Conversion Guideline NEW Movano X62

Transcription

1 Conversion Guideline NEW Movano X62 Part 2 - Chapter Edition: August 2011 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany

2 CONTENTS Conversion Guideline- Part 2 CHAPTER DESCRIPTION PAGE 24 DASH PANEL CROSS MEMBER 3 25 CAB FLOOR DRILLING AREA 5 26 DRILLING AREA ON REAR FLOOR OF PANEL VAN 6 27 CAB ROOF FOR CAMPERVAN * MIRRORS AIR EXTRACTION TYRES AND TURNING CIRCLE SPARE WHEEL AIRBAG DEPLOYMENT VOLUME * SEATS SEAT BELTS LAMP INSTALLATION EUROPEAN REGULATIONS HEIGHT OF CAB ROOF GROUND CLEARANCE * CONVERSION LIMITS WITH ESP * INSTALLATION AND ATTACHMENT OF EQUIPMENT ON DASHBOARD VEHICLE SPEED RESTRICTION TABLE OF EQUIPMENT WEIGHTS ADDITIONAL WEIGHT ON DOORS * ASSEMBLING A SECOND HEATER UNIT INSTALLING ADDITIONAL AIR-CONDITIONING INSTALLING AN ADDITIONAL BOILER 54 * = This chapter is new or has changed, last Edition Feb up-to-date data on body guidelines (online body guidelines).

3 24 BULKHEAD FEED-THROUGH Opel recommends using the existing grommet. However, if the coachbuilder faces major constraints, another hole may be used (see paragraph 2). 1. Using the existing grommet So as to not adversely affect certain performance levels, only the grommet for the main wiring harness behind the engine interconnection unit may be used. The plastic clamp on the passenger compartment side must be changed (for identical reassembly). Sealing must not be adversely affected. LOCATION OF THE HARNESS GROMMET up-to-date data on body guidelines (online body guidelines). Data status September

4 24 BULKHEAD FEED-THROUGH 2. Using another hole The area in which the hole is made must be chosen in accordance with technical constraints, particularly: - Proximity to neighbouring parts (depending on the version) - Travel/clearances (pedals, engine, etc.) - Proximity to heat sources (exhaust, etc.). In any case, no holes may be made in the bulkhead: - In weld areas - In mating areas - In the areas with structural constraints specified below: LOCATION OF AREAS WITH CONSTRAINTS ON THE BULKHEAD (INSIDE THE PASSENGER COMPARTMENT) Areas with constraints N.B: Holes adversely affect the following performance levels: - Acoustics - Sealing - Perception of external odours Perform burring and corrosion prevention treatment (see technical data sheet: Specific guidelines on corrosion) on each edge of the hole created in the bulkhead. Excluding round holes, all cut-out shapes must have a cut-out radius. Check that the sealing of the bulkhead feed-through is effective. up-to-date data on body guidelines (online body guidelines). Data status September

5 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

6 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

7 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

8 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

9 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

10 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 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, / 1.5 up-to-date data on body guidelines (online body guidelines). Data status June

11 27 CAB ROOF FOR CAMPERVAN CHASSIS CAB 523 +/ 1.5 1,396 up-to-date data on body guidelines (online body guidelines). Data status June

12 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: To change the indicator power supply, see chapter 125 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 (S) 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 September

13 28 MIRRORS LONG ARM DOOR MIRRORS (Overall width from 2,170 to 2,350 mm) Type Side Steering Reference Electric with defrosting Right (S) Left Steering left R (16W) (S) R (16W) Electric with defrosting Right (S) Left Steering right R (16W) (S) R (16W) (S): with temperature sensor up-to-date data on body guidelines (online body guidelines). Data status September

14 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

15 29 AIR EXTRACTION CHASSIS DOUBLE CAB up-to-date data on body guidelines (online body guidelines). Data status June

16 29 AIR EXTRACTION PANEL VAN air outlets up-to-date data on body guidelines (online body guidelines). Data status June

17 30 TYRES AND TURNING CIRCLE TYRES The basic tire assembly, except in specific situations, is as follows: Version Drive GVW [ kg ] Rear wheels Tyre size Rim size PANEL VAN FWD 2800 Single 215/65 R 16 C 109/107R 6 1/2Jx16/ET66 PANEL VAN FWD 3300 Single 215/65 R 16 C 109/107R 6 1/2Jx16/ET66 PANEL VAN + CHASSIS CAB + CREW CAB + PLATFORM CAB PANEL VAN + CHASSIS CAB + CREW CAB PANEL VAN + CHASSIS CAB + CREW CAB PANEL VAN + CHASSIS CAB + CREW CAB FWD 3500 Single 225/65 R16C (112/110)R 6 1/2Jx16/ET66 RWD 3500 Single 235/65 R16C (115/113)R 7Jx16/ET66 RWD 3500 Twin 195/75 R16C (107/105)T 5 1/2Jx16/ET117 RWD 4500 Twin 195/75 R16C (107/105)T 5 1/2Jx16/ET117 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) 12 13,6 15,65 13,6 15,65 Wall-to-wall turning circle diameter (m) 12,5 14,1 16,15 14,1 16,15 up-to-date data on body guidelines (online body guidelines). Data status September

18 30 TYRES AND TURNING CIRCLE TURNING CIRCLE DIAMETERS IN RELATION TO WHEELBASE 18,00 Turning circle (m) 16,00 14,1 16,15 15,65 14,00 12,5 13,6 12, , Wheelbase (mm) Wall-to-wall Kerb-to-kerb up-to-date data on body guidelines (online body guidelines). Data status September

19 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

20 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

21 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

22 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: The front passenger airbag can be deactivated. Consult the repair manual to configure the ECU in accordance with the equipment fitted. 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

23 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

24 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

25 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 (in instrument cluster) 5: Airbag 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

26 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 January

27 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). For regulatory reasons, it is not possible to replace a passenger seat with a two-seater bench or vice versa, without re-applying for approval of the new arrangement. On reassembly, tightening torques must be respected (use of a calibrated torque wrench is recommended). up-to-date data on body guidelines (online body guidelines). Data status January

28 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

29 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 September

30 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 September

31 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 September

32 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 September

33 36 LAMP INSTALLATION EUROPEAN REGULATIONS ADDITIONAL INFORMATION If the vehicle overall width > 2100mm Mandatory use of gauge lights (2 front, 2 rear). If the vehicle overall length < 6000mm 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 > 6000mm 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: National regulations apply to all lamp and turn signal units. For vehicles over 6000mm in length, there is the option UZB. This includes site preparation for flashing lights (Type W16W). See also Chapter 125. up-to-date data on body guidelines (online body guidelines). Data status September

34 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

35 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

36 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

37 40 CONVERSION LIMITS WITH ESP ESP is a dynamic vehicle control system which controls both dynamic directional and transverse forces acting on the vehicle. Modifications to vehicles with ESP may cause this system to stop functioning correctly and may lead to system shutdowns and incorrect control interventions. Conversions must not disrupt the operation of the ESP. COMPLIANCE WITH THE CENTRE OF GRAVITY See chapter 1 Calculating the centre of gravity YES Inside V red frame NO Outside V red frame If modification of: Structure Frame Powertrain Retarder ESP sensors Roof racks See table in chapter 2. Recommendation: Order a vehicle without ESP In all cases, the coach-builder, who is solely liable, will ensure the level of ESP functioning and vehicle handling. Refer to the general recommendations. up-to-date data on body guidelines (online body guidelines). Data status December

38 40 CONVERSION LIMITS WITH ESP 1. CENTRE OF GRAVITY POSITION OF THE CONVERTED VEHICLE The centre of gravity of the converted vehicle must be calculated when the vehicle is: - - Laden = GVW (Gross Vehicle Weight) with technical maximum permitted on one axle To ensure that the ESP functions properly, the centre of gravity position of the converted vehicle, when laden, must remain within the limits of the red frame V. The tolerance for X and Y is ± 8% Only the Z position of the centre of gravity when laden (GVW) should be taken into consideration. FRONT WHEEL DRIVE Wheelbase X mini/maxi (mm) Y (mm) Z maxi (mm) /2097 Y ± Panel Van and Platform Cab, GVW = 3,5t, /2435 Y ± E25 - camper van 1945/2330 Y ± (wider axle) /2742 Y ± up-to-date data on body guidelines (online body guidelines). Data status December

39 40 CONVERSION LIMITS WITH ESP REAR WHEEL DRIVE Wheelbase X mini/maxi (mm) Y (mm) Z maxi (mm) Panel van GVW = 3,5t, single wheels Panel van GVW = 4,5t twin wheels /2652 Y ± /2975 Y ± /3412 Y ± FRONT WHEEL DRIVE Wheelbase X mini/maxi (mm) Y (mm) Z maxi (mm) */2548 Y ± Chassis Cab and Double Cab GVW = 3,5t 4006 E25 - camper van 1945/2330 Y ± (wider axle) /2992 Y ± REAR WHEEL DRIVE Wheelbase X mini/maxi (mm) Y (mm) Z maxi (mm) Chassis Cab and Double Cab GVW = 3,5t single wheels Chassis Cab and Double Cab GVW = 4,5t twin wheels /2522 Y ± /2907 Y ± /3059 Y ± Note: - For the calculation of the centre of gravity and its position on the basic vehicle, see chapter The X dimensions are given in relation to the centre of the FRONT wheel - The Y dimensions are given in relation to the centreline of the vehicle - The Z dimensions are measured up-to-date data on body guidelines (online body guidelines). Data status December

40 40 CONVERSION LIMITS WITH ESP 2. MODIFICATIONS AFFECTING THE OPERATION OF THE ESP The table below details the modifications of parts or functions: * : the operation of ESP is greatly affected by this type of transformation ** : the operation of ESP is likely to be affected if the corresponding comments are not complied with. Modification Detail s * ** Comments Structure Chassis Wheelbase Body stiffness Tracks Suspension (springs, travel limits, anti-roll bars, shock absorbers) Tyres (dimensions, stiffness, etc.) Ratio of the steering wheel and wheels Braking system Power train Engine, gearbox X X X X X X X X Maximum 30% reduction in body torsional stiffness along the X axis (measured between the two axles) pre- and postconversion. Anything that changes the stiffness and/or elastokinematics of the suspension. Only tyres with characteristics identical to standard tyres (dimensions, load index, speed code) Only if different from standard tyres Only one modification of the rigid pipe routing is permitted. Electromagnetic retarder X The sensors connected to the ESP (steering wheel angle, wheel speed, lateral acceleration, yaw angle) Displacement and modification of the installation X CAN - Bus Roof rack Trailer (semi-trailer) Modifications to the sensors (steering angle sensor, yaw rate sensor, wheel rotational speed sensor). Modifications to the permissible gross vehicle weight. X X X X X Comply with the permitted load on the standard version. up-to-date data on body guidelines (online body guidelines). Data status December

41 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. It is forbidden to make modifications to the cross girder of the dashboard, as this element is part of the vehicle structure. 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 September

42 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 September

43 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 September

44 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

45 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

46 43 TABLE OF EQUIPMENT WEIGHTS up-to-date data on body guidelines (online body guidelines). Data status March

47 43 TABLE OF EQUIPMENT WEIGHTS up-to-date data on body guidelines (online body guidelines). Data status March

48 43 TABLE OF EQUIPMENT WEIGHTS up-to-date data on body guidelines (online body guidelines). Data status March

49 45 ADDITIONAL WEIGHT ON DOORS The addition of weight on the doors is tolerated within the following limits: Sliding side door: - no additional weight if glass door with sliding window. - up to 4 kg if glass door, without sliding window. - up to 10 kg if panel door and providing that the insulation has been removed. Rear swing doors Weight per door: - up to 3.5 kg if glass door. - up to 10 kg if panel door (without exceeding 5 kg on the upper area: defined by a horizontal centre line in relation to the 2 door hinges). Note On the rear swing doors the effect of the additional weight is more critical in the upper part of the doors. If there are ladder type accessories, then their weight must be deducted from the above-mentioned recommendations. up-to-date data on body guidelines (online body guidelines). Data status March

50 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 September

51 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 September

52 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. The air conditioning of series is compatible with an evaporator of 4kW. With a more important evaporator, the performance decreases. 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

53 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

54 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

55 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

56 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

57 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