Documente Academic
Documente Profesional
Documente Cultură
Contents
1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.2.1 2.3 2.4 2.4.1 2.4.2 2.4.3 2.5 2.5.1 2.5.2 2.5.3 2.6 2.7 2.8 2.9 2.10 2.11 3 3.1 3.2 3.3 3.3.1 3.4 3.5 3.6 3.7 3.7.1 3.7.2 3.8 3.9 3.9.1 3.9.2 3.9.3 3.10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 4 The aim of these Directives . . . . . . . . . . . . . . . 4 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operational safety . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Vehicle and model designations . . . . . . . . . . . 8 Overview of Vito models . . . . . . . . . . . . . . . . . 9 Seating options in the Vito. . . . . . . . . . . . . . . 10 Overview of Viano models . . . . . . . . . . . . . . . 11 Technical advice for body/equipment manufacturers . . . . . . . . . . . . . . . . . . . . . . . . 12 Certificate of endorsement . . . . . . . . . . . . . . 12 Issuing a certificate of endorsement . . . . . . . 13 Legal claims . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tender drawings, technical data, product information/Mercedes-Benz body/ equipment manufacturer system (MB-AS). . . 14 PC program (ISDN/modem) . . . . . . . . . . . . . 14 Faxback system . . . . . . . . . . . . . . . . . . . . . . . 14 Workshop Information System (WIS) . . . . . . . 14 Product liability . . . . . . . . . . . . . . . . . . . . . . . 15 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . 16 Mercedes star and logo . . . . . . . . . . . . . . . . . 17 Accident prevention . . . . . . . . . . . . . . . . . . . . 18 Reprocessing components recycling . . . . . 19 Quality assurance system . . . . . . . . . . . . . . . 20 Planning conversions . . . . . . . . . . . . . . . . . 21 Vehicle selection . . . . . . . . . . . . . . . . . . . . . . 21 Vehicle modifications. . . . . . . . . . . . . . . . . . . 22 Dimensions and weights . . . . . . . . . . . . . . . . 23 Weight distribution. . . . . . . . . . . . . . . . . . . . . 23 Vehicle identification data . . . . . . . . . . . . . . . 25 Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . 26 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Bolted and welded connections . . . . . . . . . . . 28 Bolted connections . . . . . . . . . . . . . . . . . . . . 28 Welded connections. . . . . . . . . . . . . . . . . . . . 29 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . 32 Maintenance and repairs . . . . . . . . . . . . . . . . 33 Preparation for storing the vehicle. . . . . . . . . 33 Battery maintenance and storage . . . . . . . . . 34 Preparation for handing over the converted vehicle. . . . . . . . . . . . . . . . . . . . . . 34 Optional equipment . . . . . . . . . . . . . . . . . . . . 35
4 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.5 4.5.1 4.5.2 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.7 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7
Technical threshold values for planning . . 36 Basic vehicle threshold values . . . . . . . . . . . . 36 Steerability. . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Extreme permissible positions of centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Parts which must not be welded . . . . . . . . . . 36 Parts which must not be welded . . . . . . . . . . 36 Parts in which holes may not be drilled . . . . . 36 Chassis threshold values . . . . . . . . . . . . . . . . 37 Permissible axle loads . . . . . . . . . . . . . . . . . . 37 Approved tyre sizes . . . . . . . . . . . . . . . . . . . . 37 Turning circle diameter . . . . . . . . . . . . . . . . . 37 Modifications to the axles . . . . . . . . . . . . . . . 37 Modifications to the steering system. . . . . . . 37 Modifications to the brake system . . . . . . . . 38 Modifications to the springs/spring mountings/ shock absorbers . . . . . . . . . . . . . . . . . . . . . . 38 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . 38 Bodyshell threshold values . . . . . . . . . . . . . . 39 Modifications to the bodyshell. . . . . . . . . . . . 39 Vehicle roof/roof load. . . . . . . . . . . . . . . . . . 39 Engine periphery/drive train threshold values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Modifications to the engine/drive train parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Interior threshold values . . . . . . . . . . . . . . . . 41 Modifications to the airbags and belt tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Modifications to the seats . . . . . . . . . . . . . . . 41 Electrical system/electronics threshold values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electrical lines/fuses . . . . . . . . . . . . . . . . . . 42 Vehicle outline and side marker lamps . . . . . 42 Retrofitting electrical equipment ("e" mark). . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Mobile communications systems. . . . . . . . . . 42 CAN bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electronic Stability Program . . . . . . . . . . . . . 42 Additional equipment threshold values . . . . . 43 Damage prevention . . . . . . . . . . . . . . . . . . . 44 Brake hoses/cables and lines. . . . . . . . . . . . 44 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . 45 Corrosion protection measures . . . . . . . . . . . 46 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Towing and tow-starting. . . . . . . . . . . . . . . . . 49 Storing and delivering the vehicle . . . . . . . . . 50 Electromagnetic compatibility (EMC). . . . . . . 51
Contents
6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7 6.5.8 6.5.9 6.5.10 6.5.11
Modifications to the basic vehicle . . . . . . . 52 Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Basic chassis . . . . . . . . . . . . . . . . . . . . . . . . . 52 Springs/shock absorbers . . . . . . . . . . . . . . . 52 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . 53 Pneumatic suspension . . . . . . . . . . . . . . . . . . 54 Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . 55 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Bodyshell/bodywork . . . . . . . . . . . . . . . . . . . 56 General notes on the bodyshell/ bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Modifying the partition. . . . . . . . . . . . . . . . . . 57 Sidewall, windows, doors and flaps . . . . . . . . 57 Wings and wheel arches . . . . . . . . . . . . . . . . 58 Chassis end cross-member . . . . . . . . . . . . . . 58 Bodyshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Underbody panelling . . . . . . . . . . . . . . . . . . . 59 Roof of panel van/Traveliner . . . . . . . . . . . . 59 Engine periphery/drive train . . . . . . . . . . . . . 61 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 61 Engine cooling . . . . . . . . . . . . . . . . . . . . . . . . 61 Engine air intake . . . . . . . . . . . . . . . . . . . . . . 62 Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . 62 Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Safety equipment. . . . . . . . . . . . . . . . . . . . . . 63 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Reducing noise in the vehicle interior . . . . . . 69 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Electrical system/electronics . . . . . . . . . . . . 70 General notes. . . . . . . . . . . . . . . . . . . . . . . . . 70 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Power supply interfaces . . . . . . . . . . . . . . . 71 Retrofitting electrical equipment . . . . . . . . . . 76 Mobile communications systems. . . . . . . . . . 76 Electrical lines/CAN bus . . . . . . . . . . . . . . . . 77 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . 81 Electronic Stability Program (ESP) . . . . . . . . 82 Electromagnetic compatibility (EMC). . . . . . . 83 Retrofitting an alternator . . . . . . . . . . . . . . . . 83
6.6 6.6.1 6.6.2 6.6.3 6.7 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 7 7.1 7.1.1 7.1.2 7.2 7.3 7.4 7.5 7.6 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7
Additional equipment. . . . . . . . . . . . . . . . . . . 85 Retrofitting the air conditioning . . . . . . . . . . . 85 Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . 85 Power take-offs . . . . . . . . . . . . . . . . . . . . . . . 85 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 86 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Attachment above cab. . . . . . . . . . . . . . . . . . 86 Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . 86 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . 87 Conversion work . . . . . . . . . . . . . . . . . . . . . 88 Modifications to the interior . . . . . . . . . . . . . 88 Modifications to the cockpit . . . . . . . . . . . . . 88 Retrofitting additional seats. . . . . . . . . . . . . . 88 Modifications to closed panel vans . . . . . . . . 89 Refrigerated vehicles . . . . . . . . . . . . . . . . . . . 91 Motor caravans . . . . . . . . . . . . . . . . . . . . . . . 92 Retrofitting a raised roof . . . . . . . . . . . . . . . . 93 Increasing the roof height . . . . . . . . . . . . . . . 94 Technical data . . . . . . . . . . . . . . . . . . . . . . . 95 Vito 109 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 95 Vito 111 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 97 Vito 115 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 99 Vito 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Vito 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Viano CDI 2.0/CDI 2.2 . . . . . . . . . . . . . . . . 105 Viano 3.0/3.2 . . . . . . . . . . . . . . . . . . . . . . . 107
1 Introduction
These Body/Equipment Mounting Directives provide the body manufacturers with important technical information about the basic vehicle. This information must be observed by the body manufacturer in the production of bodies and their equipment, fittings and conversions. Due to the great number of body manufacturers and body types, DaimlerChrysler AG cannot foresee all possible changes, e.g. to road performance, stability, load distribution, the vehicle's centre of gravity and its handling characteristics, caused by bodies and their equipment, fittings and conversions. For this reason, DaimlerChrysler AG can assume no liability for accidents or injuries caused by such modifications to your vehicle, even if these modifications have an adverse affect on the complete vehicle. As a manufacturer, DaimlerChrysler AG is accordingly only liable for its own designs and products. The body manufacturer itself, as manufacturer of the complete vehicle, is obliged to make sure that bodies and their equipment, fittings and conversions are not faulty and that they cannot lead to faults or hazards on the complete vehicle. If this obligation is violated in any way, the body manufacturer will assume full product liability. By drawing up these Body/ Equipment Mounting Directives, DaimlerChrysler AG fulfils its obligation to brief the body manufacturers and inform them of important aspects to observe when carrying out conversions. These Body/Equipment Mounting Directives are intended primarily for professional manufacturers of bodies and add-on equipment and who carry out fittings and conversions of our vehicles. For this reason, these Body/Equipment Mounting Directives assume that the body manufacturer possesses the necessary background knowledge. If you intend to carry out work on bodies and their equipment, fittings or conversions, please be aware that certain types of work (e.g. welding work on load-bearing components) may only be carried out by qualified personnel. This will avoid the risk of injury and will attain the degree of quality required for bodies and their equipment, fittings and conversions.
1.1
The following Body/Equipment Mounting Directives are divided into 8 related sections to help you to find information quickly: 1. Introduction 2. General 3. Planning conversions 4. Technical threshold values for planning 5. Damage prevention 6. Modifications to the basic vehicle 7. Conversion work 8. Technical data Appendix: - Index You can obtain further information and technical data from the tender drawings in the Mercedes-Benz body/ equipment manufacturer system ( page 14). The index, in PDF format, is linked to help you find information quickly. The threshold values chosen in section 4 must be adhered to and must form the basis of planning. The sections entitled "Modifications to the basic vehicle" and "Conversions specifications" are the main source of technical information contained in these Body/ Equipment Mounting Directives.
A warning draws your attention to possible risks of accident and injury to yourself and others.
Environmental note
!
This note draws your attention to possible hazards to your vehicle.
i
This tip contains advice or further information you may find useful.
page
This symbol indicates the page on which you will find further information on the subject. This continuation symbol indicates an interrupted sequence of actions that will be continued on the next page.
Risk of accident
Before installing non-Mercedes-Benz bodies or attaching, fitting or converting assemblies, please read the relevant section of the detailed Owner's Manual/ Operating Instructions. You could otherwise fail to recognise dangers and endanger yourself or others. Notes on vehicle safety We recommend the following: Use only parts and assemblies or recommended conversion parts and accessories that have been recommended by Mercedes-Benz for the type of vehicle concerned. Parts that modify the vehicle such that they: change the vehicle type approved in the general operating permit can be expected to endanger road users, or adversely affect exhaust emissions or noise levels will invalidate the vehicle's general operating permit in many countries The use of parts, assemblies or conversion parts and accessories which have not been recommended may jeopardise the safety of the vehicle.
!
Observe the national specifications since attachments, installation of bodies, conversion and installation work on the vehicle could change the approved vehicle type and may invalidate the general operating permit.
Risk of accident
Work incorrectly carried out on electronic equipment and its software could prevent this equipment from working. Since the electronic systems are networked, this might also affect systems that have not been modified. Malfunctions in the electronic systems could seriously jeopardise the operational safety of the vehicle. Have work on or modifications to electronic components carried out at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required. Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose. In particular, work relevant to safety or on safety-related systems must be carried out at a qualified specialist workshop. Some of the safety systems only function when the engine is running. For this reason, do not switch off the engine when the vehicle is in motion.
2 General
2.2 Overview of Vito models
2.2 Overview of Vito models
Long Short wheelbase, long overhang, length 4,993 mm Extra long Long wheelbase, long overhang, length 5,223 mm
Dualiner
Traveliner
You will find explanations of models and engine codes in the table ( page 8)
2 General
2.2 Overview of Vito models
2.2.1 Seating options in the Vito
N23.00-2019-00
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2 General
2.3 Overview of Viano models
2.3 Overview of Viano models
Long Short wheelbase, long overhang, length 4,993 mm Extra long Long wheelbase, long overhang, length 5,223 mm
Fun
Marco Polo
You will find explanations of models and engine codes in the table ( page 8)
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2 General
2.4 Technical advice for body/equipment manufacturers
2.4 Technical advice for body/equipment manufacturers
Technical advice regarding the basic vehicle Herr Enrique Giminez Castro and his team at the order processing centre in the Vitoria factory are available to answer any questions you may have about the basic vehicle. Telephone: Fax: Postal address: +34 (945)-18 55 44 +34 (945)-18 55 40 Mercedes Benz Espaa S.A. Avda. de los Huetos. 73 y 75 E-01010 Vitoria, Spain Technical advice outside Germany The body/equipment manufacturer advisors at the DaimlerChrysler AG organisation in your country are available to offer technical advice and to answer questions about conversions.
Technical advice regarding the feasibility of the conversion Herr Leipner and his team are available to offer technical advice to body/equipment manufacturers and to issue certificates of endorsement. The relevant members of staff can be contacted on: Telephone: +49 (0)711-17-58438 +49 (0)711-17-50810 Fax: Postal address: +49 (0)711-17-32323 DaimlerChrysler AG HPC (in-house postcode) C103 Department ET/3M 70546 Stuttgart, Germany Body/equipment manufacturer information and certification Herr Pflger and his team are available for any questions and suggestions you may have regarding the sale of existing and new products, as well as about the ABH Portal and the qualified supplier list. The relevant members of staff can be contacted on: Telephone: +49 (0)711-17-90819 +49 (0)711-17-90591 +49 (0)711-17-90507 Fax: Postal address: +49 (0)711-17-90868 DaimlerChrysler AG HPC (in-house postcode) Z602 Department VT/P3 70546 Stuttgart, Germany
2.4.1
Certificate of endorsement
DaimlerChrysler AG does not issue body/equipment approval certificates for non-Mercedes-Benz conversions. It only provides body manufacturers with important information and technical guidelines for the correct handling of the product by means of these Directives. DaimlerChrysler AG therefore recommends that conversions are carried out in accordance with these Mercedes-Benz Body/Equipment Mounting Directives. DaimlerChrysler AG advises against bodies and their equipment, fittings and conversions which: are not completed in accordance with the Mercedes-Benz body/equipment mounting directive exceed the permissible gross vehicle weight would exceed the permissible axle loads DaimlerChrysler AG issues certificates of endorsement on a discretionary basis, based on the following requirements:
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2 General
2.4 Technical advice for body/equipment manufacturers
DaimlerChrysler AG bases its assessment solely on the documents presented (by the company which carries out the conversion). It checks and declares safe only the explicitly described scopes and their general compatibility with the vehicle specified and its connection points or, in the case of vehicle modifications, the basic constructional permissibility for the specified vehicle. The certificate of endorsement does not apply to the design of the conversion as a whole, nor its functions or intended use. The endorsement is only valid if the design, production and installation carried out by the company is effected to the state of the art and in accordance with the valid DaimlerChrysler AG Body/Equipment Mounting Directives unless deviations have been endorsed in these Directives. The certificate of endorsement does not absolve the company which is carrying out the modifications from its product liability or the obligation to carry out its own calculations, checks and tests of the entire vehicle to ensure the operating safety, road safety and handling characteristics of the entire vehicle it has manufactured. Accordingly, the body manufacturer has the sole responsibility for ensuring the compatibility of the body and its equipment, fittings and conversion with the basic vehicle, as well as for the operating and road safety of the entire vehicle. Conditions of vehicle operation, e.g. on poor roads in very dusty conditions at high altitude at extremely high or low ambient temperatures Certification (e mark, seat tension test, etc.) Queries can be avoided and processing accelerated by providing complete documentation.
2.4.3
Legal claims
No legal claim can be made as to the issue of a certificate of endorsement. DaimlerChrysler AG reserves the right to refuse an endorsement certificate due to ongoing technical development and the knowledge gained from it, even if a similar certificate was granted in the past. The certificate of endorsement may be limited to single vehicles. Subsequent granting of a certificate of endorsement for vehicles already completed or delivered may be refused. The body manufacturer alone is responsible for: the functionality and compatibility of the body and its equipment, fittings and conversion with the basic vehicle the operating and road safety all bodies and their equipment, fittings and conversion and other installed parts
!
Comply with all national laws, guidelines and vehicle registration regulations.
2.4.2
In particular cases, the conversion drawings may be presented to the responsible department ( page 12) before the work is commenced. The drawings must contain the following information: All deviations from the Mercedes-Benz Body/ Equipment Mounting Directives Complete data on dimensions, weights and centre of gravity (weight certificates).
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2 General
2.5 Tender drawings, technical data, product information/Mercedes-Benz body/ equipment manufacturer system (MB-AS)
2.5 Tender drawings, technical data, product information/Mercedes-Benz body/equipment manufacturer system (MB-AS) 2.5.2 Faxback system
Vehicle data can be called up and printed out using a fax machine with "faxback" function. Additional information on this is provided in the user's manual for the fax machine. After selecting the faxback function and entering the number +49 (0)7 1117-86 40 40, you will receive the MB-AS title page containing a summary of the information categories available and their faxback numbers. A total of approximately 1,500 technical data sheets and over 3,000 tender drawings as well as additional information for body/equipment manufacturers is available on faxback. All vehicle information available, the PC program and all services associated with the faxback system are free of charge. For further information about MB-AS, call +49 (0)711-17-3 33 22.
You can obtain tender drawings and technical data from the Mercedes-Benz body/equipment manufacturer system (MB-AS) at: http://mbas.mercedes-benz.com MB-AS is a modern communications system for exchanging tender drawings, technical data and product information for all commercial vehicles. Make sure that work is only carried out in accordance with the current body/equipment mounting directive, which you can find on the Internet. Current commercial vehicle information and data can be called up with minimum effort, either in fax or data processing format, by modem or by ISDN data transfer, and can then be printed and processed. You are thus optimally equipped to provide your customers with quick, low-cost and comprehensive advice, feasibility studies and plans to determine the final vehicle design, to compile quotations and to prepare designs.
2.5.3
The Workshop Information System (WIS) is available to you as an additional source of information. For example, in the WIS you will find: Basic data (dimensions, tightening torques) Function descriptions Wiring diagrams Repair instructions Maintenance sheets Information about the WIS can be obtained from your DaimlerChrysler branch or from: Telephone: Fax: Postal address: +49 (0)711-17-83170 +49 (0)711-17- 40082 DaimlerChrysler AG HPC (in-house postcode) R800 Department GSP/TIM 70546 Stuttgart, Germany
2.5.1
PC program (ISDN/modem)
The vehicle information required can be selected and ordered directly from easy-to-use selection catalogues on your PC using this Windows program. This program is available to you free of charge. The following are available: Tender drawings in DXF, DWG and bitmap formats (DIN A4) Technical data sheets Body/Equipment Mounting Directives Body/equipment manufacturer information Information about power take-offs The data can be transferred within a few minutes via ISDN or modem.
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2 General
2.6 Product liability
2.6 Product liability
Product liability (under civil law) means the liability of a manufacturer for any consequential damage arising to the user of the product or a third party if the product does not possess the degree of operating safety or reliability which can reasonably be expected by the injured party. Please note the following points with regard to product liability: Each manufacturer is liable for the products it manufactures. As a manufacturer, DaimlerChrysler AG is accordingly only liable for its own designs and products. DaimlerChrysler AG does not therefore accept any liability for damage resulting from defects in retrofitted products produced by third-party manufacturers. The body/equipment manufacturer shall bear sole responsibility for: the operating and road safety of the conversion the operating and road safety of parts and conversion parts testing and maintaining the operating and road safety of the entire vehicle after the conversion (handling, braking and steering characteristics must not be adversely affected by the conversion) the effects of parts or conversion parts on the vehicle consequential damage resulting from the attachment, installation or conversion consequential damage resulting from retrofitted electrical and electronic systems the operational reliability and freedom of movement of all moving parts of the vehicle after the conversion (e.g. axles, springs, propeller shafts, steering, transmission linkage, etc.) even in the case of diagonal torsion Work carried out on or modifications made to the vehicle must be entered in the "Confirmations by the body manufacturer" section of the Maintenance Booklet.
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2 General
2.7 Warranty claims
2.7 Warranty claims
Warranty claims can only be made within the framework of the contract of sale between purchaser and seller. This means that each seller is liable to the purchaser for the items supplied by the former to the latter. In the following cases in particular, DaimlerChrysler AG will assume no liability: if the vehicle used does not correspond to the equipment version for the country in question and field of application if damage was caused by the conversion
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2 General
2.8 Mercedes star and logo
2.8 Mercedes star and logo
The Mercedes star and Mercedes-Benz logo are trademarks of DaimlerChrysler AG. They may not be removed or attached to another point without approval. Mercedes-Benz stars and Mercedes-Benz logos supplied separately must be attached at the points specified by Mercedes-Benz. Appearance of the entire vehicle If the vehicle fails to comply with the vehicle image and the quality standards required by Mercedes-Benz, the DaimlerChrysler AG trademarks must be removed. Third-party trademarks may not be affixed next to Mercedes-Benz trademarks may only be affixed to other points on the vehicle with permission from the relevant department of DaimlerChrysler AG ( page 12)
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2 General
2.9 Accident prevention
2.9 Accident prevention
The conversion and attached or installed equipment must comply with all applicable laws and directives and with health and safety and accident prevention regulations, safety regulations and information sheets issued by accident insurers. All technical means shall be used to avoid operating conditions that may be unsafe or liable to cause an accident. In Germany, information is provided to commercial carriers by the "Vehicles" Working Group of the "Traffic" Technical Committee at the following address: Telephone: Fax: E-mail: Postal address: +49 (0) 40 39 80- 0 +49 (0) 40 39 80-19 99 info@bgf.de Berufsgenossenschaft fr Fahrzeughaltungen (German Trade Association of Vehicle Owners) Ottenser Hauptstrae 54 22765 Hamburg, Germany National laws, guidelines and registration regulations must be complied with. The body and equipment manufacturer is responsible for compliance with these laws and regulations.
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2 General
2.10 Reprocessing components recycling
2.10 Reprocessing components recycling
Components in areas at risk from accidents must be designed in such a way that they are damage-tolerant, repairable and easy to replace. All plastic parts are to be marked in accordance with VDA code of practice 260, e.g. "PP GF30R". EU Directive 2000/53/EC must be complied with. Environmental note
Environmental note
When planning conversions, the following principles for environmentally-compatible design and material selection shall be taken into account, in particular with regard to EU Directive 2000/53/EC. Materials with risk potential, such as halogen additives, heavy metals, asbestos, CFCs and CHCs, are to be avoided. It is preferable to use materials which permit recycling and closed material cycles. Materials and production processes that generate only low quantities of waste during production must be selected such that this waste can be easily recycled. Plastics are to be used only where they provide advantages in terms of cost, function or weight. In the case of plastics, and composite materials in particular, only compatible substances within one material family are to be used. For components which are relevant to recycling, the number of different types of plastics used must be kept to a minimum. It must be assessed whether a component can be made from recycled material or admits the addition of recycled components. It must be ensured that components can be dismantled easily for recycling, e.g. by snap connections, artificially weakened points, easy accessibility, and using standard tools. It must be ensured that service products can be removed simply and in an environmentally-compatible manner by means of drain plugs, etc. Painting and coating components is to be avoided wherever possible; coloured plastic parts should be used instead.
Additional information is provided in the "Commercial vehicle recycling, ecology and economy" brochure, Order no. 6702 6187 00-00/0952 ( page 14).
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2 General
2.11 Quality assurance system
2.11 Quality assurance system
Global competition, more stringent quality standards demanded by the customer of the entire van product, national and international product liability laws, new forms of organisation and increasing cost pressures require effective quality assurance systems in all areas of the automotive industry. To be able to meet these requirements, a work group of the VDA (Association of German Automobile Manufacturers) has developed a "Guide to quality assurance for the manufacturers of trailers, bodies and containers" as VDA volume 8, based on DIN EN ISO 9000 ff. For the reasons stated above, we strongly recommend that body manufacturers set up a quality management system with the following minimum requirements: Development, implementation and monitoring of a quality assurance system in each company Details of responsibilities in an organigram Appointment of member of staff responsible for quality management Guarantee of the availability and current validity of the process, work and inspection instructions in all the departments and at all workplaces Fulfilment of the proofs of qualification for the members of staff concerned
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3.1
Vehicle selection
Careful selection of the vehicle for the required field of application is necessary to ensure that it is used safely. In particular, the: wheelbase engine/transmission axle ratio permissible gross vehicle weight centre of gravity and permissible axle loads should be taken into consideration and be appropriate for the intended use.
!
Before carrying out modification work, the delivered vehicle must be submitted to a check to verify whether it fulfils the necessary requirements. Further information about the vehicle models available can be found in the "Overview of models" section ( page 9) or can be obtained from the relevant department ( page 12).
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Visit the Mercedes-Benz home page at: http://mbks2.mercedes-benz.com/ van_konfigurator/vp.dll to configure your vehicle and view the available items of optional equipment.
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Comply with all national laws, guidelines and vehicle registration regulations.
!
Adequate clearances must be maintained in order to ensure the function and operational safety of assemblies.
Risk of accident
Do not make any modifications to the steering or brake systems. Modifications to the steering or brake systems could result in these systems no longer functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident.
!
Modifications to sound proofing are not permitted.
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The permissible axle loads must be complied with. If the permissible axle loads are exceeded on vehicles with ESP, this system may no longer function. The driver could lose control of the vehicle as a result and cause an accident. Information about changes in weight is available from your contact at Mercedes-Benz ( page 12).
!
The individual axle loads and the permissible gross vehicle weight must be observed for all conversions. The permissible number of vehicle occupants and an adequate margin for the payload must also be observed. The payload may consist of luggage, optional equipment, etc. Take the weight of optional equipment into consideration when making calculations. National regulations and guidelines shall apply.
The tyre load capacity of the vehicle must not be exceeded by overloading the vehicle above the specified gross vehicle weight. The tyres could otherwise overheat and be damaged. The driver could lose control of the vehicle as a result and cause an accident. The braking distance could be considerably longer if the vehicle is overladen. Details of the permissible weights can be found in the vehicle identification data on the vehicle ( page 25) and in the Technical data ( page 95).
3.3.1
Weight distribution
Avoid placing excessive loads on one side of the vehicle. The wheel load (1/2 the axle load) should not be exceeded by more than 4%. Observe the tyre load-bearing capacity. The maximum rear-axle load must not exceed 53% of the permissible vehicle load.
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Compact body
Long body
Extra-long body
load2
Values apply to vehicles with an OM646 DE LA engine and manual transmission with standard equipment; the unladen weight increases by 20 kg for a petrol engine and automatic transmission Data applicable depending on vehicle operating permit (without/with load increase, code XA2)
Trailer loads/payload Weight in kg Permissible trailer load, braked Permissible trailer load, unbraked Maximum trailer drawbar noseweight Maximum payload2 Panel van2 Traveliner
2 2 3
Luxury Traveliner
Dependent on unladen weight and permissible gross weight of vehicle; reduced when additional equipment is fitted 150 kg for 6 attachment points or 100 kg for 4 attachment points; maximum 50 kg for a high roof
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25
The permissible axle loads must be complied with. If the permissible axle loads are exceeded on vehicles with ESP, this system may no longer function. The driver could lose control of the vehicle as a result and cause an accident.
On vehicles with ESP and unfavourably-located centres of gravity (e.g. either at the rear, or very high or to one side), the effectiveness of ESP may be limited depending on the attachments, body, installations or conversion and the intended use. The vehicle must therefore be driven with a suitably adapted driving style (slower cornering speed, smooth steering wheel movements). The permissible axle loads, gross vehicle weights and location of the centre of gravity must be observed. Neither in kerb condition nor with equipment installed nor with modifications having been carried out may the permissible wheel, axle, or gross vehicle weight ever be exceeded.
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!
Further information ( see page 14) and ( see page 35).
Exceeding the specified tyre load capacity or maximum permissible speed for the tyre can lead to tyre damage or cause the tyres to fail. You could thus lose control of the vehicle and cause an accident, injuring yourself or others. For this reason, only use tyre types and sizes which have been approved for your vehicle and observe the tyre load capacity and speed index required for your vehicle. In particular, you must also observe the national specifications for tyres. These specifications may specify a certain tyre type or prohibit the use of certain tyre types which are approved in other countries. If you have other tyres fitted: the wheel brakes or chassis components may be damaged wheel and tyre clearance can no longer be guaranteed the wheel brakes or chassis components can no longer function correctly
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Bolted connections with particular relevance to safety (class "A" according to VDI 2862) The following bolted connections of the vehicle's safety and restraint systems, chassis and fuel supply may only be loosened and retightened in accordance with Mercedes-Benz service literature and regulations: Mountings for the airbags on the dashboard and steering wheel. Mountings for the windowbags underneath the roof trim. Mountings of the thorax bag to the seat. Attachment of driver's seat and front-passenger seat to their respective frames, and attachment of seat frames to the bodyshell, and, where applicable, partition cross member. Connections between the steering wheel and steering column. Bolted connections for the rear seat rails or seat pans. Connection between the parking brake adjuster and the longitudinal member. Brake unit and expansion tank mountings in the engine compartment. All bolted connections of the brake lines. Brake disc mounting on the wheel hub and brake calliper mounting on the front-axle swivel bearing. Bolted connection between the high-pressure oil line and the power-steering pump. High and low-pressure oil lines to the steering system. Steering system to the suspension subframe and drag link to the swivel bearing. Wishbone to suspension subframe. Suspension strut to the swivel bearing and vehicle body.
All bolt connections relevant to safety, e.g. wheel location, steering and braking functions, must not be altered, otherwise they may no longer function correctly. The driver could lose control of the vehicle as a result and cause an accident. Parts must be refitted in accordance with Mercedes-Benz after-sales service instructions and using suitable standard parts. We recommend the use of genuine Mercedes-Benz parts. VDI guideline 2862 must be applied to all installation work. A shortening of the free length of the clamping bolts, a substitution with stretch-shank bolts or the use of bolts with a shorter thread will definitely not be approved.
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Information is available from any Mercedes-Benz Service Centre. Additional tensioned parts must be of equal or greater strength than the preceding tensioned assembly. The use of Mercedes-Benz tightening torques assumes coefficients of friction for the bolts within the tolerance range [=0.08 0.14]. We recommend the use of standard Mercedes-Benz parts.
Resistance spot welding Resistance spot welding is a suitable procedure for welding overlapping parts when both sides are accessible. Avoid spot welding more than two sheets. Distance between the spot welds: You must observe the specified distances between welds (d=10e+10 mm) to avoid shunt effects.
3.7.2
Welded connections
General To maintain the high quality of welding required by Mercedes Benz, you should ensure that it is carried out by qualified personnel (certified according to DIN 8560 B1m). The following is recommended for achieving high-quality welds: Thorough cleaning of the areas to be welded Several short welding beads rather than one long one Symmetrical beads to restrict shrinkage Avoiding more than 3 welding seams in one place Avoiding welding in work-hardened areas d e Distance between the spot welds Sheet thickness
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e L
4.5
5 0.7
5.5 1
6.5
7 2
1.25 1.5
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Further information on welding work can be taken from the "Technical threshold values for planning" and "Damage prevention" sections ( page 44), the "Bodyshell" section ( page 56) and from the Mercedes Benz Workshop Information System (WIS). Anti-corrosion protection after welding Observe the corrosion protection measures ( page 46) specified after all welding work on the vehicle.
b I
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The information given by Mercedes-Benz in the "Damage prevention" ( page 45) and "Modifications to the basic vehicle" ( page 56) sections must be observed when welding.
Tack welding If the sheet is thicker than 2 mm, overlapping sheets can also be joined using tack welding (30 mm < L < 40 x e; d > 2 L).
d e L
Distance between tack weld centres Sheet thickness Length of tack weld
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If any modifications are made to the vehicle, the exterior noise of the vehicle must comply with the values specified in EC Directive 70/157/EEC.
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In order not to affect the noise level of the vehicle when modifications are made, it must be ensured that noise levels in the vehicle interior are kept to a minimum when planning conversions ( page 69).
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!
The battery may be damaged if not used for long periods. This must be avoided by disconnecting the battery and storing it appropriately ( page 34). DaimlerChrysler AG will not carry the costs for any additional work which is made necessary by the conversion and is to be carried out during warranty, maintenance or repair work. The following must be observed by the body/equipment manufacturer before delivery of the vehicle: Check the headlamp adjustment or have this checked at a qualified specialist workshop. We recommend a Mercedes-Benz Service Centre. Retighten the wheel nuts to the specified torque.
3.9.1
Storage in enclosed spaces: Clean the entire vehicle Check the oil and coolant levels Increase the specified tyre pressures by 0.5 bar Release the handbrake and chock the wheels Disconnect the battery and lubricate the cable lugs and terminals Storage in the open (less than 1 month): Perform the same tasks as for storage in enclosed spaces Close all air inlets and switch the heater to "Off" Storage in the open (more than 1 month): Perform the same tasks as for storage in enclosed spaces Fold the windscreen wipers away from the windscreen Close all air inlets and switch the heater to "Off" Remove the battery and store it according to the manufacturer's instructions ( page 34)
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3.9.3
The work and modifications carried out must be entered in the Service Booklet by the body manufacturer. Checking the entire vehicle The vehicle should be checked for faults and any damage repaired. If it is not known how long a vehicle with a hydraulic brake system has been out of use, the brake fluid must be renewed. The brake fluid must be renewed every two years. Checking the battery The battery charge must be tested before delivering the vehicle ( page 34). Checking the tyres The tyres must be checked for the correct pressure and for damage before the vehicle is delivered. Damaged tyres must be replaced. Checking the wheel alignment If is recommended that the wheel alignment is checked if modifications have been made by a bodyshop. You will find further information in the Mercedes-Benz Workshop Information System (WIS).
3.9.2
To avoid damage to the battery, disconnect the battery if the vehicle is to be parked up for a period longer than 1 week. If the vehicle is parked up for periods longer than 1 month, remove the battery and store it in a dry place at a temperature between 0 C and 30 C. The battery must be stored in an upright position. The battery charge must be above 12.55 V. If the voltage drops below 12.55 V, but is still above 12.1 V, the battery should be charged.
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If the battery voltage drops below 12.1 V, it will be damaged and will have to be replaced.
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4 Technical threshold values for planning 4.1 Basic vehicle threshold values
4.1 Basic vehicle threshold values 4.1.3 Parts which must not be welded
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This section contains the most important technical threshold values required for planning the basic vehicle. Furthermore, you will also find information in the other sections in the current body/equipment mounting directives.
Vehicle width Without additional headlamps: 1,981mm (ECE R48) in general: 2,550 mm (Section 42, Paragraph 3 of the German road traffic licensing regulations (StVZO))
4.1.4
A and B-pillars in bends near the airbags Plug welding is only permissible in the vertical web of the longitudinal frame member You can obtain further information in the "Damage prevention" ( page 45) and "Planning conversions" sections ( page 28).
4.1.1
Steerability
In all vehicle load states, the front axle load must be at least 25% of the gross vehicle weight. Comply with the permissible axle loads.
4.1.5
A and B-pillars chassis the vicinity of load application points (e.g. axle connections) front-axle or rear-axle supporting points the vicinity of the airbags
4.1.2
x direction:
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Holes in the longitudinal frame member are a result of the production process and are not suitable for all bodies and their equipment, fittings and conversions. The use of holes from the production process is not permitted, as such use could result in damage to the chassis frame. You can obtain further information in the "Planning conversions" section ( page 28).
y direction:
When the vehicle is laden, the wheel load (1/2 the axle load) must not be exceeded by more than 4%.
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4.2.2
875 (775)
6J x 16" ET60 steel/ aluminium 6J x 16" ET60 steel/ aluminium 7J x 17" ET56 aluminium
225/60R16 C 101/99H Summer tread and all season tread 225/60R16 Rf 102H Summer tread 225/55R17 Rf 101H (-V) Summer tread
825
850
825
4.2.3
See:
4.2.4
Section 32d of the German road traffic licensing regulations (StVZO) European Union: 97/27/EC European Union: 96/53/EC
Modifications to the chassis and axles are not permitted ( page 52).
4.2.5
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4.2.7
Any modifications to the springs and shock absorbers must be carried out in such a manner that front and rear are fine-tuned to each other. The use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permitted. We recommend the use of standard Mercedes-Benz parts. Modifications to the spring mountings are not permitted ( page 52).
4.2.8
Wheel alignment
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See the "Modifications to the basic vehicle" section ( page 56). Lowering the wheel arches is not permitted. No modifications to the cross member structure from the front of the vehicle to behind the B-pillar are permitted. Modifications to the rear portal, including the roof area, are not permitted. If any modifications are made to the load-bearing structure, a resulting structural rigidity equal to that of the basic vehicle must be achieved. The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained. It is not permissible to drill holes in or perform welding work on the A-pillar or B-pillar. In the event of modifications to the sidewall, the rigidity of the modified body must be equal to that of the basic vehicle.
4.3.2
The roof arch or load-bearing parts must be replaced if they are removed or damaged. The connection between the roof arch and the sidewall must have sufficient bending strength.
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4 Technical threshold values for planning 4.4 Engine periphery/drive train threshold values
4.4 4.4.1 Engine periphery/drive train threshold values Fuel system
4.4.2
Modifications to the engine air intake are not permitted. Propeller shafts cannot be extended or shortened. It is not possible to retrofit any engine speed control equipment, other than that which is available as optional equipment.
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Risk of accident
Risk of injury
Modifications to the airbag system and the belt tensioner system are not permitted. Modifications to or work incorrectly carried out on a restraint system (seat belt and its anchorages, belt tensioners or airbags) or their wiring could result in the restraint systems no longer functioning correctly. Airbags or belt tensioners, could then, for instance, fail in accidents with sufficient deceleration or could be activated unintentionally. Modifications to airbag components, or in the vicinity of the airbags, are not permitted. Subsequent modifications to the roof lining are not permissible on vehicles equipped with windowbags. The vehicle interior must be designed in such a way that airbags can fully deploy without impediment. Modifications to the area around the airbag control unit are not permitted. You can obtain further information in the "Modifications to the basic vehicle" section ( page 63).
Modifications to the driver's and front-passenger seat are not permitted. Seats may not be mounted on the wheel housing. The seats could be torn out of their anchorages in an accident. You can obtain further information in the "Modifications to the basic vehicle" ( page 52) and "Modifications to the interior" sections ( page 88).
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4 Technical threshold values for planning 4.6 Electrical system/electronics threshold values
4.6 Electrical system/electronics threshold values 4.6.3 Retrofitting electrical equipment ("e" mark)
All electrical equipment installed must be tested in accordance with EC Directive 94/54/EEC and must bear the "e" mark.
4.6.1
Electrical lines/fuses
Rated fusing current [A] 5 10 20 30 40 50 70 100 125 150 Wire crosssection [mm2] 0.5 1 2.5 4 6 10 46 25 35 50
4.6.4
The maximum transmission output must not be exceeded. Frequency range Short wave < 50Mhz 4 m waveband 2 m waveband 70 cm waveband 25 cm waveband Maximum transmission output [W] 100 20 50 35 10
4.6.5
CAN bus
It is not permitted to tamper with the CAN bus or components connected to it.
4.6.2
4.6.6
Under Section 51b, Paragraph 2 of the German road traffic licensing regulations (StVZO), all vehicles with a total width of 2.10 m or over are required to be equipped with vehicle outline lamps.
The location, spatial orientation and attachment of the ESP yaw rate sensor must not be modified. Modifications to the lines and ESP components are not permitted. Modifications to the area around the ESP yaw sensors are not permitted.
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4 Technical threshold values for planning 4.7 Additional equipment threshold values
4.7 Additional equipment threshold values
Additional equipment must never obstruct vehicle components nor impair their clearance and operation.
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Specific national guidelines and laws must be observed.
Work carried out incorrectly on the brake hoses or cables may impair their function. This may lead to failure of components or parts relevant to safety.
5.1
Plastic lines and brake hoses must be covered, or removed if necessary before welding, drilling, grinding or working with cutting discs.
Check the system for pressure loss and leaks after installing hydraulic lines. No other lines may be secured to the brake hoses. Lines must be protected from heat with appropriate insulation. The lines must be routed in such a manner that pressure loss is not increased.
44
!
Do not connect the arc welder earth clamp terminal to assemblies such as the engine, transmission or axles.
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Welding work is not permitted on assemblies such as the engine, transmission or axles.
Warning
If in spite of the warning not to, welding work is performed in the vicinity of the airbags, this can lead to a malfunction of the restraint systems. For this reason, it is not permitted to perform welding work near the airbags. In Germany, the handling, transportation and storage of airbag units is subject to the law concerning hazardous explosive substances (Gesetz ber explosionsgefhrliche Stoffe).
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Further information on welding work can be taken from the "Planning conversions" ( page 28), "Modifications to the basic vehicle" ( page 52) and "Bodyshell" ( page 56) sections and from the Mercedes-Benz Workshop Information System (WIS).
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!
If two different metals are connected through an electrolyte (e.g. atmospheric humidity), a galvanic connection is created. Electrochemical corrosion occurs, with the baser of the two metals being damaged. The further apart the two metals are in the electrochemical potential series, the more intense electrochemical corrosion becomes. Electrochemical corrosion must therefore be prevented by treating the components appropriately or isolation, or it must be kept to a minimum by selecting suitable materials.
1 2
The use of electrical insulation such as washers, sleeves or bushings can prevent contact corrosion. Avoid welding work on inaccessible cavities.
46
unsuitable (gaps)
47
!
Do not exceed a temperature of 80 C for drying the paint.
48
Warning
Before towing or tow-starting, please make sure that you read the section on towing in the detailed Owner's Manual/Operating Instructions. You could otherwise fail to recognise dangers, which could result in injury to yourself or others.
!
Failure to observe the Owner's Manual/Operating Instructions can result in damage to the vehicle.
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50
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6.1 6.1.1
Before carrying out welding work, springs must be covered to protect them against welding spatter. Do not touch springs with welding electrodes or welding tongs. The use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permitted. We recommend the use of standard Mercedes-Benz parts. Risk of accident
Unauthorised modifications to chassis components can adversely affect the vehicle's handling characteristics, even leading to unstable handling characteristics. Modifications to chassis components are therefore not permitted. This is especially valid for: Front transverse link: modification of the wheel alignment is not permitted. Front axle subframe: no changes to the front-axle subframe may be made when attaching additional equipment and making other modifications. Anti-roll bars: modifications to the front and rear anti-roll bars (diameter, material) and retrofitting require a certificate of endorsement from the relevant department. Rear axle: modifications are not permitted. Brakes: modifications are not permitted. Equipment, sensors, line routing for ESP/ABS Modifications are not permitted.
The use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permitted. On vehicles with ESP, this may otherwise result in the ESP system not functioning correctly and failing.The driver could lose control of the vehicle as a result and cause an accident.
!
Observe the items of optional equipment available at the factory as codes ( page 35).
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Risk of accident
Risk of accident
Work carried out incorrectly on the brake hoses, lines or cables may impair their function. This may lead to failure of components or parts relevant to safety. Have work on the brake hoses, lines or cables carried out only at a qualified specialist workshop. When the work is complete, check that the brake system is working properly. We recommend that the brake system be inspected and approved by a technical inspection centre. If the routing has to be altered, avoid routing across sharp edges and through narrow cavities or near moving components. Hydraulic brake system Hydraulic brake lines are to be completely replaced by approved 4.75 mm x 0.7 up to 6 mm x 0.7 mm rolled laminated tube. The bending radius must be > 17.5 mm. Lines must only be shaped in a bending machine. The cross-section must not be reduced. Attach nuts (part no. 000 428 04 72) to the ends of the lines and prepare a flange (F DIN 74234). The inside of the lines must be cleaned before installation. The use of plastic lines in hydraulic systems is not permissible. If the standing time of a vehicle with hydraulic brake system is not known, the brake fluid must be renewed. The brake fluid must be renewed every two years.
An adequate distance between brake lines and heat sources, sharp-edged and moving parts must be maintained. Otherwise, the brake system function could be impaired or the brake system could even suffer total failure due to the formation of bubbles in the brake fluid or from chafing points in the brake lines. For securing, we recommend using Mercedes-Benz genuine brake line support brackets to clip in the brake line. The maximum permissible distance between loops is 500 mm. Routing the lines along the brake hoses No other lines may be secured to the brake hoses.
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6.1.4
Pneumatic suspension
Risk of accident
No modifications may be made to the air inflow and outflow of the brake system. Modifications to the steering and brake system could result in this system no longer functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident. Overheating of the brake system may cause tyre damage and will also impair braking ability. For this reason, make sure there is a sufficient supply of cooling air at all times.
The use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permitted. This applies to the retrofitting of pneumatic suspension in particular. This may otherwise result in ESP, for example, not functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident.
Risk of accident
Modifications to parts of the brakes (e.g. brake callipers, discs, etc.) are not permitted. Modifications to parts of the brakes could result in this system no longer functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident. Additional brakes/retarder A certificate of endorsement from the relevant department is required when retrofitting additional brakes.
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Risk of accident
For this reason, only use tyre types and sizes which have been approved for your vehicle and observe the tyre load capacity and speed index required for your vehicle. In particular, comply with national regulations for tyres. These regulations may specify a certain type of tyre for your vehicle or forbid the use of certain tyre types which may be permitted in other countries. If you fit tyres other than these: the wheel brakes or chassis components may be damaged free movement of the wheels and tyres can no longer be guaranteed the wheel brakes or chassis components may no longer function correctly The body/equipment manufacturer must ensure that: the distance between the tyre and the wing or wheel housing is sufficient even when snow or anti-skid chains are fitted, with the suspension fully compressed (including any axle twist). Specifications in the tender drawings must be observed only permissible tyre sizes are used (see vehicle documents) ( page 14) ( page 37) only approved wheels are used ( page 14)
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Further information on wheels/tyres can be obtained from any Mercedes-Benz Service Centre or in the "Optional equipment" section ( page 35).
55
Conversions must not have a negative effect on the operation or strength of the vehicle's assemblies or controls or on the strength of load-bearing elements. In the case of vehicle conversions, it is not permissible to make modifications that affect the operation or freedom of movement of vehicle parts (e.g. during maintenance and inspection work) or ease of access to these parts. Observe the following: Modifications to the wheelbase are not permitted. No modifications to the cross member structure from the front of the vehicle to behind the B-pillar are permitted. On no account are modifications to be made to the roof area or to the rear portal. The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained ( page 61). Avoid sharp-edged corners. It is not permissible to drill holes in or perform welding work on the A-pillar or B-pillar. The maximum permissible axle loads must not be exceeded. Trailer connections must be checked for correct operation. If a trailer coupling is installed, the necessary reinforcements must be present ( page 87). Holes in the longitudinal frame member are a result of the production process and are not suitable for all bodies and their equipment, fittings and conversions The use of holes from the production process is not permitted, as such use could result in damage to the chassis frame.
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Further information on welding work can be found in the sections entitled "Planning of conversions" ( page 28), "Damage prevention" ( page 45) and "Bodyshell" ( page 56) and in the Mercedes-Benz Workshop Information System (WIS). Welding work may not be performed on the lower chord of the frame. Plug welding is only permissible in the vertical frame of the longitudinal frame member. Do not perform welding work in bends. Risk of accident
If welding work is performed in the vicinity of the airbags, this can lead to a malfunction of the airbag units (e.g. unintentional deployment during operation; total failure) ( page 63). For this reason, it is not permitted to perform welding work near the airbags. In Germany, the handling, transportation and storage of airbag units is subject to the law concerning hazardous explosive substances (Gesetz ber explosionsgefhrliche Stoffe).
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6.2.3
Do not drill holes: on the lower chord of the frame in areas with a supporting function for the rear axle or parts fastened to the frame at load application points After drilling, deburr and countersink all holes, remove as much swarf as possible and treat the holes with body cavity sealing.
Sidewall If any modifications are made to the sidewall on the panel van or Traveliner, a resulting structural rigidity equal to that of the basic vehicle must be achieved. The function of the roof frame must not be impaired and must be maintained. A certificate of endorsement from the relevant department is required ( page 12).
!
Observe the corrosion protection measures ( page 46) specified after all work on the vehicle. Windows Windows must be set in a stable frame. This frame must be positively joined to other bodywork components. If the retrofitting of windows (panoramic glass sunroof) affects the load-bearing structure of the basic vehicle, (pillars, reinforcements, connection to roof arches), a resulting structural rigidity equal to that of the basic vehicle must be achieved. Doors and flaps If modifications are made to the doors which affect the load-bearing structure, (cross members, frames, pillars, reinforcements, connection to roof arches), a resulting structural rigidity equal to that of the basic vehicle must be achieved.
6.2.2
If the partition is to be cut out due to conversion or installation work, this is possible in conjunction with a continuous frame. Partitions can be fully or partially removed. Observe the "Modifications to closed panel vans" section for notes on how to do this ( page 89). Risk of accident
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags).
!
Modifications to the rear portal including the roof area are only permitted in extreme cases and with a certificate of endorsement from the relevant department ( page 12).
57
Risk of accident
Lowering the wheel arches is not permitted. The vehicle (e.g. wheel arches and tyres) could otherwise be damaged.
6.2.5
Modifications to the chassis end cross-member are only possible after consultation with the relevant department ( page 12).
6.2.6
N23.00-2031-00
Bodyshell
Observe the following: Modifications to the wheelbase, windscreen, windscreen frame, the A-pillar or the B-pillar and tampering with the longitudinal member structure, are not permitted. No modifications to the cross member structure from the front of the vehicle to behind the B-pillar are permitted. All modifications must be depicted in their entirety in advance by drawings and calculations and must be approved by the vehicle manufacturer. The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained. Avoid sharpedged corners. The seat mounting brackets for the 1st and 2nd rear seat rows and the standard lashing eyelets and their mounting points must be used where possible to secure retrofitted installations in the vehicle interior. Brackets (plug welds) must be used to secure additional equipment to the longitudinal and cross members and require approval. It is not permissible to drill holes in or perform welding work on the A-pillar or B-pillar. The maximum permissible axle loads must not be exceeded.
The seats must be directly accessible from the outside through a door or from the cab. It must be possible to open locked doors quickly and easily from the inside. The doors must open wide enough and the door entrances must be shaped in such a way as to enable persons to get in and out of the vehicle safely and comfortably. The distance between the road surface and the lowest step must be no greater than 400 mm. Fittings must allow sufficient clearance to the interior door handles regardless of the position of the load compartment sliding door (trap guard). Modifications to the central locking system in the immediate area around the door or in the area of the pillars or cross members are not permitted.
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Observe the corrosion protection measures ( page 46) specified after all work on the vehicle.
58
The arches must be connected to the side panels in such a way that a force-locked connection is guaranteed (bend-resistant connection of arch and roof frame). Plastic roofs have limited suitability for installing roof hatches. The roof load-bearing capacity is limited. In the event of any deviation from these specifications, approval is required from the relevant department ( page 12). If a raised roof is fitted, at least 2/3 of the original roof area must be retained. Pillars or other load-bearing components must not be removed. The height of the roof may only be increased in conjunction with integrated arches and reinforcement frames. The vehicle's centre of gravity must not be displaced upwards. No roof load is permissible if the increase in roof height is permanently connected to the body. When fitting a structural support system direct to the rivet nuts, use only mounting brackets that have been approved by DaimlerChrysler or brackets conforming to drawings issued by DaimlerChrysler which provide a direct attachment to the roof. It is only permissible to fit other roof support systems to these brackets. A load of 25 kg for each support point may not be exceeded. However, it is not permissible to exceed a maximum total load of 150 kg for a normal roof and 50 kg for a high roof.
6.2.7
Underbody panelling
It is necessary to treat the entire underbody with additional anti-corrosion protection if parts of the standard underbody panelling are removed. Removing parts of the panelling could create additional airflow noise.
6.2.8
Risk of accident
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). Number of roof arches If the roof skin is separated from the roof arches and it is not possible to fit a continuous sectional frame, at least two additional roof arches must be fitted to the front and rear of the area from which the arch was removed.
59
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If roof arches or load-bearing parts are removed or damaged, they must be replaced ( page 60). Maximum roof load Normal roof [kg] 150 High roof [kg] 50
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The new roof structure must be as rigid as the standard roof.
The threshold values for the maximum vehicle centre of gravity location must not be exceeded. Modifications to the cab roof Risk of accident
Risk of accident
The maximum permissible centre of gravity location must not be exceeded. On vehicles with ESP, this may otherwise result in the ESP system not functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident ( page 82). Retrofitting a raised roof Risk of accident
Modifications to the cab must not impair the function of parts relevant to safety (such as airbag units, sensors, pedals, gear lever, lines, etc.). This may lead to failure of components or parts relevant to safety. No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). The "Cab sliding/tilting glass sunroof" code DS1 can be supplied as optional equipment from the factory ( page 35). Plastic roofs have limited suitability for installing roof hatches. The roof load capacity is limited ( page 39).
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). Plastic roofs have limited suitability for installing roof hatches. The roof load-bearing capacity is restricted (see the following table). If a raised roof is fitted, at least 2/3 of the original roof area must be retained.
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If roof arches or load-bearing parts are removed or damaged, they must be replaced. Observe the permissible centre of gravity location and maintain the permissible axle loads.
60
Modifications to the fuel system may only be carried out with the approval of the relevant department ( page 12). The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained
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Inadmissible modifications to the fuel system (tank, lines, etc.) may impair the vehicle's driving characteristics and lead to engine emergency running mode. For connections supplying fuel for auxiliary heating, the procedure for design approval must be followed. Environmental note
Incorrectly performed modifications to the fuel system can cause damage to the environment.
Changes to the air flow in the brake system may impair braking performance. In extreme cases, overheating of the brake system may cause tyre damage and will also impair braking ability. The permission of DaimlerChrysler AG must therefore be sought for modifications which impair the flow of cooling air to the brake system ( page 13).
6.3.2
Exhaust system
No modifications may be made to the exhaust system. In the case of all conversions, the following minimum distances to plastic lines, electric cables and spare wheels must be maintained: 200 mm when the exhaust system is without shielding 80 mm when there is sheet metal shielding 40 mm when there is sheet metal shielding and additional insulation Additional shielding is required Around the control units. Around the assemblies, equipment and fittings, if they are not made from heat-resistance material.
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Euro 4 OM 646 DE22LA 65 80 110 M 112 E32 165 6.2 6.9 8.3 9.0
Water Make sure that water cannot reach the intake points through any fresh-air intakes. The flow rate at the intake points must not be increased by modifications to the opening of the intake points. Dust/dirt The area of the air intake chamber must be protected against dust being thrown up from the wheel housing. Increased dust intake will lead to shorter maintenance intervals for the air cleaner.
6.3.5
Propeller shafts
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Modifications to the drive train are not permitted.
62
On no account may modifications be made in the cockpit and above the vehicle body waistline. Risk of injury
Modifications to the airbag system and the seat belt system are not permitted. Modifications to or work incorrectly carried out on a restraint system (seat belt and its anchorages, belt tensioners or airbags) or their wiring could result in the restraint systems no longer functioning correctly. Airbags or belt tensioners, for example, could thenfore fail in accidents with sufficient deceleration or could be activated unintentionally. This applies in particular to the inflation areas of the airbags (wooden trim, additional attachments, mobile phone holders, bottle holders, etc.). See the illustrations of airbag deployment areas for more information ( page 64). The permissible centre of gravity location and maximum permissible axle loads may not be exceeded. You will find information on motor caravan conversion in the "Motor caravan" section ( page 92). For the conversion of vehicles in Germany, appropriate bulletins can be ordered from the relevant technical testing centres for motor vehicles (e.g. TV, DEKRA). The interior fittings must be designed in such a way that there are no sharp edges or corners (accident prevention). Fittings must be made of flame-resistant materials and be fitted securely. Unimpeded access to the seats must be ensured. There must not be any protruding parts, edges or corners which could cause injury in the area of the seats.
63
Deployment area of the thorax bag in the front-passenger seat Driver's airbag deployment area
64
Vehicle parts that produce vibrations must not be attached in the vicinity of airbag control units or sensor mounting points, otherwise the reliable functioning of the front airbags, windowbag and belt tensioners is no longer guaranteed. This could result in personal injury. The airbag control unit, including the trigger sensors and the ESP yaw rate sensor, is installed in the footwell/ centre console behind the trim.
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It is not permissible to modify the floor structure in the area of the airbag control unit.
Risk of injury
In the event of modifications to the vehicle structure by the body manufacturer, such as: Modifications to the seats and thus changes to the kinematics of the occupants in the event of an impact Modifications to the front end Installation of parts in the vicinity of airbag inflation points or airbag deployment areas Installation of non-Mercedes-Benz seats Modifications to the A-pillar and B-pillar, the roof frame and its lining reliable operation of the front airbags, windowbags and belt tensioners can no longer be guaranteed. This could result in personal injury.
3
N54.21-2111-00
ESP yaw rate sensor Airbag control unit Front of vehicle The ESP yaw rate sensor is susceptible to shocks and must be stored where it is free from vibrations.
65
If you drop the ESP yaw rate sensor, it must not be refitted to the vehicle for safety reasons. In such cases, a genuine Mercedes-Benz replacement must be fitted. The side-impact sensors are located on either side of the vehicle behind the trim at the bottom of the B-pillar (the same on the left side of the vehicle).
Storing airbag and belt tensioner units Airbag and belt tensioner units must be stored in accordance with the Second Ordinance to the German Explosives Law (Zweite Verordnung zum Sprengstoffgesetz) dated 17/04/86. This ordinance allows small amounts of substances and materials to be stored in secure areas as specified in the German Explosives Law without requiring special storage permission. Class T1 pyrotechnic materials may only be stored in limited quantities on premises used for commercial purposes. Under Section 6 of the appendix to the Second Ordinance to the German Law on Hazardous Explosive Substances, the following maximum storage quantities are permissible without obtaining special approval from the relevant authority, where materials are stored on premises used for commercial purposes and certain conditions are fulfilled (e.g. steel cabinet). General storage space: 20 kg gross weight The gross mass of the component which has been approved in accordance with the law on explosive substances is used to calculate the actual stored mass.
N54.21-2110-00
Side-impact sensor Front of vehicle Transporting airbag and belt tensioner units For in-plant transport these sensors should always be kept in their spare parts packaging and in the vehicle luggage or load compartment.
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It is strictly forbidden to transport any sort of airbag units in the passenger compartment. The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag and windowbag.
66
Fitting and removing airbag and belt tensioner units The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag, windowbag and thorax bag as optional equipment. Test and installation work may only be carried out and supervised by specialist personnel. The airbag and belt tensioner units must be fitted without delay and immediately on removal from storage. The vehicle battery must have been disconnected, negative pole covered or negative terminal covered and test coupling/connection disconnected. If work is interrupted, the airbag and belt tensioner units must be locked away again. Precautionary measures for the handling of airbag and belt tensioner units Risk of injury
Risk of injury
Removed airbag units must always be stored in such a way that the upholstered side faces upwards. If the upholstered side faces down, the airbag control unit could be thrown through the air if it is triggered unexpectedly. The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag and windowbag.
Disposing of the airbag and belt tensioner units is carried out by qualified personnel. Comply with the accident prevention regulations. Hazards arise from disposal by cutting torch, smelting, or if primed components are disposed of on open fires or on smouldering fires on waste disposal sites, for example.
67
6.4.3
Seats
Approval is required from the relevant department if any seats other than those available from the factory are to be retrofitted ( page 12). Proof of the strength of the seats delivered from the factory is only valid if the seats are secured in original mountings. Any deviation from these specifications must be approved by the relevant department. Any rear bench seat with 2-point or 3-point belts that deviates from the standard seating must conform to the requirements of ECE R14. It is not permissible to fit seats without belts. The ECE R14 test certificate (tensile test including floor assembly) must be submitted to DaimlerChrysler AG for approval. Test certificates for seats mounted on rigid panels are not accepted. Risk of accident
It is not permissible to re-cover seats protected by thorax bags (observe the relevant notes in the Owner's Manual/Operating Instructions).
i
Information on retrofitting seats can be obtained in the "Conversion work" section ( page 88).
68
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Insulating films, e.g. bituminous felt, possess limited temperature resistance. They should therefore not be installed in the immediate vicinity of the engine or exhaust system.
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). Seals Openings, gaps and slots between the engine compartment, the underside of the vehicle, the front bulkhead and the vehicle interior must be carefully sealed with a resilient material. Airing and ventilation openings may not be positioned in the immediate vicinity of sources of noise. In addition, manufacturers or suppliers of soundproofing materials should be consulted. They will be able to provide you with suggestions on how to design optimum noise insulation for your particular conversion.
6.4.5
Ventilation
The passenger compartment and the driver's seat must have adequate ventilation with provision for air to enter and exit. 1 2 3 4 Carpet (bonded underside) Wooden floor (12 mm plywood) Heavy-duty insulating foil (weight per unit area: 8 10 kg/m2) Load-bearing construction The windscreen and side windows demisting function must remain operational, especially if the driver's area forms part of the passenger compartment or if the layout and design of the interior does not correspond to that of the standard equipment.
69
Do not loosen or disconnect the battery terminals when the engine is running. Rapid-charge the batteries only after disconnecting both the positive and negative terminals from the vehicle's electrical system. A positive total charge balance must be ensured when additional electrical consumers are installed ( page 76).
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More detailed information can be obtained from the relevant department ( page 12). Electrical and electronic components must fulfil the test requirements of ISO 16750. Observe the notes on ( page 71) when installing additional batteries. Cables routed in the vicinity of exhaust systems must be covered with fireproof sleeves ( page 53). Cables must be routed such that there are no chafing points ( page 53). The battery must be disconnected if the vehicle is not in use for extended periods (more than 10 days). The battery must have sufficient charge when the vehicle is put into operation again ( page 34). Observe the Owner's Manual/Operating Instructions. Retrofitting a battery isolating switch Installation is only permissible after consulting the relevant department ( page 12).
70
6.5.4
Please observe the following if auxiliary electrical consumers are retrofitted: Batteries and alternators with higher power ratings can be supplied on request. Do not connect any additional consumers to fuses already in use. Do not connect any additional lines to existing lines (e.g. using insulation piercing connecting devices (IPCDs)). Provide for adequate fusing of extra equipment by installing additional fuses. Auxiliary electrical consumers must be connected via the + battery terminal installed ex works. Additional lines can be secured to the 6 mm threaded connection if additional fusing is provided.
6.5.3
Battery
Retrofitting an additional battery An additional battery may only be installed in the righthand seat base in conjunction with a cutoff relay. This battery may only be used to power specified auxiliary consumers such as the auxiliary heating, loading aids or electrical equipment in motor caravans (fridge, etc.). Maintenance and storage of the batteries Even low-maintenance batteries require care. Low-maintenance simply means that the fluid level does not need to be checked. All batteries are subject to self-discharge, and if it this inadequately monitored it could lead to battery damage due to deep discharging. Information on maintaining and storing batteries can be found in the "Planning conversions" section ( page 34).
If the vehicle's electrics/electronics are tampered with or impermissible installation work is carried out on them, operational safety may be jeopardised and the vehicle warranty/operating permit may be invalidated. Tampering of any kind with the vehicle electronics is not permitted for reasons concerning the warranty and operation of the vehicle, and to ensure that no faults occur (e.g. electromagnetic compatibility). The programmable special module (PSM) can be ordered or retrofitted using the code ED5. The fuses are located in the box under the seat (2 x 25 A), and the earth connection and CAN are near the PSM (front-passenger footwell).
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N00.00-2638-20
PSM installation location Direction of travel The following information can be made available from the "signal pool" via the PSM by reprogramming the PSM parameters using Star Diagnosis. Information Terminal 15C Terminal 15R Terminal 15 Terminal 15X Terminal 50 Terminal 61 Distance covered Engine speed Stable idle Reverse gear engaged Left-hand turn signal operated Right-hand turn signal operated Main-beam headlamps operated Headlamp flasher operated Horn operated Single wipe operated Wipers operated Intermittent wipe operated Wipe stage 1 operated Wipe stage 2 operated Front fog lamps switched on Main-beam headlamps switched on Horn active Left-hand parking lamp switched on Right-hand parking lamp switched on Rotary light switch position left-hand parking lamp
72
73
Function
Left-hand parking lamp1) Right-hand parking lamp Lights automatic (only in combination with rain sensor) Lights "off" Lights "side lamps" Lights "dipped-beam headlamps" Lights "front fog lamps"1) Lights "rear foglamp"
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Function
Other functions
LADEN_AKT
1
Important: Only one signal may be active at any time; therefore, use either the rotary switch or the electronics. 2 Important: Use buttons, not switches. 3 Important: Function requires approximately 750 ms; no contrary action is possible during this time. You can obtain further information about the PSM from MB-AS ( page 14).
75
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If the vehicle's electrics/electronics are tampered with or impermissible installation work is carried out on them, operational safety may be jeopardised and the vehicle warranty/operating permit may be invalidated.
The mobile communications systems and brackets must not be positioned in the deployment area of the airbags ( page 64). The equipment must be permanently installed. Operation of portable or mobile equipment inside the vehicle is permissible only when connected to a reflexion-free exterior aerial. The transmitter unit must be installed as far away from the vehicle's electronic system as possible. Protect the unit from moisture and heavy mechanical vibration; observe the permissible operating temperature.
76
6.5.7
If it is necessary to change the routing, avoid routing over sharp edges and routing through narrow cavities or in the vicinity of moving components. Additional circuits If additional circuits are installed, safeguard these from the main circuit using suitable fuses. The wires must be dimensioned in such a manner that they are adequate to the strength of the current drawn, they must be protected against shocks and heat.
Both cable ducts must be taken into consideration when modification or installation work is carried out in the load compartment or passenger compartment. The position of the cable duct on the transmission tunnel depends on the location of the steering wheel, i.e. in a left-hand-drive vehicle, the cable duct is on the righthand side and vice versa. The cable duct must neither be damaged nor relocated in the event of installation or modification work in the area of the transmission tunnel.
N54.00-2210-20
77
The electronic systems in the engine and passenger compartments are interconnected via networks. Data is exchanged between the individual networks via gateways. The individual networks include: Class C engine CAN Class B passenger compartment CAN D2B network (digital domestic bus)
As all consumers are networked via CAN network and internally monitored, cables and wiring harnesses may neither be disconnected nor lengthened. Any modifications to the wiring harness, e.g. length, cross-section or resistance may lead to fault messages appearing in the instrument cluster.
78
On no account should any modifications be made to the CAN bus (e.g. interruptions or "tapping"). Unauthorised modifications to the CAN bus may adversely affect the standard vehicle. In addition to causing inconvenience, this may also lead to failure of components or parts relevant to safety.
Any interruption or tapping of these networks may result in malfunctions which affect the operational and road safety of the vehicle. The programmable special module ( page 71) is designed for connecting electronic components. CAN bus All Mercedes-Benz Vito/Viano vehicles are equipped with a Class C engine CAN as standard.
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6 1 2 3 4 7 8 12
30 5 9 10 14 15 16 17 18 13 19 20 21 22 23 24 25
5400-2211.00
11 28
29
26
31
27
Schematic overview of networks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Meaning/abbreviation Electronic Stability Program (ESP) Engine electronics Electronic transmission control (EGS) Signal receiver and control module (SAM) E box Front right door control panel (TVR) Voice control system (SBS) CD changer (TA) (RLS) Overhead control panel (DBE) Front passenger seat control unit Auxiliary heating (STH) Upper control panel (OBF) Programmable special module (PSM) Heater booster system (PTC) Head unit (radio/navigation system) (HU) Electric selector lever module (EWM)
N54.00-2237-00
19 20 21 22 23 24 25 26 27 28 29 30 31 A B C D
Meaning/abbreviation Heatmatic/Tempmatic (KLA) Restraint system (SRS) Parktronic (PTS) Electronic ignition switch (EZS) Steering angle sensor (LWS) Instrument cluster (INS) Tachograph Driver's seat control unit Front left door control panel (TVL) Rear passenger compartment air-conditioning (FKLA) Rear sliding sunroof (SDE) Trailer control unit (AAG) Pneumatic suspension (ENR) Engine bus (CAN C) Interior bus (Can B) D2B Optional equipment
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6.5.8
Wiring diagrams
As all consumers are networked and internally monitored, cables and wiring harnesses of the C-class engine CAN may neither be disconnected nor lengthened. Any modifications to the length, cross-section or resistance of the wiring harness can lead to malfunction messages appearing in the instrument cluster and the failure of components relevant to safety. Communication with the control unit can be established using the STAR Diagnosis tester and the software developed for this unit. Risk of accident
Wiring diagrams can be made available to body manufacturers. Enquiries should be addressed to: E-mail: Service.Information@DaimlerChrysler.com Fax: +49 (0)7 11-17-8 34 17
On no account should any modifications be made to the CAN bus (e.g. interruptions or "tapping"). Unauthorised modifications to the CAN bus may adversely affect the standard vehicle. In addition to causing inconvenience, this may also lead to failure of components or parts relevant to safety.
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Further information is available from your Mercedes-Benz Service Centre.
81
N00.00-2639-20
Installation location of ESP yaw rate sensor Airbag control unit Front of vehicle Together with the signals of other sensors, a processor monitors whether the direction desired by the driver is maintained. If the vehicle deviates from the correct path (oversteering or understeering), the system produces a stabilising counteraction by applying the brakes on individual wheels. To guarantee operating safety: on no account should modifications be made to the CAN bus, nor may CAN bus signals be tapped any additional equipment (e.g. a DVD player) may only be installed without interfering with the onboard electronics Risk of accident
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It must be ensured that the sensor is easily accessible at all times.
On no account should any modifications be made to the CAN bus (e.g. interruptions or "tapping"). Unauthorised modifications to the CAN bus may adversely affect the standard vehicle. In addition to causing inconvenience, this may also lead to failure of components or parts relevant to safety.
82
Further important notes can be found in the "Damage prevention" section ( page 51).
On no account may the following modifications be carried out on vehicles equipped with ESP: Modifications to the wheelbase Modifications to the sensor system (steering angle sensor, yaw rate sensor, wheel rotational speed sensor) Changes to the vibration characteristics in the vicinity of the yaw rate sensor point of installation due to modifications to the body Modifying the position of components Modifications to the chassis Modifications to the permissible wheels and tyres Modifications to the engine Modifications to the steering system Modifications to the brake system Conversion to a semitrailer tractor vehicle On vehicles with ESP, modifications may result in the ESP system not functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident.
Risk of accident
If you drop the ESP yaw rate sensor, it must not be refitted to the vehicle for safety reasons. In such cases, a genuine Mercedes-Benz replacement must be fitted.
83
84
6.6.1
All electrical equipment installed must be tested in accordance with EC Directive 95/54/EU and must bear the "e" mark. We recommend the relevant versions available as optional equipment at the factory for retrofitting air conditioning. If other air-conditioning systems are retrofitted, the following points relating to compatibility with the basic vehicle must be observed in addition to the equipment manufacturer's specifications: Damage to vehicle parts and their function caused by installation of an air conditioning system is not permitted. The battery must have sufficient capacity ( page 71) and the alternator ( page 83) must generate sufficient power. Additional fuse protection for the air-conditioning power circuit ( page 77). The additional pulley (code N60) is available from the factory as optional equipment to drive air-conditioning compressors. Make sure that lines and ( page 44) electrical lines ( page 77) are routed correctly. Access to installed components and ease of maintenance must be not impaired. The operating instructions and the maintenance manual for the additional equipment must be supplied with the vehicle when it is handed over. The air supply required and engine cooling must not be adversely affected ( page 61)
6.6.2
Auxiliary heating
The floor of the vehicle must be air-tight if exhaust gases are routed out under the vehicle. Openings in the vehicle floor provided for control elements must be sealed with rubber sleeves.
6.6.3
Power take-offs
General Power take-off models supplied from the factory: Engine power take-off at front Information on maximum transferable torques (Nm) for the individual power take-offs are guide values for operation without impact or vibration. The gear ratio of the power take-off should be selected such that a minimum engine speed of 1,000 1,200 rpm is maintained when the power take-off is under load. The power output should be within the range of the maximum engine torque. Exposed propeller shafts, fan wheels or pulleys must be covered.
85
6.7.1
Winch
The attachment of winches requires a certificate of endorsement from the relevant department ( page 12). If winches are attached to the basic vehicle, the permissible axle loads must be adhered to. Winch on the front of the frame Carry out the attachment as described in the "Bodyshell/bodywork" section ( page 56). Observe the guidelines on drilling work on the chassis ( page 57). The use of spacers is required. Provide also for additional support on the longitudinal frame member for temporary support.
6.7.4
Fitted shelving
Fitted shelving must: be sufficiently strong and self-supporting rest on the cross and longitudinal members of the vehicle floor distribute forces evenly
!
The airbag units may need to be deactivated if attachments are fitted to the front of the frame, as these may change the impact structure. The relevant department can provide you with information on this ( page 12).
!
On no account should attachments transfer forces only to the vehicle sidewalls.
6.7.2
Observe the permissible centre of gravity and front axle load ( page 36). Carry out the attachment to the roof as specified in the "Bodyshell" (roof panel van) section ( page 59).
86
87
Modifications to the cockpit above the waistline are not permitted. This applies in particular to the inflation areas of the airbags (wooden trim, additional attachments, mobile phone holders, bottle holders, etc.). See the illustrations of airbag inflation points for more information ( page 64).
7.1.2
DaimlerChrysler AG will issue a certificate of endorsement at their discretion ( page 12) for modifications to the seat attachments (including seat bases) and seat belt anchorages or for the installation of seats other than those available from the factory. Proof of the strength of the seats delivered from the factory is only valid if the seats are secured in their original mountings. When the seat belts are fastened again, the specified bolts must be tightened to the original torque. Risk of accident
Seats may not be mounted on the wheel housing. Persons could be injured in an accident if seats are torn out of their anchorages and the vehicle could be further damaged. Any rear bench seat with 2-point or 3-point belts that deviates from the standard seating must conform to the requirements of ECE R14. It is not permissible to fit seats without belts. The ECE R14 test certificate (tensile test including floor assembly) must be submitted for approval by DaimlerChrysler AG. Test certificates for seats mounted on rigid panels are not accepted. Risk of injury
Modifications to the driver's and front-passenger seat are not permitted. Seats may not be mounted on the wheel housing. The seats could be torn out of their anchorages in an accident. Passenger/cargo area On panel vans, the bodyshell floor assembly is available from the factory as optional equipment under Code V40 (Traveliner floor assembly) for retrofitting bench seats. The number of attachment options for the Traveliner floor assembly depends on the model series and the equipment and registration variants (the mounting shells for the bench seats are not included in the scope of delivery).
It is not permissible to retrofit covers on seats with thorax bags (see notes in the Owner's Manual/ Operating Instructions).
88
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags).
Areas that must be retained Designation of partition level with B-pillar View in the direction of travel
89
90
91
92
93
94
63960313
Traveliner
Normal 3,200 11.8 4,748 1,875 1,350 XA2 Normal 3,200 11.8 4,993 1,901 1,350 XA2
63960513
Traveliner
Normal 3,200 11.8 4,993 1,875 1,350 Normal 3,430 12.5 5,223 1,901 1,350 XA2 XA2 1,550 1,470 1,550 1,550 1,470 1,550 2,940 2,770 2,940 4,940 4,940 4,940 1,115 1,150 1,150 825 720 720
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 EU3Gr.3 8.00 8.50 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
Permissible tractor- [kg] trailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l] [ccm] [kW] [bhp] [rpm] [Nm] rpm] [kg] [kg] [kg] [kg]
1,820 1,820 950 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 1,120 M0C1
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C1 OM646LA 2,148 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 EU3Gr.3 8.00 8.50 75 1,095 885 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 1,055 M0C1
1,940 1,870 1,870 1,000 900 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 EU3Gr.3 8.00 8.50 75 1,070
Engine
95
63960313
Traveliner
Normal NSG250 1.50 Normal NSG250 1.50
63960513
Traveliner
Normal NSG250 1.50 Normal NSG250 1.50
Panel van
High NSG250 1.50 G250-6 (4.99-0.82) A0C2 4.111
Panel van
High
Traveliner
Normal NSG250 1.50 G250-6 (4.99-0.82) A0C2 4.111 Coil springs Coil springs 205/65 R 16 6.5 J
Drive train
Coil springs Coil springs Coil springs Coil springs 205/65 R 16 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 205/65 R 65 R 16 16 6.5 J 6.5 J 195/ 205/ 65 R 65 R 16 16 6 J x 6.5 J
Chassis
96
63960313
Traveliner
Normal 3,200 11.8 4,748 1,875 1,350 XA2 Normal 3,200 11.8 4,993 1,901 1,350 XA2
63960513
Traveliner
Normal 3,200 11.8 4,993 1,875 1,350 Normal 3,430 12.5 5,223 1,901 1,350 XA2 XA2 1,550 1,470 1,550 1,550 1,470 1,550 2,940 2,770 2,940 4,940 4,940 4,940 1,115 1,150 1,150 825 720 720
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EU3Gr.3 8.00 8.50 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
Permissible tractor- [kg] trailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l] [ccm] [kW] [bhp] [rpm] [Nm] [rpm] [kg] [kg] [kg] [kg]
1,820 1,820 950 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 Euro3 8.00 8.50 75 1,120 M0C2
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 Euro3 8.00 8.50 75 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EU3Gr.3 8.00 8.50 75 1,095 885 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 Euro3 8.00 8.50 75 1,055 M0C2
1,940 1,870 1,870 1,000 900 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 Euro3 8.00 8.50 75 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EU3Gr.3 8.00 8.50 75 1,070
Engine
97
63960313
Traveliner
Normal NSG370 1.80 Normal NSG370 1.80
63960513
Traveliner
Normal NSG370 1.80 Normal NSG370 1.80
Panel van
High NSG370 1.80 G370-6 (5.01-0.80) A0C6 3.727
Panel van
High
Traveliner
Normal NSG370 1.80 G370-6 (5.01-0.80) A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J
Drive train
Coil springs Coil springs Coil springs Coil springs 205/65 R 16 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 205/65 R 65 R 16 16 6.5 J 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Chassis
98
63960313
Traveliner
Normal 3,200 11.8 4,748 1,875 1,350 XA2 Normal 3,200 11.8 4,993 1,901 1,350 XA2
63960513
Traveliner
Normal 3,200 11.8 4,993 1,875 1,350 Normal 3,430 12.5 5,223 1,901 1,350 XA2 XA2 1,550 1,470 1,550 1,550 1,470 1,550 2,940 2,770 2,940 4,940 4,940 4,940 1,115 1,150 1,150 825 720 720
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EU3Gr.3 8.00 8.50 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 Euro3 8.00 8.50 75 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EU3Gr.3 8.00 8.50 75 1,095 885 M0C3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 Euro3 8.00 8.50 75 1,055 M0C3
1,940 1,870 1,870 1,000 900 M0C3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EU3Gr.3 8.00 8.50 75 Euro3 8.00 8.50 75 OM646LA 2,148.0 110 150 3,800 330 1,800 1,070
2,148.0 110 150 3,800 330 1,800 2,400 Euro3 8.00 8.50 75
Engine
Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l]
99
63960313
Traveliner
Normal NSG370 1.80 Normal NSG370 1.80
63960513
Traveliner
Normal NSG370 1.80 Normal NSG370 1.80
Panel van
High NSG370 1.80 G370-6 (5.01-0.80) A0C1 3.455
Panel van
High
Traveliner
Normal NSG370 1.80 G370-6 (5.01-0.80) A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J
Drive train
Coil springs Coil springs Coil springs Coil springs 205/65 R 16 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 205/65 R 65 R 16 16 6.5 J 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Chassis
100
63960313
Traveliner
Normal 3,200 11.8 4,748 1,875 1,350 XA2 Normal 3,200 11.8 4,993 1,901 1,350 XA2
63960513
Traveliner
Normal 3,200 11.8 4,993 1,875 1,350 Normal 3,430 12.5 5,223 1,901 1,350 XA2 XA2 1,550 1,470 1,550 1,550 1,470 1,550 2,940 2,770 2,940 4,940 4,940 4,940 1,115 1,150 1,150 825 720 720
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
Permissible tractor- [kg] trailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l] [ccm] [kW] [bhp] [rpm] [Nm] [rpm] [kg] [kg] [kg] [kg]
1,820 1,820 950 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,120 M0C8
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,095 885 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,055 M0C8
1,940 1,870 1,870 1,000 900 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,070
Engine
101
63960313
Traveliner
Normal NAGW5A 9.00 Normal NAGW5A 9.00
63960513
Traveliner
Normal NAGW5A 9.00 Normal NAGW5A 9.00
Panel van
High NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727
Panel van
High
Traveliner
Normal NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727 Coil springs Coil springs 205/65 R 16 6.5 J
Drive train
Coil springs Coil springs Coil springs Coil springs 205/65 R 16 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 205/65 R 65 R 16 16 6.5 J 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Chassis
102
63960313
Traveliner
Normal 3,200 11.8 4,748 1,875 1,350 XA2 Normal 3,200 11.8 4,993 1,901 1,350 XA2
63960513
Traveliner
Normal 3,200 11.8 4,993 1,875 1,350 Normal 3,430 12.5 5,223 1,901 1,350 XA2 XA2 1,550 1,470 1,550 1,550 1,470 1,550 2,940 2,770 2,940 4,940 4,940 4,940 1,115 1,150 1,150 825 720 720
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 1,095 885 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 1,055 M0C7
1,940 1,870 1,870 1,000 900 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 1,070
3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75
Engine
Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l]
103
63960313
Traveliner
Normal NAGW5A 9.00 Normal NAGW5A 9.00
63960513
Traveliner
Normal NAGW5A 9.00 Normal NAGW5A 9.00
Panel van
High NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727
Panel van
High
Traveliner
Normal NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727 Coil springs Coil springs 205/65 R 16 Drop centre rims, 6.5 J
Drive train
Coil springs Coil springs Coil springs Coil springs 205/65 R 16 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 205/65 R 65 R 16 16 6.5 J 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Chassis
*Well-base rim
104
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EUGr.3 8.00 8.50 75
63981113
3,200 11.8 4,748 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,180 890 2,070 870 MOC3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EUGr.3 8.00 8.50 75
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EUGr.3 8.00 8.50 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code
Permissible front axle [kg] load Permissible rear axle [kg] load
Weights
Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle
Unladen vehicle [kg] (including driver, tank 90% full) Payload [kg] Engine code Engine designation Displacement Output Output At rated engine speed Torque From engine speed To engine speed Emissions level Minimum engine oil quantity Maximum engine oil quantity Tank capacity
Engine
105
63981513
NSG370 1.80
63981113
NSG370 1.80
63981513
NSG370 1.80
Drive train
Transmission oil quantity Transmission designation Rear-axle code Rear-axle ratio Front suspension
G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J
Chassis
*Well-base rim
106
3.0 63981313
3,200 11.8 4,993 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,170 925 2,095 845 MOC8 M112Ered 3,199.0 110 190 3,800 270 2,750 4,750 EUGr.4Gr.1 9.50 10.00 75
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC8 M112Ered 3,199.0 110 190 3,800 270 2,750 4,750 EUGr.4Gr.1 9.50 10.00 75
63981113
3,200 11.8 4,748 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,180 890 2,070 870 MOC7 M112E 3,199.0 140 217 3,800 305 2,800 4,750 EUGr.4Gr.1 9.50 10.00 75
3.2 63981313
3,200 11.8 4,993 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,170 925 2,095 845 MOC7 M112E 3,199.0 140 217 3,800 305 2,800 4,750 EUGr.4Gr.1 9.50 10.00 75
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC7 M112E 3,199.0 140 217 3,800 305 2,800 4,750 EUGr.4Gr.1 9.50 10.00 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code
Permissible front axle [kg] load Permissible rear axle [kg] load
Weights
Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle
Unladen vehicle [kg] (including driver, tank 90% full) Payload [kg] Engine code Engine designation Displacement Output Output At rated engine speed Torque From engine speed To engine speed Emissions level Minimum engine oil quantity Maximum engine oil quantity Tank capacity
Engine
107
Index
A Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Additional battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Additional equipment. . . . . . . . . . . . . . . . . . . . . . . . . . 85 Additional equipment threshold values . . . . . . . . . 43 Aerial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 Airbag control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Anti-corrosion protection for welding . . . . . . . . . . . 31 Attachment above cab . . . . . . . . . . . . . . . . . . . . . . . . . 86 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Battery isolating switch . . . . . . . . . . . . . . . . . . . . . . . 70 Belt tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 Bodies for motor caravans . . . . . . . . . . . . . . . . . . . . . 92 Bodies for refrigerated vehicles . . . . . . . . . . . . . . . . 91 Body/equipment approval . . . . . . . . . . . . . . . . . . . . . 12 Bodyshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56, 58 Bodyshell threshold values . . . . . . . . . . . . . . . . . . . . 39 Bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 53 C Cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Cable duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77, 78 Cables and lines . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 53 CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 78, 79 Centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Certificate of endorsement . . . . . . . . . . . . . . . . 12, 13 Chassis end cross-member . . . . . . . . . . . . . . . . . . . . 58 Checking the entire vehicle . . . . . . . . . . . . . . . . . . . . 34 Clearance dimensions, trailer coupling . . . . . . . . . 87 Closed panel van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Conversion work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . 31, 46
D Damage prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Damage prevention by painting . . . . . . . . . . . . . . . . 48 Damage prevention when storing and delivering the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 36 Disc brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Drilling holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Drilling work on the chassis. . . . . . . . . . . . . . . . . . . . 57 Drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 61 Drive train threshold values. . . . . . . . . . . . . . . . . . . . 40 Dust/dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 E Electrical interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electromagnetic compatibility . . . . . . . . . . . . . . . . . 83 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Engine air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Engine periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Engine periphery threshold values . . . . . . . . . . . . . 40 ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 82 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 F Faxback system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Floor assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 61 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 77 G General operating permit . . . . . . . . . . . . . . . . . . . . . . . 6 I Increasing the roof height . . . . . . . . . . . . . . . . . . . . . 94 Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 L Legal claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Line cross-sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
108
! Always print out the complete section from the current version.
Index
M Maintenance and repairs . . . . . . . . . . . . . . . . . . . . . . 33 Mercedes star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mercedes-Benz body/equipment manufacturer system (MB-AS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MIG plug welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mobile communications systems . . . . . . . . . . . 42, 76 Model designation. . . . . . . . . . . . . . . . . . . . . . . . 8, 9, 11 Model overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 11 Modifications to closed panel vans . . . . . . . . . . . . . 89 Modifications to mobile communications systems . 76 Modifications to the basic vehicle . . . . . . . . . . . . . . 52 Modifications to the bodyshell . . . . . . . . . . . . . . . . . 39 Motor caravans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 N Noise in the vehicle interior . . . . . . . . . . . . . . . . . . . . 69 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Noise level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 O Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Overview of Vito models . . . . . . . . . . . . . . . . . . . . . . . . 9 P Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Panel van/Traveliner roof . . . . . . . . . . . . . . . . . . . . . . 59 Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57, 89 PC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Permissible tyre sizes . . . . . . . . . . . . . . . . . . . . . . . . . 37 Pneumatic suspension . . . . . . . . . . . . . . . . . . . . . . . . 54 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Power take-offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Product liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 15 Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 PSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 72, 73 Q Quality assurance system . . . . . . . . . . . . . . . . . . . . . 20
R Raised roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 92, 93 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Reducing noise in the vehicle interior . . . . . . . . . . . 69 Refrigerated vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Reprocessing components . . . . . . . . . . . . . . . . . . . . . 19 Retrofitting electrical equipment . . . . . . . . . . . . . . . 76 Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 S Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 88 Securing points on the frame . . . . . . . . . . . . . . . . . . 39 Shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 52 Side-impact sensors . . . . . . . . . . . . . . . . . . . . . . . 65, 66 Sidewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 52 Steerability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Storing and delivering the vehicle . . . . . . . . . . . . . . 50 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T Tack welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Technical advice for body/equipment manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Tender drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Third-party trademarks . . . . . . . . . . . . . . . . . . . . . . . . 17 Towing and tow-starting . . . . . . . . . . . . . . . . . . . . . . . 49 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Tyre load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27, 55 U Underbody panelling . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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Index
V Vehicle approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Vehicle dimension threshold values . . . . . . . . . . . . 36 Vehicle dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Vehicle frame threshold values . . . . . . . . . . . . . . . . 39 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . 25 Vehicle identification plate . . . . . . . . . . . . . . . . . . . . 25 Vehicle modifications . . . . . . . . . . . . . . . . . . . . . . . . . 22 Vehicle outline lamps. . . . . . . . . . . . . . . . . . . . . . . . . . 42 Vehicle overhang. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Vehicle overhang threshold values . . . . . . . . . . . . . 39 Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Vehicle selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Vehicle width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 W Warranty claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Weight distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Welded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 36 Welding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Welding work on the bodyshell . . . . . . . . . . . . . . . . . 56 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Wheel arch lowering threshold values . . . . . . . . . . 39 Wheel arches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 81 Workshop Information System (WIS) . . . . . . . . . . . 14
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