS: front-wheel drive vehicle - PRS: rear-wheel drive vehicle with single-wheel - PRJ: rear-wheel drive vehicle with twin-wheel - E1-3: wheelbase (from 1 to 3) E1 = 3182 mm E2 = 3682 mm E3 = 4332 mm - P1-2: rear overhang (1 and 2) P1* = short P2* = long - H1-3: roof height* (from 1 to 3) - D1-2: Motor (1-2) - EURO 5: emissions compliance - t: Tons (Weight for GVW 2,8 / 3,3 / 3,5 / 4,5) = For the corresponding values, refer to the Chapter 7 up-to-date data on body guidelines (online body guidelines). Data status June

62 148 DETERMINING THE CENTRE OF GRAVITY PANEL VAN MIN. UNLADEN (no options) Vehicle variant X (mm) Y (mm) Z (mm) / floor X (mm) MAX. UNLADEN (all options) Y (mm) Z (mm) / floor PRS-E2P2H2 EURO5 D1/D2 3,5t PRS-E2P2H3 EURO5 D1/D2 3,5t PRJ-E2P2H2 EURO5 D1/D2 4,5t PRJ-E2P2H3 EURO5 D1/D2 4,5t PRJ-E3P2H2 EURO5 D1/D2 4,5t PRJ-E3P2H3 EURO5 D1/D2 4,5t TRS-E1P1H1 EURO5 D1/D2 2,8t TRS-E1P1H1 EURO5 D1/D2 3,3t TRS-E1P1H1 EURO5 D1/D2 3,5t TRS-E1P1H2 EURO5 D1/D2 2,8t TRS-E1P1H2 EURO5 D1/D2 3,3t TRS-E1P1H2 EURO5 D1/D2 3,5t TRS-E2P1H3 EURO5 D1/D2 3,3t TRS-E2P1H3 EURO5 D1/D2 3,5t TRS-E3P1H2 EURO5 D1/D2 3,5t TRS-E3P1H3 EURO5 D1/D2 3,5t TRS-E2P1H2 EURO5 D1/D2 3,3t TRS-E2P1H2 EURO5 D1/D2 3,5t PLATFORM CAB MIN. UNLADEN (no options) Vehicle variant X (mm) Y (mm) Z (mm) / floor X (mm) MAX. UNLADEN (all options) Y (mm) Z (mm) / floor TRS-E2P1H1 EURO5 D1/D2 3,5t TRS-E2P1H2 EURO5 D1/D2 3,5t TRS-E3P1H1 EURO5 D1/D2 3,5t TRS-E3P1H2 EURO5 D1/D2 3,5t TRS-E1P1H1 EURO5 D2 3,5t up-to-date data on body guidelines (online body guidelines). Data status June

63 148 DETERMINING THE CENTRE OF GRAVITY CHASSIS CAB MIN. UNLADEN (no options) Vehicle variant X (mm) Y (mm) Z (mm) / floor X (mm) MAX. UNLADEN (all options) Y (mm) Z (mm) / floor PRJ-E2P2 EURO5 D1/D2 4,5t PRJ-E3P2 EURO5 D1/D2 4,5t PRJ-E2P1 prime EURO5 D1/D2 4,5t PRS-E2P1 EURO5 D1/D2 3,5t PRS-E3P1 EURO5 D1/D2 3,5t TRS-E2P1 EURO5 D1/D2 3,5t TRS-E3P1 EURO5 D1/D2 3,5t CHASSIS CREW CAB MIN. UNLADEN (no options) Vehicle variant X (mm) Y (mm) Z (mm) / floor X (mm) MAX. UNLADEN (all options) Y (mm) Z (mm) / floor PRJ-E2P2 EURO5 D1/D2 4,5t PRJ-E3P2 EURO5 D1/D2 4,5t PRS-E2P1 EURO5 D1/D2 3,5t PRS-E3P1 EURO5 D1/D2 3,5t TRS-E2P1 EURO5 D1/D2 3,5t TRS-E3P1 EURO5 D1/D2 3,5t N.B.: The floor specified in the tables is an unladen floor in running condition. X, Y and Z refer to the fixed reference system in the vehicle, see Chapter 6 Other important measurements are in the Conversion Guideline, Part 1, Chapter 7 up-to-date data on body guidelines (online body guidelines). Data status June