Mercedes Vito Viano 2005

Vito/Viano Body/Equipment Mounting Directives

Mercedes-Benz Body/Equipment Mounting Directives for Vito/Viano as at: 20.07.2004

! Always print out complete sections from the current version.

Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 The aim of these Directives . . . . . . . . . . . . . . . 41.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . 7

2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 Vehicle and model designations . . . . . . . . . . . 82.2 Overview of Vito models . . . . . . . . . . . . . . . . . 92.2.1 Seating options in the Vito. . . . . . . . . . . . . . . 102.3 Overview of Viano models . . . . . . . . . . . . . . . 112.4 Technical advice for body/equipment

manufacturers . . . . . . . . . . . . . . . . . . . . . . . . 122.4.1 Certificate of endorsement . . . . . . . . . . . . . . 122.4.2 Issuing a certificate of endorsement . . . . . . . 132.4.3 Legal claims . . . . . . . . . . . . . . . . . . . . . . . . . . 132.5 Tender drawings, technical data,

product information/Mercedes-Benz body/equipment manufacturer system (MB-AS). . . 14

2.5.1 PC program (ISDN/modem) . . . . . . . . . . . . . 142.5.2 Faxback system . . . . . . . . . . . . . . . . . . . . . . . 142.5.3 Workshop Information System (WIS) . . . . . . . 142.6 Product liability . . . . . . . . . . . . . . . . . . . . . . . 152.7 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . 162.8 Mercedes star and logo . . . . . . . . . . . . . . . . . 172.9 Accident prevention . . . . . . . . . . . . . . . . . . . . 182.10 Reprocessing components – recycling . . . . . 192.11 Quality assurance system . . . . . . . . . . . . . . . 20

3 Planning conversions . . . . . . . . . . . . . . . . . 213.1 Vehicle selection . . . . . . . . . . . . . . . . . . . . . . 213.2 Vehicle modifications. . . . . . . . . . . . . . . . . . . 223.3 Dimensions and weights . . . . . . . . . . . . . . . . 233.3.1 Weight distribution. . . . . . . . . . . . . . . . . . . . . 233.4 Vehicle identification data . . . . . . . . . . . . . . . 253.5 Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . 263.6 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.7 Bolted and welded connections . . . . . . . . . . . 283.7.1 Bolted connections . . . . . . . . . . . . . . . . . . . . 283.7.2 Welded connections. . . . . . . . . . . . . . . . . . . . 293.8 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . 323.9 Maintenance and repairs . . . . . . . . . . . . . . . . 333.9.1 Preparation for storing the vehicle. . . . . . . . . 333.9.2 Battery maintenance and storage . . . . . . . . . 343.9.3 Preparation for handing over the

converted vehicle. . . . . . . . . . . . . . . . . . . . . . 343.10 Optional equipment . . . . . . . . . . . . . . . . . . . . 35

4 Technical threshold values for planning. . 364.1 Basic vehicle threshold values . . . . . . . . . . . . 364.1.1 Steerability. . . . . . . . . . . . . . . . . . . . . . . . . . . 364.1.2 Extreme permissible positions of centre of

gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.1.3 Parts which must not be welded . . . . . . . . . . 364.1.4 Parts which must not be welded . . . . . . . . . . 364.1.5 Parts in which holes may not be drilled . . . . . 364.2 Chassis threshold values . . . . . . . . . . . . . . . . 374.2.1 Permissible axle loads . . . . . . . . . . . . . . . . . . 374.2.2 Approved tyre sizes . . . . . . . . . . . . . . . . . . . . 374.2.3 Turning circle diameter . . . . . . . . . . . . . . . . . 374.2.4 Modifications to the axles . . . . . . . . . . . . . . . 374.2.5 Modifications to the steering system. . . . . . . 374.2.6 Modifications to the brake system . . . . . . . . 384.2.7 Modifications to the springs/spring mountings/

shock absorbers . . . . . . . . . . . . . . . . . . . . . . 384.2.8 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . 384.3 Bodyshell threshold values . . . . . . . . . . . . . . 394.3.1 Modifications to the bodyshell. . . . . . . . . . . . 394.3.2 Vehicle roof/roof load. . . . . . . . . . . . . . . . . . 394.4 Engine periphery/drive train threshold

values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404.4.1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 404.4.2 Modifications to the engine/drive train

parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404.5 Interior threshold values . . . . . . . . . . . . . . . . 414.5.1 Modifications to the airbags and belt

tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 414.5.2 Modifications to the seats . . . . . . . . . . . . . . . 414.6 Electrical system/electronics threshold

values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424.6.1 Electrical lines/fuses . . . . . . . . . . . . . . . . . . 424.6.2 Vehicle outline and side marker lamps . . . . . 424.6.3 Retrofitting electrical equipment

("e" mark). . . . . . . . . . . . . . . . . . . . . . . . . . . . 424.6.4 Mobile communications systems. . . . . . . . . . 424.6.5 CAN bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424.6.6 Electronic Stability Program . . . . . . . . . . . . . 424.7 Additional equipment threshold values . . . . . 43

5 Damage prevention . . . . . . . . . . . . . . . . . . . 445.1 Brake hoses/cables and lines. . . . . . . . . . . . 445.2 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . 455.3 Corrosion protection measures . . . . . . . . . . . 465.4 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485.5 Towing and tow-starting. . . . . . . . . . . . . . . . . 495.6 Storing and delivering the vehicle . . . . . . . . . 505.7 Electromagnetic compatibility (EMC). . . . . . . 51



Contents

6 Modifications to the basic vehicle. . . . . . . 526.1 Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526.1.1 Basic chassis . . . . . . . . . . . . . . . . . . . . . . . . . 526.1.2 Springs/shock absorbers . . . . . . . . . . . . . . . 526.1.3 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . 536.1.4 Pneumatic suspension . . . . . . . . . . . . . . . . . . 546.1.5 Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . 556.1.6 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 556.2 Bodyshell/bodywork . . . . . . . . . . . . . . . . . . . 566.2.1 General notes on the bodyshell/

bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566.2.2 Modifying the partition. . . . . . . . . . . . . . . . . . 576.2.3 Sidewall, windows, doors and flaps . . . . . . . . 576.2.4 Wings and wheel arches . . . . . . . . . . . . . . . . 586.2.5 Chassis end cross-member . . . . . . . . . . . . . . 586.2.6 Bodyshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586.2.7 Underbody panelling . . . . . . . . . . . . . . . . . . . 596.2.8 Roof of panel van/Traveliner . . . . . . . . . . . . 596.3 Engine periphery/drive train . . . . . . . . . . . . . 616.3.1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 616.3.2 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 616.3.3 Engine cooling . . . . . . . . . . . . . . . . . . . . . . . . 616.3.4 Engine air intake . . . . . . . . . . . . . . . . . . . . . . 626.3.5 Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . 626.4 Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636.4.2 Safety equipment. . . . . . . . . . . . . . . . . . . . . . 636.4.3 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686.4.4 Reducing noise in the vehicle interior . . . . . . 696.4.5 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.5 Electrical system/electronics . . . . . . . . . . . . 706.5.1 General notes. . . . . . . . . . . . . . . . . . . . . . . . . 706.5.2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706.5.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716.5.4 Power supply – interfaces . . . . . . . . . . . . . . . 716.5.5 Retrofitting electrical equipment . . . . . . . . . . 766.5.6 Mobile communications systems. . . . . . . . . . 766.5.7 Electrical lines/CAN bus . . . . . . . . . . . . . . . . 776.5.8 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . 816.5.9 Electronic Stability Program (ESP) . . . . . . . . 826.5.10 Electromagnetic compatibility (EMC). . . . . . . 836.5.11 Retrofitting an alternator . . . . . . . . . . . . . . . . 83

6.6 Additional equipment. . . . . . . . . . . . . . . . . . . 856.6.1 Retrofitting the air conditioning . . . . . . . . . . . 856.6.2 Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . 856.6.3 Power take-offs . . . . . . . . . . . . . . . . . . . . . . . 856.7 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 866.7.1 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 866.7.2 Attachment above cab. . . . . . . . . . . . . . . . . . 866.7.3 Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . 866.7.4 Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . 866.7.5 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . 87

7 Conversion work . . . . . . . . . . . . . . . . . . . . . 887.1 Modifications to the interior . . . . . . . . . . . . . 887.1.1 Modifications to the cockpit . . . . . . . . . . . . . 887.1.2 Retrofitting additional seats. . . . . . . . . . . . . . 887.2 Modifications to closed panel vans . . . . . . . . 897.3 Refrigerated vehicles . . . . . . . . . . . . . . . . . . . 917.4 Motor caravans . . . . . . . . . . . . . . . . . . . . . . . 927.5 Retrofitting a raised roof . . . . . . . . . . . . . . . . 937.6 Increasing the roof height . . . . . . . . . . . . . . . 94

8 Technical data . . . . . . . . . . . . . . . . . . . . . . . 958.1 Vito 109 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 958.2 Vito 111 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 978.3 Vito 115 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 998.4 Vito 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018.5 Vito 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1038.6 Viano CDI 2.0/CDI 2.2 . . . . . . . . . . . . . . . . 1058.7 Viano 3.0/3.2 . . . . . . . . . . . . . . . . . . . . . . . 107



4

1 Introduction

These Body/Equipment Mounting Directives provide the body manufacturers with important technical infor-mation 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 pos-sible changes, e.g. to road performance, stability, load distribution, the vehicle's centre of gravity and its han-dling characteristics, caused by bodies and their equip-ment, 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 con-versions 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/ Equip-ment 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 intend-ed 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 back-ground 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 inju-ry and will attain the degree of quality required for bodies and their equipment, fittings and conversions.

1.1 The aim of these Directives The following Body/Equipment Mounting Directives are divided into 8 related sections to help you to find infor-mation 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 infor-mation quickly.

The threshold values chosen in section 4 must be ad-hered 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/ Equip-ment Mounting Directives.


! Always print out complete section from the current version.

1.2 Symbols

1 Introduction

5

1.2 SymbolsYou will find the following symbols used in these direc-tives:

� page This symbol indicates the page on which you will find further information on the subject.

This continuation symbol indicates an inter-rupted sequence of actions that will be con-tinued on the next page.

Warning GA warning draws your attention to possible risks of ac-cident and injury to yourself and others.

Environmental note HAn environmental note gives you tips on the protec-tion of the environment.

!This note draws your attention to possible hazards to your vehicle.

iThis tip contains advice or further information you may find useful.

��



1.3 Vehicle safety

1 Introduction

6

1.3 Vehicle safety

Notes on vehicle safety

We recommend the following:

Use only parts and assemblies or recommended conver-sion parts and accessories that have been recommend-ed 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 ac-cessories which have not been recommended may jeop-ardise the safety of the vehicle.

Risk of accident GBefore installing non-Mercedes-Benz bodies or at-taching, 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.

!Observe the national specifications since attach-ments, installation of bodies, conversion and installa-tion work on the vehicle could change the approved vehicle type and may invalidate the general operating permit.



1.4 Operational safety

1 Introduction

7

1.4 Operational safety

Risk of accident GWork 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 serious-ly jeopardise the operational safety of the vehicle.

Have work on or modifications to electronic compo-nents 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-re-lated systems must be carried out at a qualified spe-cialist 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.

2.1 Vehicle and model designations



8

2 General

2.1 Vehicle and model designationsThese Body/Equipment Mounting Directives apply to the following vehicle model designation numbers:

Commercial use: Vito (BM 639.6/7) Private use: Viano (BM 639.7 (Fun)/8)

Trend Fun

Ambiente Marco Polo

Vito 119 140 kW/190 bhp Viano 3.0 140 kW/190 bhp



Vito 109 CDI 65 kW/88 bhp Viano CDI 2.0 80 kW/109 bhp

Vito 111 CDI 80 kW/109 bhp Viano CDI 2.2 110 kW/150 bhp

Vito 115 CDI 110 kW/150 bhp

Model designation according to permissible gross vehicle weight

Engine code Engine Output [kW]

2,590 [kg]

2,800 [kg]

3,500 [kg]

4,600 [kg]

5,990 [kg]

MQ3 OM611 DE22LA 60 208 CDI 208 CDI 308 CDI 408 CDI




MR8 M111 E23 105 214 214 314 414



2 General

9

2.2 Overview of Vito models


You will find explanations of models and engine codes in the table (� page 8)

Compact

Short wheelbase, short overhang, length 4,748 mm

LongShort wheelbase, long overhang, length 4,993 mm

Extra longLong wheelbase, long overhang, length 5,223 mm

Panel van

Dualiner

Traveliner



2 General

10


2.2.1 Seating options in the Vito

Double seat next to the driver optionEasy entry option

N23.00-2019-00



2 General

11

2.3 Overview of Viano models

2.3 Overview of Viano models

You will find explanations of models and engine codes in the table (� page 8)

Compact

Short wheelbase, short overhang, length 4,748 mm

LongShort wheelbase, long overhang, length 4,993 mm

Extra longLong wheelbase, long overhang, length 5,223 mm

Trend, Ambiente

Fun

Marco Polo



2 General

12

2.4 Technical advice for body/equipment manufacturers


Herr Leipner and his team are available to offer techni-cal advice to body/equipment manufacturers and to is-sue certificates of endorsement.

The relevant members of staff can be contacted on:

Herr Pflüger and his team are available for any ques-tions 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:

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 ve-hicle.

The body/equipment manufacturer advisors at the DaimlerChrysler AG organisation in your country are available to offer technical advice and to answer ques-tions about conversions.

2.4.1 Certificate of endorsementDaimlerChrysler AG does not issue body/equipment ap-proval certificates for non-Mercedes-Benz conversions. It only provides body manufacturers with important in-formation and technical guidelines for the correct han-dling of the product by means of these Directives. DaimlerChrysler AG therefore recommends that conver-sions 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 require-ments:

Technical advice regarding the feasibility of the conversion

Telephone: +49 (0)711-17-58438

+49 (0)711-17-50810

Fax: +49 (0)711-17-32323

Postal address: DaimlerChrysler AG

HPC (in-house postcode) C103

Department ET/3M

70546 Stuttgart, Germany

Body/equipment manufacturer information and certification

Telephone: +49 (0)711-17-90819

+49 (0)711-17-90591

+49 (0)711-17-90507

Fax: +49 (0)711-17-90868


HPC (in-house postcode) Z602

Department VT/P3


Technical advice regarding the basic vehicle

Telephone: +34 (945)-18 55 44

Fax: +34 (945)-18 55 40

Postal address: Mercedes Benz España S.A.

Avda. de los Huetos. 73 y 75

E-01010 Vitoria, Spain

Technical advice outside Germany



2 General

13


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 ex-plicitly described scopes and their general compatibility with the vehicle specified and its connection points or, in the case of vehicle modifications, the basic construc-tional permissibility for the specified vehicle. The certifi-cate 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 Direc-tives – unless deviations have been endorsed in these Directives. The certificate of endorsement does not ab-solve the company which is carrying out the modifica-tions 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 man-ufactured.Accordingly, the body manufacturer has the sole respon-sibility for ensuring the compatibility of the body and its equipment, fittings and conversion with the basic vehi-cle, as well as for the operating and road safety of the en-tire vehicle.

2.4.2 Issuing a certificate of endorsementIn particular cases, the conversion drawings may be pre-sented to the responsible department (� page 12) be-fore 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).

� 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 cer-

tificate 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 conver-sion and other installed parts

!Comply with all national laws, guidelines and vehicle registration regulations.



2 General

14

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 sys-tem (MB-AS)

You can obtain tender drawings and technical data from the Mercedes-Benz body/equipment manufacturer sys-tem (MB-AS) at:

http://mbas.mercedes-benz.com

MB-AS is a modern communications system for ex-changing 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 op-timally equipped to provide your customers with quick, low-cost and comprehensive advice, feasibility studies and plans to determine the final vehicle design, to com-pile quotations and to prepare designs.

2.5.1 PC program (ISDN/modem)The vehicle information required can be selected and or-dered 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.

2.5.2 Faxback systemVehicle 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 11-17-86 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 infor-mation 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.

2.5.3 Workshop Information System (WIS)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: +49 (0)711-17-83170

Fax: +49 (0)711-17- 40082


HPC (in-house postcode) R800

Department GSP/TIM




2 General

15

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 reli-ability 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 manufac-tures. As a manufacturer, DaimlerChrysler AG is accord-ingly only liable for its own designs and products. DaimlerChrysler AG does not therefore accept any liabil-ity for damage resulting from defects in retrofitted prod-ucts produced by third-party manufacturers.

The body/equipment manufacturer shall bear sole re-sponsibility for:

� the operating and road safety of the conversion

� the operating and road safety of parts and conver-sion 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 vehi-cle

� consequential damage resulting from the attach-ment, 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, trans-mission 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 man-ufacturer" section of the Maintenance Booklet.



2 General

16

2.7 Warranty claims

2.7 Warranty claimsWarranty 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 equip-ment version for the country in question and field of application

� if damage was caused by the conversion



2 General

17

2.8 Mercedes star and logo

2.8 Mercedes star and logo The Mercedes star and Mercedes-Benz logo are trade-marks 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.

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.

� may not be affixed next to Mercedes-Benz trade-marks

� may only be affixed to other points on the vehicle with permission from the relevant department of DaimlerChrysler AG (� page 12)

Appearance of the entire vehicle

Third-party trademarks



2 General

18

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 regula-tions, safety regulations and information sheets issued by accident insurers.

All technical means shall be used to avoid operating con-ditions that may be unsafe or liable to cause an accident.

In Germany, information is provided to commercial car-riers by the "Vehicles" Working Group of the "Traffic" Technical Committee at the following address:

National laws, guidelines and registration regulations must be complied with.

The body and equipment manufacturer is responsible for compliance with these laws and regulations.

Telephone: +49 (0) 40 39 80- 0

Fax: +49 (0) 40 39 80-19 99

E-mail: [email protected]

Postal address: Berufsgenossenschaft für Fahrzeughaltungen (German Trade Association of Vehicle Owners)

Ottenser Hauptstraße 54

22765 Hamburg, Germany



2 General

19

2.10 Reprocessing components – recycling

2.10 Reprocessing components – recycling

Materials with risk potential, such as halogen additives, heavy metals, asbestos, CFCs and CHCs, are to be avoid-ed.

� It is preferable to use materials which permit recy-cling 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 ad-vantages 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 disman-tled 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 re-moved 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.

� Components in areas at risk from accidents must be designed in such a way that they are damage-toler-ant, 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 HWhen 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.

Environmental note HAdditional information is provided in the "Commercial vehicle recycling, ecology and economy" brochure, Order no. 6702 6187 00-00/0952 (� page 14).



2 General

20

2.11 Quality assurance system

2.11 Quality assurance systemGlobal competition, more stringent quality standards de-manded by the customer of the entire van product, na-tional and international product liability laws, new forms of organisation and increasing cost pressures require ef-fective quality assurance systems in all areas of the au-tomotive industry.

To be able to meet these requirements, a work group of the VDA (Association of German Automobile Manufac-turers) 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 mem-bers of staff concerned

3.1 Vehicle selection



21

3 Planning conversions

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.

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 depart-ment (� page 12).

!As well as a user-friendly and easy-to-maintain de-sign, selection of the correct materials and subse-quent observation of the corrosion protection measures are important when planning conversions (� page 46).

!Before carrying out modification work, the delivered vehicle must be submitted to a check to verify wheth-er it fulfils the necessary requirements.

iVisit 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.




22

3.2 Vehicle modifications

3.2 Vehicle modifications Before starting conversion work, the body/equipment manufacturer must check whether:

� the vehicle is suitable for the planned conversion

� the vehicle model and equipment are suitable for the conditions of use intended for the conversion

Tender drawings, product information and technical data for planning conversions can be requested from the rel-evant department or retrieved from the communications system (� page 14).

Furthermore, attention must be paid to optional equip-ment fitted ex works (� page 35).

As supplied ex works, all vehicles comply with EC direc-tives and national regulations (except for some vehicles for non-European countries).

The vehicles must still comply with EC directives or na-tional regulations after modifications have been carried out.

The body/equipment manufacturer must inform the of-ficially recognised technical expert or inspector of any modifications to the vehicle.

!Adequate clearances must be maintained in order to ensure the function and operational safety of assem-blies.

Risk of accident GDo not make any modifications to the steering or brake systems. Modifications to the steering or brake systems could result in these systems no longer func-tioning correctly and failing. The driver could lose con-trol of the vehicle as a result and cause an accident.

!Modifications to sound proofing are not permitted.

Vehicle approval

!Comply with all national laws, guidelines and vehicle registration regulations.




23

3.3 Dimensions and weights

3.3 Dimensions and weights Modifications to the vehicle width, height and length which would exceed the maximum values specified in the current body/equipment mounting directive are not permitted.

Dimensions and weights shall be taken from tender drawings and the Technical data in the Mercedes-Benz body/equipment manufacturer system (� page 14) and from the Technical threshold values (� page 36). These are based on vehicle that is fitted with standard equip-ment.

Weight tolerances of up to +5% in production must be adhered to (in accordance with DIN 70020 in Germany).

Do not exceed the maximum permissible axle loads or gross vehicle weights specified in the "Technical thresh-old values for planning" section (� page 36) and in the "Technical data" section (� page 95).

Information about changes in weight is available from your contact at Mercedes-Benz (� page 12).

The permissible number of vehicle occupants and an ad-equate margin for the payload must also be observed.

The payload may consist of luggage, optional equipment, etc.

Take the weight of optional equipment into considera-tion when making calculations.

National regulations and guidelines shall apply.

3.3.1 Weight distributionAvoid placing excessive loads on one side of the vehicle.

The wheel load (1/2 the axle load) should not be ex-ceeded by more than 4%. Observe the tyre load-bearing capacity.

The maximum rear-axle load must not exceed 53% of the permissible vehicle load.

Risk of accident GThe tyre load capacity of the vehicle must not be ex-ceeded by overloading the vehicle above the specified gross vehicle weight. The tyres could otherwise over-heat 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).

Risk of accident GThe 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.

!The individual axle loads and the permissible gross vehicle weight must be observed for all conversions.




24

3.3 Dimensions and weights

Vehicle weights

1 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

2 Data applicable depending on vehicle operating permit (without/with load increase, code XA2)

Trailer loads/payload

1 2,500 kg as option, code D442 Dependent on unladen weight and permissible gross weight of vehicle; reduced when additional equipment is fitted3 150 kg for 6 attachment points or 100 kg for 4 attachment points; maximum 50 kg for a high roof

Weight in kg Compact body Long body Extra-long body

Unladen weight in accordance with 92/91 EEC1

Panel van 1,790 1,845 1,870

Traveliner 1,900 1,925 1,950

Luxury Traveliner 2,070 2,095 2,120

Permissible gross weight2 2,770/2,940 2,770/2,940 2,940

Permissible front axle load2 1,470/1,550 1,470/1,550 1,470/1,550

Permissible rear axle load2 1,470/1,550 1,470/1,550 1,470/1,550

Weight in kg Compact body Long body Extra-long body

Permissible trailer load, braked 2,0001 2,0001 2,0001

Permissible trailer load, unbraked 750 750 750

Maximum trailer drawbar nose-weight

100 100 100

Maximum payload2

Panel van2 950 – 1,120 925 – 1,095 900 – 1,070

Traveliner2 1,040 1015 990

Luxury Traveliner2 700 – 870 675 – 845 820

Permissible roof load3 100/150 50/100/150 100/150

Maximum tailgate rack load 45 45 45




25

3.4 Vehicle identification data

3.4 Vehicle identification data The vehicle identification plate with the chassis number is located in the front-passenger door frame.

The vehicle identification plate and chassis number must not be modified or moved to a different location.

Vehicle identification plate with chassis number




26

3.5 Vehicle stability

3.5 Vehicle stabilityDuring approval of the vehicle with body/equipment, a calculation of the centre of gravity height of the laden ve-hicle must be provided in accordance with EC Brakes Di-rective 71/320/EEC.

The permissible centre of gravity heights can be found in the "Technical threshold values for planning" section (� page 36).

DaimlerChrysler AG cannot provide any information about the:

� handling characteristics

� braking characteristics

� steering characteristics and

� behaviour during ESP intervention

of converted vehicles for payloads with an unfavourably-located centre of gravity (e.g. either at the rear, or very high or to one side) as conversions will have a consider-able impact on the above characteristics and can there-fore only be assessed by the body manufacturer.

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.

Risk of accident GOn vehicles with ESP and unfavourably-located cen-tres 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.

Risk of accident GThe 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.




27

3.6 Tyres

3.6 TyresThe body/equipment manufacturer must ensure that:

� the clearance between the tyre and the wing or wheel housing is sufficient even when snow or anti-skid chains are fitted and the suspension is fully compressed (including axle twist)

� specifications in the tender drawings are observed

� only permissible tyre sizes are used (see vehicle doc-uments)

Risk of accident GExceeding the specified tyre load capacity or maxi-mum 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 spec-ifications 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 guar-anteed

� the wheel brakes or chassis components can no longer function correctly

!Further information (� see page 14) and (� see page 35).




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3.7 Bolted and welded connections


3.7.1 Bolted connections

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, par-tition cross member.

� Connections between the steering wheel and steer-ing 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 en-gine compartment.

� All bolted connections of the brake lines.

� Brake disc mounting on the wheel hub and brake cal-liper 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 sys-tem.

� 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.

� Fuel line bolted connections.

� Tank fastening strap mountings.

� Rear-axle drive shaft mountings (side shafts).

� Brake disc to wheel hub and sliding calliper to rear-axle semi-trailing arm.

� Rear-axle semi-trailing arm mounting to the sub-structure.

� Trailer coupling mountings to the substructure and trailer bracket bolted connections.

� Towing eye attachments to the longitudinal and cross members.

� Suspension subframe to the longitudinal frame member.

If it is necessary to replace standard bolts with longer bolts, use only bolts:

� of the same diameter

� of the same strength grade

� of the same type

� with the same thread pitch

� 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 ap-proved.

Bolted connections with particular relevance to safety (class "A" according to VDI 2862)

Risk of accident GAll bolt connections relevant to safety, e.g. wheel location, steering and braking functions, must not be altered, otherwise they may no longer function cor-rectly. 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.




29


� If bolts have been tightened to a specific torque and angle by Mercedes-Benz, a design modification will not be possible.

� The settling characteristics of bolted connections must be taken into account.

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.

3.7.2 Welded connections

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

The mechanical properties of welds depend on the choice of welding procedure and the geometry of the parts to be welded.

For overlapping sheets, the welding procedure is to be chosen depending on whether only one or both sides are accessible.

Resistance spot welding is a suitable procedure for weld-ing 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.

d Distance between the spot weldse Sheet thickness

iInformation is available from any Mercedes-Benz Service Centre.

General

Choice of welding procedure

Accessible sides

1 MIG plug welding

2 Resistance spot welding

Resistance spot welding




30


Distance to the edge of the sheet:

To prevent electrode damage, the specified distances to the edge of the sheet must be observed (L=3e+2 mm).

e Sheet thicknessL Distance to the edge of the sheet

If overlapping sheets are accessible from one side only, they can be welded using MIG plug welding or tack weld-ing.

If the parts are joined using punched or drilled holes and then plug welded, the drilling area must be deburred be-fore welding.

MIG plug welding

D = plug hole diameter [mm]

4.5 5 5.5 6 6.5 7

e = sheet thick-ness [mm]

0.6 0.7 1 1.25 1.5 2




31


The mechanical properties can also be improved by us-ing "slots" (l=2*b).

b Slot widthI Slot length

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 Distance between tack weld centrese Sheet thicknessL Length of tack weld

� assemblies such as the engine, transmission, axles, etc.

� the vehicle frame

Observe the corrosion protection measures (� page 46) specified after all welding work on the vehicle.

Tack welding

Do not perform welding work on:

iFurther 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 Mer-cedes Benz Workshop Information System (WIS).

Anti-corrosion protection after welding

!The information given by Mercedes-Benz in the "Dam-age prevention" (� page 45) and "Modifications to the basic vehicle" (� page 56) sections must be ob-served when welding.




32

3.8 Noise insulation

3.8 Noise insulationIf modifications are carried out on any parts whose oper-ation produces noise e.g.

� engine

� exhaust system

� air intake system

� tyres, etc.

sound level measurements must be made.

Comply with national regulations and guidelines.

In Germany, the EC Directive 70/157/EEC or Section 49.3 of the German road traffic licensing regula-tions (low-noise) (StVZO) must be observed.

� Noise-insulating parts fitted as standard must not be removed or modified.

� The level of interior noise must not be adversely af-fected.

!If any modifications are made to the vehicle, the exte-rior noise of the vehicle must comply with the values specified in EC Directive 70/157/EEC.

!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 mini-mum when planning conversions (� page 69).




33

3.9 Maintenance and repairs

3.9 Maintenance and repairs Maintenance and repair of the vehicle must not be hin-dered by the conversion.

Maintenance points and assemblies must remain easily accessible.

� Observe the Owner's Manual/Operating Instruc-tions.

� Stowage boxes must be fitted with maintenance flaps or removable rear panels.

� Check the condition and capacity of batteries and service them in accordance with the manufacturer's specifications (� page 34).

DaimlerChrysler AG will not carry the costs for any addi-tional 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 rec-ommend a Mercedes-Benz Service Centre.

� Retighten the wheel nuts to the specified torque.

� DaimlerChrysler AG recommends that the scope of maintenance work to be carried out on the conver-sion parts corresponds to the Mercedes-Benz main-tenance systems applicable to the relevant vehicle. This applies both to the scope and type of service work, and for determining the servicing intervals based on time elapsed and distance covered.

The Owner's Manual/Operating Instructions and main-tenance instructions for conversion work and for any ad-ditional equipment installed must be included with the vehicle in the language of the country of use on delivery by the body/equipment manufacturer.

3.9.1 Preparation for storing the vehicle

� 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

� Perform the same tasks as for storage in enclosed spaces

� Close all air inlets and switch the heater to "Off"

� Perform the same tasks as for storage in enclosed spaces

� Fold the windscreen wipers away from the wind-screen

� Close all air inlets and switch the heater to "Off"

� Remove the battery and store it according to the manufacturer's instructions (� page 34)

!The battery may be damaged if not used for long pe-riods. This must be avoided by disconnecting the bat-tery and storing it appropriately (� page 34).

Storage in enclosed spaces:

Storage in the open (less than 1 month):

Storage in the open (more than 1 month):




34

3.9 Maintenance and repairs

� Check the oil level monthly

� Check the coolant level monthly

� Check the tyre pressure monthly

� Check the fluid levels in the vehicle

� Correct the tyre pressures to those specified

� Check the charge and fit the battery

� Clean the entire vehicle

3.9.2 Battery maintenance and storageTo 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.

3.9.3 Preparation for handing over the converted vehicle

The work and modifications carried out must be entered in the Service Booklet by the body manufacturer.

The vehicle should be checked for faults and any dam-age 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.

The battery charge must be tested before delivering the vehicle (� page 34).

The tyres must be checked for the correct pressure and for damage before the vehicle is delivered. Damaged tyres must be replaced.

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).

Maintenance of stored vehicles (in storage for more than 1 month)

Taking the vehicle out of storage

!If the battery voltage drops below 12.1 V, it will be damaged and will have to be replaced.

Checking the entire vehicle

Checking the battery

Checking the tyres

Checking the wheel alignment




35

3.10 Optional equipment

3.10 Optional equipmentTo convert the vehicle in the best possible way, we rec-ommend the items of optional equipment available as a code.

All items of optional equipment available as a code from Mercedes Benz can be obtained from a Mercedes-Benz Service Centre or from the technical advice service of body manufacturers (� page 12).

You can also visit the Mercedes-Benz home page at:

http://mbks2.mercedes-benz.com/van_konfigurator/vp.dll where you can configure your vehicle and view the avail-able items of optional equipmen.

Optional equipment (e.g. reinforced springs, frame rein-forcement, auxiliary tanks, anti-roll bars, etc.) and retro-fitted equipment increases the unladen weight of the vehicle.

The actual vehicle weight and axle loads must be deter-mined by weighing before conversion work.

Not all optional equipment can be installed in any vehicle without problems. This applies particularly to retrofit-ting.

4.1 Basic vehicle threshold values



36

4 Technical threshold values for planning

4.1 Basic vehicle threshold values

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.

4.1.2 Extreme permissible positions of cen-tre of gravity

4.1.3 Parts which must not be welded

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 Parts which must not be welded� 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 pre-vention" (� page 45) and "Planning conversions" sec-tions (� page 28).

4.1.5 Parts in which holes may not be drilled� A and B-pillars

� chassis

� the vicinity of load application points (e.g. axle con-nections)

� front-axle or rear-axle supporting points

� the vicinity of the airbags

You can obtain further information in the "Planning con-versions" section (� page 28).

!This section contains the most important technical threshold values required for planning the basic vehi-cle. Furthermore, you will also find information in the other sections in the current body/equipment mount-ing directives.

x direction: At R1 = 3,200 mm < 1,700 mm (approximately 53% rear axle load)

At R2 = 3,430 mm < 1,800 mm (approximately 53% rear axle load)

y direction: When the vehicle is laden, the wheel load (1/2 the axle load) must not be exceeded by more than 4%.

Vehicle width

!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.




37

4.2 Chassis threshold values


4.2.1 Permissible axle loadsSee the "Technical data" section (� page 95).

4.2.2 Approved tyre sizes

4.2.3 Turning circle diameterSee:

� Section 32d of the German road traffic licensing reg-ulations (StVZO)

� European Union: 97/27/EC

� European Union: 96/53/EC

4.2.4 Modifications to the axles Modifications to the chassis and axles are not permitted (� page 52).

4.2.5 Modifications to the steering systemModifications to the steering system are not permitted (� page 52).

Rim Tyres Load (kg) Comments

6J x 16" ET54 steel

195/65R16 C 100/98T

800 only panel van and only for permissible gross vehi-cle weight 2.77tons

only steel rims (as summer and winter tyres)the use of snow chains is only possible with

winter tyres

6J x 16" ET60 steel/aluminium

205/65R16 C 103/101T (99H)

875 (775) series production with steel rims for Traveliner, panel van with a permissible gross vehicle weight of

2.94tonsaluminium rims fitted as optional equipment

the use of snow chains is only possible on winter tyres with steel rims


225/60R16 C 101/99H

Summer tread and all season tread

825 series production with steel rimsaluminium rims fitted as optional equipment

the use of snow chains is not possible


225/60R16 Rf 102H

Summer tread

850 series production with steel rimsaluminium rims fitted as optional equipment

the use of snow chains is not possible

7J x 17" ET56 aluminium

225/55R17 Rf 101H (-V)

Summer tread

825 only aluminium rimsthe use of snow chains is not possible




38


4.2.6 Modifications to the brake systemModifications to the brake system are not permitted.

Modifications to the airflow into and out of the disc brakes are not permitted (� page 53).

Chocks are specified in accordance with Section 41, Paragraph 14 of the German road traffic licensing regu-lations (StVZO) for vehicles with a permissible gross ve-hicle weight > 4 tons.

4.2.7 Modifications to the springs/spring mountings/shock absorbers

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 alignmentModification of the wheel alignment is not permitted (� page 52).




39

4.3 Bodyshell threshold values

4.3 Bodyshell threshold values

4.3.1 Modifications to the bodyshellSee 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 weld-ing work on the A-pillar or B-pillar.

� In the event of modifications to the sidewall, the ri-gidity of the modified body must be equal to that of the basic vehicle.

4.3.2 Vehicle roof/roof load

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.

Maximum roof loads

Normal roof [kg] High roof [kg]

150 50




40

4.4 Engine periphery/drive train threshold values

4.4 Engine periphery/drive train threshold values

4.4.1 Fuel system� Modifications to the fuel system are not permitted

(� page 61).

4.4.2 Modifications to the engine/drive train parts

� Modifications to the engine air intake are not permit-ted.

� 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 op-tional equipment.




41

4.5 Interior threshold values

4.5 Interior threshold values

4.5.1 Modifications to the airbags and belt tensioners

� Modifications to airbag components, or in the vicini-ty 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).

4.5.2 Modifications to the seats

You can obtain further information in the "Modifications to the basic vehicle" (� page 52) and "Modifications to the interior" sections (� page 88).

Risk of injury GModifications to the airbag system and the belt ten-sioner 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.

Risk of accident GModifications 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 an-chorages in an accident.




42

4.6 Electrical system/electronics threshold values

4.6 Electrical system/electronics threshold values

See the "Modifications to the basic vehicle" section (� page 70).

4.6.1 Electrical lines/fuses

4.6.2 Vehicle outline and side marker lampsUnder Section 51b, Paragraph 2 of the German road traf-fic licensing regulations (StVZO), all vehicles with a total width of 2.10 m or over are required to be equipped with vehicle outline lamps.

4.6.3 Retrofitting electrical equipment ("e" mark)

All electrical equipment installed must be tested in ac-cordance with EC Directive 94/54/EEC and must bear the "e" mark.

4.6.4 Mobile communications systems� The maximum transmission output must not be ex-

ceeded.

4.6.5 CAN busIt is not permitted to tamper with the CAN bus or com-ponents connected to it.

4.6.6 Electronic Stability Program� 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 sen-sors are not permitted.

Maximum per-manent current

[A]

Rated fusing current

[A]

Wire cross-section [mm2]

0 – 4.9 5 0.5

5 – 9.9 10 1

10 – 18 20 2.5

19 – 28 30 4

29 – 35 40 6

36 – 48 50 10

49 – 69 70 46

70 – 98 100 25

99 – 123 125 35

124 – 148 150 50

Frequency range Maximum transmis-sion output [W]

Short wave < 50Mhz 100

4 m waveband 20

2 m waveband 50

70 cm waveband 35

25 cm waveband 10




43

4.7 Additional equipment threshold values

4.7 Additional equipment threshold valuesAdditional equipment must never obstruct vehicle com-ponents nor impair their clearance and operation.

5.1 Brake hoses/cables and lines



44

5 Damage prevention

5.1 Brake hoses/cables and linesPlastic lines and brake hoses must be covered, or re-moved if necessary before welding, drilling, grinding or working with cutting discs.

Check the system for pressure loss and leaks after in-stalling hydraulic lines.

No other lines may be secured to the brake hoses.

Lines must be protected from heat with appropriate in-sulation.

The lines must be routed in such a manner that pressure loss is not increased.

!Accident prevention regulations must be observed when working on the vehicle.

!Specific national guidelines and laws must be ob-served.

Warning GWork carried out incorrectly on the brake hoses or ca-bles may impair their function. This may lead to failure of components or parts relevant to safety.



5 Damage prevention

45

5.2 Welding work

5.2 Welding work The following safety measures must be observed to pre-vent damage to components caused by overvoltage dur-ing welding work

� Welding work on the vehicle may only be carried out by trained personnel.

� Disconnect the positive and negative terminals from the battery and cover them.

� Connect the welding-unit earth terminal directly to the part to be welded.

� Do not touch electronic component housings (e.g. control modules) and electric lines with the welding electrode or the earth contact clamp of the welding unit.

� Before welding, cover springs and air bellows to pro-tect them from welding spatter. Do not touch springs with welding electrodes or welding tongs.

� Cover the fuel tank and fuel system (lines, etc.) be-fore carrying out welding work.

� The earth terminal of the arc welder must be con-nected directly to the part of the vehicle to be welded.

� It is not permitted to perform welding work near the airbags.

� The battery must be disconnected.

� Use only completely dry lime basic jacket electrodes (2.5 mm diameter).

� The maximum current may be 40 A per mm of elec-trode diameter.

� Weld only with electrodes connected to the positive pole of a direct current source. Always weld from bottom to top.

� MIG welding is permissible.

� Only use welding wires with a thickness of between 1 and 1.2 mm.

� The yield point and tensile strength of the welding material must be at least equal to that of the material to be welded.

� Plug welding is only permissible in the vertical webs of the longitudinal frame member.

� Welds must be ground down and reinforced with an-gular sections to prevent notching from welding pen-etration.

� Avoid welds in bends.

� A distance of at least 15 mm should be present be-tween the weld and the outer edges.

!Do not connect the arc welder earth clamp terminal to assemblies such as the engine, transmission or ax-les.

!Welding work is not permitted on assemblies such as the engine, transmission or axles.

Warning GIf in spite of the warning not to, welding work is per-formed 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 über explo-sionsgefährliche Stoffe).

!Further information on welding work can be taken from the "Planning conversions" (� page 28), "Modi-fications to the basic vehicle" (� page 52) and "Bodyshell" (� page 56) sections and from the Mercedes-Benz Workshop Information System (WIS).



5 Damage prevention

46

5.3 Corrosion protection measures


Surface and anti-corrosion protection measures must be carried out on the areas affected after modifications and installation work have been performed on the vehicle.

Corrosion protection measures should be included in the planning and design through the selection of suitable materials and the arrangement of the components.

Prevention of contact corrosion by electrical insulation

1 Insulating washers2 Insulating sleeves

The use of electrical insulation such as washers, sleeves or bushings can prevent contact corrosion.

Avoid welding work on inaccessible cavities.

Planning measures

!If two different metals are connected through an electrolyte (e.g. atmospheric humidity), a galvanic connection is created. Electrochemical corrosion oc-curs, with the baser of the two metals being dam-aged. The further apart the two metals are in the electrochemical potential series, the more intense electrochemical corrosion becomes.

Electrochemical corrosion must therefore be pre-vented by treating the components appropriately or isolation, or it must be kept to a minimum by select-ing suitable materials.



5 Damage prevention

47


Corrosion can be reduced by design measures, in partic-ular by the arrangement of the joints between the same or different materials.

There is a risk of dirt or humidity accumulating in cor-ners, edges, beads and folds.

Corrosion protection can be implemented at the design stage by using suitable surfaces and run-offs and avoid-ing gaps where components are joined.

Gaps at welded connections caused by the design and how to avoid them

The vehicle can be protected against corrosion by the application of a protective coating (e.g. galvanisation, protective paint or flame-applied zinc coating) (� page 48).

� Remove drilling swarf.

� Deburr sharp edges.

� Remove any burned paintwork and thoroughly pre-pare surfaces for painting.

� Prime and paint all unprotected parts.

� Preserve cavities with wax preservative.

� Carry out corrosion protection measures on the un-derbody and frame parts.

Component design measures

suitable

(welded through)

unsuitable

(gaps)

Coating measures

After all work on the vehicle



5 Damage prevention

48

5.4 Painting

5.4 Painting

Check the compatibility of the paint before painting over. To prevent colour deviations when painting, we recom-mend that you use genuine Mercedes-Benz paints. The primer used in the factory and the Mercedes-Benz paint numbers can be obtained from the relevant department (� page 12).

Mask the following areas before painting:

� Sealing surfaces

� Windows

� Contact areas between wheels and wheel hubs

� Contact areas for wheel nuts

� Vents on transmission, axles, etc.

� Disc brakes

� Door locks

� Door retainers in the rear door hinges

� Contact surfaces on the guide rails for the sliding doors

� Door retainers and opening limiters in the centre guide rails

� Moving parts of the sliding door carriage

!Do not exceed a temperature of 80 °C for drying the paint.



5 Damage prevention

49

5.5 Towing and tow-starting

5.5 Towing and tow-starting

Warning GBefore towing or tow-starting, please make sure that you read the section on towing in the detailed Own-er's Manual/Operating Instructions. You could other-wise fail to recognise dangers, which could result in injury to yourself or others.

!Failure to observe the Owner's Manual/Operating In-structions can result in damage to the vehicle.



5 Damage prevention

50

5.6 Storing and delivering the vehicle

5.6 Storing and delivering the vehicle

To prevent damage when storing vehicles, we recom-mend that you maintain and store the vehicle as de-scribed in the manufacturer's instructions (� page 33).

To prevent damage to the vehicle or to repair any exist-ing damage, we recommend that the vehicle be subject-ed to a full function check and a complete visual inspection before it is handed over (� page 34).

Storage

Delivery



5 Damage prevention

51

5.7 Electromagnetic compatibility (EMC)

5.7 Electromagnetic compatibility (EMC)Electrical interference occurs in the vehicle electrical circuits because of the various consumers. At Mercedes-Benz, electronic components installed at the factory are checked for their electromagnetic com-patibility in the vehicle.

When electric or electronic systems are retrofitted, they must be tested in terms of their electromagnetic com-patibility, which must then be documented.

The equipment must have type approval in accordance with EC Directive 95/54/EC and must bear the "e" mark.

The following standards provide information on this:

� DIN 40839

� DIN 57879, Part 3

� VDE 0879, Part 3

� DC 10614 (EMC component requirements)

� DC 10613 (EMC vehicle requirements)

� EU Directive 95/54/EC

6.1 Chassis



52

6 Modifications to the basic vehicle

6.1 Chassis

6.1.1 Basic chassis Modifications to chassis components are 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 re-quire 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 Mod-ifications are not permitted.

6.1.2 Springs/shock absorbersAny 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.

� We recommend the use of genuine Mercedes-Benz springs.

� Do not damage the surface or corrosion protection of the springs during installation work.

� 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 GUnauthorised modifications to chassis components can adversely affect the vehicle's handling character-istics, even leading to unstable handling characteris-tics. Modifications to chassis components are there-fore not permitted.

Risk of accident GThe use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permit-ted. On vehicles with ESP, this may otherwise result in the ESP system not functioning correctly and fail-ing.The driver could lose control of the vehicle as a re-sult and cause an accident.

!Observe the items of optional equipment available at the factory as codes (� page 35).




53

6.1 Chassis

6.1.3 Brake system

When the work is complete, check that the brake system is working properly. We recommend that the brake sys-tem be inspected and approved by a technical inspec-tion centre.

If the routing has to be altered, avoid routing across sharp edges and through narrow cavities or near moving components.

� 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 instal-lation.

� 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 re-newed.

� The brake fluid must be renewed every two years.

� 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.

No other lines may be secured to the brake hoses.

Risk of accident GWork 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.

Hydraulic brake system

Routing lines

Risk of accident GAn 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 suf-fer total failure due to the formation of bubbles in the brake fluid or from chafing points in the brake lines.

Routing the lines along the brake hoses




54

6.1 Chassis

Cooling must not be impaired by attaching spoilers be-low the bumper, additional hub caps or brake disc cov-ers, etc.

A certificate of endorsement from the relevant depart-ment is required when retrofitting additional brakes.

6.1.4 Pneumatic suspensionDisc brakes

Risk of accident GNo 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 dam-age and will also impair braking ability.

For this reason, make sure there is a sufficient supply of cooling air at all times.

Risk of accident GModifications to parts of the brakes (e.g. brake calli-pers, discs, etc.) are not permitted. Modifications to parts of the brakes could result in this system no long-er functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an ac-cident.

Additional brakes/retarder

Risk of accident GThe use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permit-ted. This applies to the retrofitting of pneumatic sus-pension in particular. This may otherwise result in ESP, for example, not functioning correctly and fail-ing. The driver could lose control of the vehicle as a re-sult and cause an accident.




55

6.1 Chassis

6.1.5 Wheels/tyres

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 com-pressed (including any axle twist). Specifications in the tender drawings must be observed

� only permissible tyre sizes are used (see vehicle doc-uments) (� page 14) (� page 37)

� only approved wheels are used (� page 14)

6.1.6 Spare wheel

For the spare wheel mounting, observe the following:

� Legal requirements

� Ease of access and handling

� Double security against loss

Risk of accident GFor 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

iFurther information on wheels/tyres can be obtained from any Mercedes-Benz Service Centre or in the "Optional equipment" section (� page 35).




56

6.2 Bodyshell/bodywork


6.2.1 General notes on the bodyshell/bodywork

Conversions must not have a negative effect on the op-eration or strength of the vehicle's assemblies or con-trols 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 free-dom of movement of vehicle parts (e.g. during mainte-nance and inspection work) or ease of access to these parts.

Observe the following:

� Modifications to the wheelbase are not 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.


� The maximum permissible axle loads must not be ex-ceeded.

� Trailer connections must be checked for correct op-eration.

� If a trailer coupling is installed, the necessary rein-forcements 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.

Welding work may only be performed by skilled person-nel.

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.

Welding work on the bodyshell

iFurther 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).

Risk of accident GIf welding work is performed in the vicinity of the air-bags, 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 permit-ted 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 über explo-sionsgefährliche Stoffe).




57


After drilling, deburr and countersink all holes, remove as much swarf as possible and treat the holes with body cavity sealing.

6.2.2 Modifying the partitionIf the partition is to be cut out due to conversion or in-stallation work, this is possible in conjunction with a con-tinuous 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).

6.2.3 Sidewall, windows, doors and flaps

If any modifications are made to the sidewall on the pan-el 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 depart-ment is required (� page 12).

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 re-sulting structural rigidity equal to that of the basic vehi-cle must be achieved.

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.

Drilling work on the chassis

!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

Risk of accident GNo modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate cor-rectly (e.g. delayed or incomplete inflation of window-bags).

Sidewall

!Observe the corrosion protection measures (� page 46) specified after all work on the vehicle.

Windows

Doors and flaps

!Modifications to the rear portal including the roof area are only permitted in extreme cases and with a certificate of endorsement from the relevant de-partment (� page 12).




58


1 Rear portal area (certificate of endorsement re-quired)

� The seats must be directly accessible from the out-side 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 en-trances 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 low-est step must be no greater than 400 mm.

� Fittings must allow sufficient clearance to the interi-or door handles regardless of the position of the load compartment sliding door (trap guard).

� Modifications to the central locking system in the im-mediate area around the door or in the area of the pillars or cross members are not permitted.

6.2.4 Wings and wheel arches

6.2.5 Chassis end cross-memberModifications to the chassis end cross-member are only possible after consultation with the relevant department (� page 12).

6.2.6 BodyshellObserve the following:

� Modifications to the wheelbase, windscreen, wind-screen frame, the A-pillar or the B-pillar and tamper-ing with the longitudinal member structure, are not 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 sharp-edged 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 se-cure retrofitted installations in the vehicle interior.

� Brackets (plug welds) must be used to secure addi-tional equipment to the longitudinal and cross mem-bers and require approval.


� The maximum permissible axle loads must not be ex-ceeded.

!Observe the corrosion protection measures (� page 46) specified after all work on the vehicle.

N23.00-2031-00

Risk of accident GLowering the wheel arches is not permitted. The vehi-cle (e.g. wheel arches and tyres) could otherwise be damaged.




59


� Trailer connections must be checked for correct op-eration.

� If a trailer coupling is installed, the necessary rein-forcements must be present.

If the vehicle is equipped with driver's and front-passen-ger windowbags, it is prohibited to cut into the partition (� page 57) for the purposes of conversion or attach-ment in the area illustrated from a distance of 145 mm from the protrusion towards the B-pillar and from the roof down to a point level with the waistline (minimum 650 mm). This is to ensure that the windowbags inflate without obstruction.

Subsequent conversion of vehicles with windowbags is not permissible in the roof area around the B-pillar.

6.2.7 Underbody panellingIt is necessary to treat the entire underbody with addi-tional 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 Roof of panel van/Traveliner

� Number of roof archesIf 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.

� Location of roof arches:

� behind the front doors (B-pillar)

� in the middle of the vehicle behind the load com-partment sliding door (C-pillar)

� The new roof structure must be as rigid as the stand-ard roof. The minimum moment of inertia required per roof arch is Ix = 4,000 mm4.

� 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 con-junction 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 con-forming 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 ex-ceeded. 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.


!The arches must be connected to the side panels in such a way that a force-locked connection is guaran-teed (bend-resistant connection of arch and roof frame).




60


Observe the permissible centre of gravity location and axle loads.

The height of the roof may only be increased in conjunc-tion with integrated arches and reinforcement frames.

Plastic roofs have limited suitability for installing roof hatches.

The roof load-bearing capacity is restricted (see the fol-lowing table).

If a raised roof is fitted, at least 2/3 of the original roof area must be retained.

The threshold values for the maximum vehicle centre of gravity location must not be exceeded.

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).

Observe the permissible centre of gravity location and maintain the permissible axle loads.

Superstructure

Increasing the roof height

!The new roof structure must be as rigid as the stand-ard roof.

Risk of accident GThe 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


!If roof arches or load-bearing parts are removed or damaged, they must be replaced (� page 60).

Maximum roof load

Normal roof [kg] High roof [kg]

150 50

Modifications to the cab roof

Risk of accident GModifications to the cab must not impair the function of parts relevant to safety (such as airbag units, sen-sors, 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 cor-rectly (e.g. delayed or incomplete inflation of window-bags).

!If roof arches or load-bearing parts are removed or damaged, they must be replaced.




61

6.3 Engine periphery/drive train


6.3.1 Fuel systemModifications 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

For connections supplying fuel for auxiliary heating, the procedure for design approval must be followed.

6.3.2 Exhaust systemNo 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

� Around the control units.

� Around the assemblies, equipment and fittings, if they are not made from heat-resistance material.

6.3.3 Engine coolingIt is not permissible to modify the cooling system (radia-tor, radiator grille, air ducts, coolant circuit, etc.).

A sufficient flow of cooling air must be ensured:

� Do not obstruct the radiator air inlet.

� Do not affix warning signs, labels or decorative ob-jects in the area in front of the radiator.

Additional cooling for assemblies is to be provided for when the vehicle is stationary if a high continuous output is approved.

Disc brakes

Do not impede cooling by attaching spoilers below the bumper, additional hub caps or brake disc covers, etc.

!Inadmissible modifications to the fuel system (tank, lines, etc.) may impair the vehicle's driving character-istics and lead to engine emergency running mode.

Environmental note HIncorrectly performed modifications to the fuel sys-tem can cause damage to the environment.

Additional shielding is required

Risk of accident GChanges to the air flow in the brake system may im-pair 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).




62


6.3.4 Engine air intakeModifications to the engine air intake are not permitted.

The filtered-air side of the engine air intake system must not be modified in any way.

� The intake of warm air will lead to a loss of engine power.

� It is therefore essential to shield off the air intake from the engine compartment by appropriate means.

� The intake temperature must not exceed the outside temperature by more than 10 °C (� page 62).

Filter area required for NCV2 vehicles in cm2:

� Make sure that water cannot reach the intake points through any fresh-air intakes. The flow rate at the in-take 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 protect-ed against dust being thrown up from the wheel housing.

� Increased dust intake will lead to shorter mainte-nance intervals for the air cleaner.

6.3.5 Propeller shafts

Warm air

Engine kW Air requirement (m3/min)

Filter area with standard filter paper (cm2)

Specific filter area (cm2/m3/min)

Euro 4 EU4/III Euro 4 EU4/III

OM 646 DE22LA 65 6.2 -- 19,100 4,032 --

80 6.9 7.5 19,100 3,623 3,333

110 8.3 8.2 19,100 3,012 3,048

M 112 E32 165 9.0 19,100 2,110 -- --

Water

!Modifications to the drive train are not permitted.




63

6.4 Interior

6.4 Interior

6.4.1 General On no account may modifications be made in the cockpit and above the vehicle body waistline.

This applies in particular to the inflation areas of the air-bags (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 test-ing centres for motor vehicles (e.g. TÜV, DEKRA).

The interior fittings must be designed in such a way that there are no sharp edges or corners (accident preven-tion).

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.

6.4.2 Safety equipment

Vehicles designed with a type-tested top speed of more than 25 km/h must be equipped with seat belts. Outer seats must be equipped with seat belts (see Minimum requirements for seat belts 77/541/EEC).

Seat belt anchorages must be tested in accordance with EC Directive 76/115/EEC.

The legal requirements detailed in this section relate to current legislation in Germany. The relevant national leg-islation must be observed in all other countries.

The driver's and front-passenger airbag units, the win-dowbags and the belt tensioners are pyrotechnic com-ponents.

Handling, transportation and storage are subject to leg-islation concerning hazardous explosive substances (for example, the "Gesetz über explosionsgefährliche Stoffe" in Germany) and must therefore be reported to the rele-vant Trade Supervisory Office.

The purchase, transportation, storage, fitting, removal and disposal of hazardous explosive substances may only be carried out by trained personnel and in accord-ance with the relevant safety regulations.

Risk of injury GModifications 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 then-fore fail in accidents with sufficient deceleration or could be activated unintentionally.

Seat belts

Airbags and belt tensioners




64

6.4 Interior

All airbag units are labelled with the letters "SRS":

� The driver's airbag unit is identified by the "SRS" inscription on the steering wheel boss.

� The front-passenger airbag unit is also identified by the "SRS" inscription.

� Windowbags are identified by the "SRS Airbag" inscription at the side of the roof lining.

Another feature to note is the red "SRS" warning lamp in the instrument cluster.

The following illustrations show the location and deploy-ment area of the thorax bags, driver's and front-passen-ger airbags and windowbags.

Deployment area of the thorax bag in the front-pas-senger seat

Driver's seat backrest with cover panel

Driver's airbag deployment area

Front-passenger airbag deployment area




65

6.4 Interior

Deployment and coverage area of the front-passen-ger windowbagFront of vehiclel

The airbag units fitted in the Vito/Viano include a driv-er's airbag, front-passenger airbag, thorax bags in the driver's and front-passenger seats and windowbags.These parts/assemblies may only be modified after ap-proval has been granted by DaimlerChrysler AG.

It is not permitted to change the installation point, spa-tial orientation and attachment of the occupant-safety airbag control units and the side-impact sensors on ve-hicles with windowbags from those of the standard vehi-cle. It is not permitted to attach or locate other vehicle components on the airbag control unit, nor on the side-impact sensors and their points of attachment.

The airbag control unit, including the trigger sensors and the ESP yaw rate sensor, is installed in the footwell/ cen-tre console behind the trim.

ESP yaw rate sensorAirbag control unitFront of vehicle

The ESP yaw rate sensor is susceptible to shocks and must be stored where it is free from vibrations.

!It is not permissible to modify the floor structure in the area of the airbag control unit.

Risk of injury GIn 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 infla-tion 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.

Airbag control unit and side-impact sensors

Risk of injury GVehicle parts that produce vibrations must not be at-tached 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 inju-ry.

3N54.21-2111-00




66

6.4 Interior

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).

Side-impact sensorFront of vehicle

For in-plant transport these sensors should always be kept in their spare parts packaging and in the vehicle lug-gage or load compartment.

The airbag units fitted in the Vito/Viano include a driv-er's airbag, front-passenger airbag and windowbag.

Airbag and belt tensioner units must be stored in accord-ance with the Second Ordinance to the German Explo-sives 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 stor-age permission.

Class T1 pyrotechnic materials may only be stored in lim-ited quantities on premises used for commercial purpos-es.

Under Section 6 of the appendix to the Second Ordi-nance to the German Law on Hazardous Explosive Sub-stances, 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.

Risk of accident GIf you drop the ESP yaw rate sensor, it must not be re-fitted to the vehicle for safety reasons. In such cases, a genuine Mercedes-Benz replacement must be fit-ted.

Transporting airbag and belt tensioner units

!It is strictly forbidden to transport any sort of airbag units in the passenger compartment.

N54.21-2110-00

Storing airbag and belt tensioner units




67

6.4 Interior

The weights of the individual components are:

The airbag units fitted in the Vito/Viano include a driv-er's airbag, front-passenger airbag, windowbag and tho-rax 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 stor-age. The vehicle battery must have been disconnect-ed, negative pole covered or negative terminal cov-ered and test coupling/connection disconnected.

� If work is interrupted, the airbag and belt tensioner units must be locked away again.


� The airbag and belt tensioner units must not be treated with grease, cleaning agents or other similar products.

� The airbag and belt tensioner units must not be ex-posed to temperatures above 100 °C, even for a short period of time.

Airbag and belt tensioner units that have been dropped more than 0.5 m must be replaced. Airbag and belt ten-sioner units may only be subjected to electrical tests using the prescribed testers when the airbag and ten-sioner units have been fitted. We recommend that you have these tests carried out at a Mercedes-Benz Service Centre.

The vehicle battery must be disconnected, the negative terminal covered and the test coupling/connection dis-connected prior to removal of the airbag and belt ten-sioner unit.


In Germany, airbag and belt tensioner units must be electrically triggered as specified in accident prevention regulations to render them unusable prior to disposal.

These safety measures are necessary because pyrotech-nic materials could cause injury if activated incorrectly.

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 exam-ple.

Driver's airbag 1.6 kg

Front-passenger airbag 3.2 kg

Windowbag 0.6 kg

Thorax bag 0.7 kg

Belt tensioners 1.2 kg (integrated in belt reel)

Fitting and removing airbag and belt tensioner units

Precautionary measures for the handling of airbag and belt tensioner units

Risk of injury GRemoved 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 unex-pectedly.

Disposing of airbag and belt tensioner units

Risk of injury GDisposing of the airbag and belt tensioner units is car-ried out by qualified personnel. Comply with the acci-dent prevention regulations.




68

6.4 Interior

To prevent these safety measures from resulting in an in-creased workload, we recommend that pyrotechnic ma-terials be handed over to a scrap dealer who will take the necessary safety measures during disposal (e.g. 10 m safety distance, special detonator).

When the materials are handed over, the person respon-sibly for disposal must sign a declaration containing the obligation to dispose of the pyrotechnic materials in ac-cordance with accident prevention regulations. Agree-ments of this kind must ensure that it is not possible to sort out pyrotechnic materials after disposal and to for-ward hand them on for reconditioning.


Work involving removed airbag and belt tensioner units may only be carried out by skilled personnel.

� In the event of a crash, the belt tensioner and airbag are triggered from a certain deceleration upwards lay by an electrical signal sent from the control unit. This makes a replacement necessary.

� If belt tensioners that have not been triggered have to be detonated for disposal purposes, place them in the footwell of a vehicle which has been sent for scrapping, and connect them directly using a 2-pin plug.

� If the upholstery pads on the airbag units have not been destroyed, the airbag units must be detonated using the 2-pin plug by trained personnel.

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 fac-tory 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 de-viates from the standard seating must conform to the re-quirements 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.

Handling airbag and belt tensioner units

Risk of accident GIt is not permissible to re-cover seats protected by thorax bags (observe the relevant notes in the Own-er's Manual/Operating Instructions).

iInformation on retrofitting seats can be obtained in the "Conversion work" section (� page 88).




69

6.4 Interior

6.4.4 Reducing noise in the vehicle interior In order to reduce the noise level inside the vehicle, noise-insulating, non-inflammable materials can be used.

A structure as shown in the illustration is advisable for in-sulation and soundproofing. An additional covering with heavy-duty insulating foil may be provided in the area of the wheel arches.

1 Carpet (bonded underside)2 Wooden floor (12 mm plywood)3 Heavy-duty insulating foil (weight per unit area:

8 – 10 kg/m2)4 Load-bearing construction

Rock wool, glass wool, fibrous web or soft, open-pore, PE- or PU-based foam are well suited for providing effec-tive insulation.

The inside must be covered with a sound-transmissive material (perforated card, plastic, fabric).

Openings, gaps and slots between the engine compart-ment, 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.

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.

Floor area

!Insulating films, e.g. bituminous felt, possess limited temperature resistance. They should therefore not be installed in the immediate vicinity of the engine or ex-haust system.

Roof and side panels


Seals




70

6.5 Electrical system/electronics


6.5.1 General notes � 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 ve-hicle's electrical system.

� A positive total charge balance must be ensured when additional electrical consumers are installed (� page 76).

� 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 chaf-ing 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 ve-hicle is put into operation again (� page 34).

� Observe the Owner's Manual/Operating Instruc-tions.

Installation is only permissible after consulting the rele-vant department (� page 12).

6.5.2 Lighting

Country-specific regulations shall apply.

The headlamp basic setting must be observed (see vehi-cle identification plate).

Only check the headlamp setting with the vehicle unlad-en (ready to drive – full tank and with 1 driver or 75 kg load).

� Park the vehicle on a level, horizontal surface.

� Align the headlamp beam adjuster and the vehicle at right angles to each other.

� Correct the tyre pressures (refer to the tyre pressure table).

� Move the headlamp range control to basic setting 0.

� Switch on the headlamps.

� Test each headlamp individually; cover over the sec-ond headlamp and the other lights when doing so.

The light-dark boundary of the dipped-beam headlamp at a distance of 10 m can be calculated from the height of the headlamp (centre of headlamp to floor) minus the specified headlamp basic setting.

!More detailed information can be obtained from the relevant department (� page 12).

Retrofitting a battery isolating switch

Adjusting the headlamps




71


Headlamp basic setting:

1.0% = 10 cm

1.5% = 15 cm

2.0% = 20 cm

etc.

National regulations shall apply.

If lighting equipment is covered by more than 50% when moving vehicle parts are in operation, the vehicle must be safeguarded accordingly.

An appropriate note must be attached at a point where it can easily be seen by the driver of the vehicle.

Perimeter lamps increase passive safety and are re-quired by law for vehicles having a width greater than 2.10 m. They are permissible on vehicles with a width of 1.80 m or greater (Section 51b, Paragraph 2 of the German road traffic licensing regulations (StVZO).

6.5.3 Battery

An additional battery may only be installed in the right-hand seat base in conjunction with a cutoff relay.

This battery may only be used to power specified auxilia-ry consumers such as the auxiliary heating, loading aids or electrical equipment in motor caravans (fridge, etc.).

Even low-maintenance batteries require care. Low-main-tenance 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 bat-tery damage due to deep discharging.

Information on maintaining and storing batteries can be found in the "Planning conversions" section (� page 34).

6.5.4 Power supply – interfacesPlease observe the following if auxiliary electrical con-sumers 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 de-vices (IPCDs)).

� Provide for adequate fusing of extra equipment by in-stalling 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 ad-ditional fusing is provided.

Tampering of any kind with the vehicle electronics is not permitted for reasons concerning the warranty and oper-ation 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).

Installing lighting

Vehicle outline lamps/perimeter lamps

Retrofitting an additional battery

Maintenance and storage of the batteries

!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 inval-idated.




72


PSM installation locationDirection of travel

The following information can be made available from the "signal pool" via the PSM by reprogramming the PSM parameters using Star Diagnosis.

InformationTerminal 15CTerminal 15RTerminal 15Terminal 15XTerminal 50Terminal 61Distance coveredEngine speedStable idleReverse gear engagedLeft-hand turn signal operatedRight-hand turn signal operatedMain-beam headlamps operatedHeadlamp flasher operatedHorn operatedSingle wipe operatedWipers operatedIntermittent wipe operatedWipe stage 1 operatedWipe stage 2 operatedFront fog lamps switched onMain-beam headlamps switched onHorn activeLeft-hand parking lamp switched onRight-hand parking lamp switched onRotary light switch position – left-hand parking lamp

N00.00-2638-20

Rotary light switch position – right-hand parking lampRotary light switch position – automaticRotary light switch position – offRotary light switch position – side lampsRotary light switch position – dipped-beam headlampsTailgate openRotary light switch position – front foglampsRotary light switch position – rear foglampRear window heating switched onLeft-hand sliding door unlockedRight-hand sliding door unlockedTailgate unlockedHazard warning lamps activeLeft-hand turn signal activeRight-hand turn signal activeRear window heating switch operatedHazard warning lamp switch operatedRear window wipe/wash switch operatedRear window intermittent wipe switch operatedAnti-theft alarm system primedFront right-hand door unlockedFront left-hand door unlockedAir-conditioning compressorTerminal 58D (pwm)V signal (pwm)Daylight driving lights activatedCrash event occurredBrake lamp controlledLoad compartment centrally lockedFront doors centrally lockedEntire vehicle centrally lockedImmobiliser deactivatedImmobiliser activatedFront left-hand door openFront right-hand door openLeft-hand sliding door openRight-hand sliding door openSide lamps switched onDipped-beam headlamps switched onRear foglamp switched onHandbrake applied

Information




73


The following parameters can be determined via the PSM interface

Designation Function

Alarm functions

! Alarm functions have the highest priority. They must only be used in accordance with all legal regulations.

PSM_NSW_EIN Flashes/alarm flashes front fog lamps (programmable)

PSM_FL_EIN Flashes/alarm flashes main-beam headlamps (programmable)

PSM_NSF_FL_INT Flashes main-beam headlamps/front fog lamps synchronously/asynchronously (default: asynchronously)

PSM_IL_ALARM Interior light alarm

PSM_WBL_EIN Hazard warning lamp alarm

PSM_SGH_EIN Horn alarm (intermittent)

Steering column switch functions

PSM_SGH_LENK Horn

PSM_BLI_LI_LSS Left-hand turn signal

PSM_BLI_RE_LSS Right-hand turn signal

PSM_FL_LSS Main-beam headlamps

PSM_LH_LSS Headlamp flasher

PSM_WBL_EIN_OBF Hazard warning lamps

PSM_IL_VO_EIN Front interior light

PSM_IL_HI_EIN Rear interior light

PSM_TIPP_WISCH_LSS Windscreen wipers "single wipe"1)

PSM_WASCHEN_LSS Windscreen wipers "wash"

PSM_SCH_W_INT_LSS Windscreen wipers "intermittent"

PSM_SCH_W_1_LSS Windscreen wipers "stage 1"

PSM_SCH_W_2_LSS Windscreen wipers "stage 2"

PSM_HECK_WISCH Activates rear window wiper 2)

PSM_HECK_INT Rear window wiper – intermittent wipe

PSM_HHS_EIN Rear window heating




74


Rotary light switch functions

PSM_PL_LDS Left-hand parking lamp1)

PSM_PR_LDS Right-hand parking lamp

PSM_AUTO_LDS Lights – automatic (only in combination with rain sensor)

PSM_AUS_LDS Lights – "off"

PSM_STL_LDS Lights – "side lamps"

PSM_ABL_LDS Lights – "dipped-beam headlamps"

PSM_NSF_LDS Lights – "front fog lamps"1)

PSM_NSL_LDS Lights – "rear foglamp"

Central locking functions

PSM_V_ENTRI Unlocks front of vehicle (driver's + front-passenger doors)3)

PSM_V_VERRI Locks front of vehicle (driver's + front-passenger doors)

PSM_LR_ENTRI Unlocks load compartment (all rear doors)

PSM_LR_VERRI Locks load compartment (all rear doors)

PSM Gesamtfahrzeug entriegeln Unlocks entire vehicle

PSM Gesamtfahrzeug verriegeln Locks entire vehicle

Sliding sunroof functions

PSM_SD_MH Front sliding sunroof – raises manually

PSM_SD_AH Front sliding sunroof – raises automatically

PSM_SD_MSE Front sliding sunroof – lowers manually

PSM_SD_ASE Front sliding sunroof – lowers automatically

PSM_SD_MOE Front sliding sunroof – opens manually

PSM_SD_AOE Front sliding sunroof – opens automatically

PSM_SD_MSCH Front sliding sunroof – closes manually

PSM_SD_ASCH Front sliding sunroof – closes automatically

PSM_PD_MH Panorama sunroof – raises manually

PSM_PD_AH Panorama sunroof – raises automatically

PSM_PD_MSE Panorama sunroof – lowers manually

PSM_PD_ASE Panorama sunroof – lowers automatically

PSM_PD_MOE Panorama sunroof – opens manually

PSM_PD_AOE Panorama sunroof – opens automatically

PSM_PD_MSCH Panorama sunroof – closes manually

PSM_PD_ASCH Panorama sunroof – closes automatically





75


1 Important: Only one signal may be active at any time; therefore, use either the rotary switch or the elec-tronics.

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).

Seat functions

PSM_SVL_VOR Front left-hand seat – adjusts forwards

PSM_SVL_ZUR Front left-hand seat – adjusts backwards

PSM_SVL_HI_AUF Front left-hand seat – raises height at rear

PSM_SVL_HI_AB Front left-hand seat – lowers height at rear

PSM_SVL_LE_VOR Front left-hand seat – backrest forwards

PSM_SVL_LE_ZUR Front left-hand seat – backrest backwards

PSM_SVL_VO_AUF Front left-hand seat – raises height at front

PSM_SVL_VO_AB Front left-hand seat – lowers height at front

PSM_SVL_KST_AUF Front left-hand seat – raises headrest

PSM_SVL_KST_AB Front left-hand seat – lowers headrest

PSM_SVR_VOR Front right-hand seat – adjusts forwards

PSM_SVR_ZUR Front right-hand seat – adjusts backwards

PSM_SVR_HI_AUF Front right-hand seat – raises height at rear

PSM_SVR_HI_AB Front right-hand seat – lowers height at rear

PSM_SVR_LE_VOR Front right-hand seat – backrest forwards

PSM_SVR_LE_ZUR Front right-hand seat – backrest backwards

PSM_SVR_LE_ZUR Front right-hand seat – backrest backwards

PSM_SVR_VO_AUF Front right-hand seat – raises height at front

PSM_SVR_VO_AB Front right-hand seat – lowers height at front

PSM_SVR_KST_AUF Front right-hand seat – raises headrest

Other functions

LADEN_AKT Disables terminal 50 (e.g. if a battery charger is connected)





76


6.5.5 Retrofitting electrical equipment Please observe the following if auxiliary electrical con-sumers are retrofitted:

� Batteries and alternators with higher power ratings, available as optional equipment, must be catered for.

� 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 de-vices (IPCDs)).

� Provide for adequate fusing of extra equipment by in-stalling additional fuses.

All electrical equipment installed must be tested in ac-cordance with EC Directive 95/54/EU and must bear the "e" mark (� page 51).

Auxiliary electrical consumers must be connected as de-scribed in the "Power supply – interfaces" section (� page 71).

6.5.6 Mobile communications systems

When mobile communication systems (e.g. telephone, CB radio) are retrofitted (� page 42), the following re-quirements must be fulfilled in order to avoid malfunc-tions developing on the vehicle at a later stage.

All electrical equipment installed require type approval in accordance with EC Directive 95/54/EU and must bear the "e" mark (� page 51).

� The maximum transmission output must not be ex-ceeded.

� 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. Oper-ation 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 mechani-cal vibration; observe the permissible operating tem-perature.

!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 invali-dated.

Equipment

Frequency range Maximum transmis-sion output [W]

Short wave < 50Mhz 100

4 m waveband 20

2 m waveband 50

70 cm waveband 35

25 cm waveband 10




77


� Comply with manufacturer's notes and installation instructions.

� The connection should be made directly to terminal 30 via an additional fuse. Disconnect the unit from the electrical system before jump-starting.

� The wiring routes must be kept as short as possible. The wires must be twisted and shielded (coaxial ca-ble). Chafing points must be avoided.

� Ensure that the system has a good earth connection to the body (aerial and equipment).

� The aerial and connecting cables between the trans-mitter, receiver and operating panel must be routed separately from the vehicle wiring harness, as close to the body earth as possible.

� Route the aerial cable in such a way that it is not bent back on itself or pinched.

� Comply with regulations on the transport of hazard-ous goods (GGVS: German Law on the Road Trans-port of Hazardous Goods), and ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road).

6.5.7 Electrical lines/CAN busIf it is necessary to change the routing, avoid routing over sharp edges and routing through narrow cavities or in the vicinity of moving components.

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.

The wires must be dimensioned and safeguarded by fus-es adequate to the strength of the current drawn.

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 right-hand 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.

Cable ductFront of vehicle

Connection and cable routing for the aerial (radio)

Additional circuits

Line cross-sections/fuses

Maximum permanent current [A]

Rated fusing current [A]

Wire cross-section [mm2]

0 – 4.9 5 0.5

5 – 9.9 10 1

10 – 18 20 2.5

19 – 28 30 4

29 – 35 40 6

36 – 48 50 10

49 – 69 70 46

70 – 98 100 25

99 – 123 125 35

124 – 148 150 50

N54.00-2210-20




78


The cable duct in the load compartment/passenger compartment is located centrally and is parallel to the length of the vehicle; it can be seen from the area of the rear door/tailgate as shown in the adjacent illustration. When installation or modification work is carried out in this area, the cable duct must be routed in such a way that the total length of the individual wiring harnesses is maintained (� page 78).

Floor panelCable ductFront of vehicle

The electronic systems in the engine and passenger compartments are interconnected via networks. Data is exchanged between the individual networks via gate-ways.

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 messag-es appearing in the instrument cluster.




79


The control units in the CLASS B network are still availa-ble when the ignition is switched off and the key is re-moved.

The D2B ring network installed in the vehicle uses an op-tical waveguide as data carrier for transmitting audio and control signals. This system allows data to be trans-ferred synchronously at high baud rates. It is immune to electromagnetic interference (EMC), produces no elec-tromagnetic interference itself and can transmit audio and control data at the same time. The system is still available when the ignition is switched off and it is acti-vated via its own wake-up line.

Internal and external vehicle diagnostics use the K line between the individual bus systems. This line ends in the OBD diagnostic socket (SAE1962). Each control unit is capable of performing self-diagnostics and therefore has an internal malfunction memory.

Communication with the relevant control unit can be es-tablished using the STAR Diagnosis tester and the soft-ware developed for this unit.

The programmable special module (� page 71) is de-signed for connecting electronic components.

All Mercedes-Benz Vito/Viano vehicles are equipped with a Class C engine CAN as standard.

Risk of accident GAny interruption or tapping of these networks may re-sult in malfunctions which affect the operational and road safety of the vehicle.

CAN bus

Risk of accident GOn no account should any modifications be made to the CAN bus (e.g. interruptions or "tapping"). Unau-thorised modifications to the CAN bus may adversely affect the standard vehicle. In addition to causing in-convenience, this may also lead to failure of compo-nents or parts relevant to safety.




80


Schematic overview of networks

5400-2211.00

A

B

C

D

N54.00-2237-00

1 2 3 47 8 12

30

29

28

31

14 15 16 17 18

19 20 21

119 10

6

5

13

26

25

24

2223

27

Meaning/abbreviation Meaning/abbreviation1 Electronic Stability Program (ESP) 19 Heatmatic/Tempmatic (KLA)2 Engine electronics 20 Restraint system (SRS)3 Electronic transmission control (EGS) 21 Parktronic (PTS)4 Signal receiver and control module (SAM) 22 Electronic ignition switch (EZS)5 E box 23 Steering angle sensor (LWS)6 Front right door control panel (TVR) 24 Instrument cluster (INS)7 Voice control system (SBS) 25 Tachograph8 CD changer 26 Driver's seat control unit9 (TA) 27 Front left door control panel (TVL)

10 (RLS) 28 Rear passenger compartment air-conditioning (FKLA)11 Overhead control panel (DBE) 29 Rear sliding sunroof (SDE)12 Front passenger seat control unit 30 Trailer control unit (AAG)13 Auxiliary heating (STH) 31 Pneumatic suspension (ENR)14 Upper control panel (OBF)15 Programmable special module (PSM) A Engine bus (CAN C)16 Heater booster system (PTC) B Interior bus (Can B)17 Head unit (radio/navigation system) (HU) C D2B18 Electric selector lever module (EWM) D Optional equipment




81


Communication with the control unit can be established using the STAR Diagnosis tester and the software devel-oped for this unit.

6.5.8 Wiring diagrams Wiring diagrams can be made available to body manufac-turers. Enquiries should be addressed to:

Risk of accident GAs all consumers are networked and internally moni-tored, cables and wiring harnesses of the C-class en-gine CAN may neither be disconnected nor length-ened.

Any modifications to the length, cross-section or re-sistance of the wiring harness can lead to malfunction messages appearing in the instrument cluster and the failure of components relevant to safety.


!Further information is available from your Mercedes-Benz Service Centre.

E-mail:

[email protected]

Fax:

+49 (0)7 11-17-8 34 17




82


6.5.9 Electronic Stability Program (ESP) ESP is a dynamic driving control system which actively regulates the longitudinal dynamics and transverse dy-namics of the vehicle.

ESP achieves increased directional stability thanks to an enhanced sensor system which constantly compares the current path of the vehicle with the correct path desired by the driver.

ESP contributes in all driving situations to the stability of the vehicle when accelerating, braking and coasting, when driving in a straight line or when cornering.

The location, spatial orientation and attachment of the ESP yaw rate sensor (yaw rate/lateral acceleration sen-sor) must not be different from that of the standard ve-hicle.

It is located at the front in the centre of the bulkhead when the vehicle is delivered.

The ESP yaw rate sensor can be identified by its square black housing bearing a white sticker which specifies details such as the manufacturer (BOSCH) and the Mercedes-Benz part number A002 542 66 18.

Installation location of ESP yaw rate sensor Airbag control unitFront 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 (oversteer-ing 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 on-board electronics

Installation instructions for the ESP yaw rate sensor

!It must be ensured that the sensor is easily accessi-ble at all times.


3N00.00-2639-20




83


6.5.10 Electromagnetic compatibility (EMC)Electromagnetic compatibility is the characteristic of an electrical system which behaves in a completely neutral manner towards other systems in its vicinity, neither af-fecting them adversely through its operation nor suffer-ing any adverse effects itself through the operation of these systems.

Further important notes can be found in the "Damage prevention" section (� page 51).

6.5.11 Retrofitting an alternator If additional electrical consumers are retrofitted, the in-crease in power requirement can be supplied by using a more powerful alternator.

All electrical equipment installed must be tested in ac-cordance with EC Directive 95/54/EC and must bear the "e" mark.

We recommend Versions N62, available as optional equipment at the factory, for retrofitting alternators. This includes a modified subframe in order to create suffi-cient clearance.

If other alternators are to be subsequently installed, comply with the following points on compatibility with the basic vehicle in addition to the equipment manufac-turer's guidelines:

� Damage to vehicle parts and their function caused by installation of the alternator is not permitted.

� The battery capacity (-> page 74) and the existing output of the alternator (-> page 86) must be ade-quately dimensioned.

� Additional protection of the alternator circuit (-> page 80).

� The additional pulleys (code N62, available as op-tional equipment from the factory), are available to drive the refrigerant compressors.

� Make sure that the electrical lines are routed cor-rectly (-> page 80).

� Access to installed components and ease of mainte-nance must be not impaired.

Risk of accident GOn no account may the following modifications be carried out on vehicles equipped with ESP:

� Modifications to the wheelbase

� Modifications to the sensor system (steering an-gle sensor, yaw rate sensor, wheel rotational speed sensor)

� Changes to the vibration characteristics in the vi-cinity 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 GIf you drop the ESP yaw rate sensor, it must not be re-fitted to the vehicle for safety reasons. In such cases, a genuine Mercedes-Benz replacement must be fit-ted.




84


� The operating instructions and the maintenance manual for the additional equipment is to be sup-plied with the vehicle when it is handed over.

� The air supply required and engine cooling must not be adversely affected (-> page 64).




85

6.6 Additional equipment

6.6 Additional equipmentIf additional equipment is fitted, factory-fitted power take-offs must be used (� page 85).

6.6.1 Retrofitting the air conditioningAll electrical equipment installed must be tested in ac-cordance with EC Directive 95/54/EU and must bear the "e" mark.

We recommend the relevant versions available as op-tional equipment at the factory for retrofitting air condi-tioning.

If other air-conditioning systems are retrofitted, the fol-lowing points relating to compatibility with the basic ve-hicle 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-condition-ing compressors.

� Make sure that lines and (� page 44) electrical lines (� page 77) are routed correctly.

� Access to installed components and ease of mainte-nance must be not impaired.

� The operating instructions and the maintenance manual for the additional equipment must be sup-plied with the vehicle when it is handed over.

� The air supply required and engine cooling must not be adversely affected (� page 61)

� When assembling compact systems (evaporator, condensor and blower) on the cab roof, the permis-sible roof loads must not be exceeded (� page 60).

� Connections to the roof require a certificate of en-dorsement from the relevant department (� page 12).

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 ele-ments must be sealed with rubber sleeves.

6.6.3 Power take-offs

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 oper-ation 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 maxi-mum engine torque.

Exposed propeller shafts, fan wheels or pulleys must be covered.

General




86

6.7 Attachments

6.7 AttachmentsAttachments to the frame require a certificate of en-dorsement from the relevant department (� page 12).

The permissible axle loads must always be adhered to (� page 152).

The function of vehicle parts must not be impaired by at-tachments.

Comply with national legal requirements.

6.7.1 WinchThe attachment of winches requires a certificate of en-dorsement from the relevant department (� page 12).

If winches are attached to the basic vehicle, the permis-sible axle loads must be adhered to.

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.

6.7.2 Attachment above cab � 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).

6.7.3 Roof rack � Make sure that the load is distributed evenly across

the entire roof area.

� We recommend installing an anti-roll bar to the front axle.

� Support feet must be spaced at regular intervals.

� With shorter roof racks, the load must be reduced proportionally.

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

Winch on the front of the frame

!The airbag units may need to be deactivated if attach-ments are fitted to the front of the frame, as these may change the impact structure. The relevant de-partment can provide you with information on this (� page 12).

Roof rack threshold values

Maximum roof loads

Minimum number of sup-

port points

Low roof 150 kg 5

High roof 50 kg 4

!On no account should attachments transfer forces

only to the vehicle sidewalls.




87

6.7 Attachments

6.7.5 Trailer coupling

� Only secure trailer couplings that have been ap-proved by Mercedes-Benz to the special mounting points on the bodyshell (rear longitudinal member).

� Access to the spare wheel must be guaranteed if a trailer coupling with a non-detachable ball neck is fit-ted (especially with a fully laden vehicle).

� Fitting the trailer coupling must comply with national regulations. The relevant standard in Germany is DIN 74050.

� Clearance dimensions must be taken into consider-ation. The relevant standard in Germany is DIN 74058.

� Retrofitting a trailer coupling to a vehicle with fittings for a trailer coupling (code E 57) should pose no technical problem. If a trailer coupling is fitted to a vehicle without fit-tings, the vehicle will require a wiring harness and, in addition, the trailer control unit and a variant coding of the Electronic Ignition Lock will need to be pro-grammed by a Mercedes-Benz diagnostic tool at a Mercedes-Benz specialist workshop. Otherwise mal-functions cannot be ruled out.

7.1 Modifications to the interior



88

7 Conversion work

7.1 Modifications to the interior

7.1.1 Modifications to the cockpitModifications to the cockpit above the waistline are not permitted. This applies in particular to the inflation areas of the airbags (wooden trim, additional attachments, mo-bile phone holders, bottle holders, etc.).

See the illustrations of airbag inflation points for more in-formation (� page 64).

7.1.2 Retrofitting additional seatsDaimlerChrysler AG will issue a certificate of endorse-ment 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 fac-tory 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.

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 de-livery).

Further information on code V40 optional equipment can be obtained from your Mercedes-Benz Service Cen-tre, the relevant department (� page 12) or in the "Op-tional equipment" section (� page 35).

Any rear bench seat with 2-point or 3-point belts that de-viates from the standard seating must conform to the re-quirements of EC Directives 76/115/EEC and 74/408/EEC.

Seat belt anchorages may be retrofitted. Aftermarket so-lutions have been developed for this. An appropriate re-port may be requested from the relevant department (� page 12).

Any rear bench seat with 2-point or 3-point belts that de-viates from the standard seating must conform to the re-quirements 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 accident GModifications 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 an-chorages in an accident.

Passenger/cargo area

Risk of accident GSeats may not be mounted on the wheel housing. Per-sons could be injured in an accident if seats are torn out of their anchorages and the vehicle could be fur-ther damaged.

Risk of injury GIt is not permissible to retrofit covers on seats with thorax bags (see notes in the Owner's Manual/

Operating Instructions).



7 Conversion work

89

7.2 Modifications to closed panel vans


If body parts are modified or fitted, if possible join them by means of a bonded connection, and only if this is not possible, weld them. For this reason, windows, roof hatches and vent openings must be mounted in a sturdy frame. The frame must then be joined by a force-locked attachment to the other bodywork elements.

If the partition is to be cut out due to conversion or in-stallation work, this is possible in conjunction with a con-tinuous 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).

Areas that must be retainedDesignation of partition level with B-pillarView in the direction of travel

Floor assembly

Partitions




7 Conversion work

90


Further information on optional equipment can be ob-tained from your Mercedes-Benz Service Centre, the relevant department (� page 12) or in the "Optional equipment" section (� page 35).

Information on modifications to the roof can be found in the "Panel van/Traveliner roof" section (� page 59).

Vehicle roof



7 Conversion work

91

7.3 Refrigerated vehicles

7.3 Refrigerated vehiclesConversions for refrigerated vehicles require a certifi-cate of endorsement from the relevant department (� page 12).

See the following sections:

� "Retrofitting the air conditioning" (� page 85).

� "Attachment to the roof" (� page 59).

� "Retrofitting electrical equipment" (� page 76).



7 Conversion work

92

7.4 Motor caravans

7.4 Motor caravansPrior to conversion into a motor caravan, please make sure that:

� legal requirements are observed (German road traf-fic licensing regulations (StVZO) or relevant EC direc-tives)

� the minimum requirements for interior design and motor caravan equipment are fulfilled

� the permissible centre of gravity location and maxi-mum permissible axle loads are not exceeded

For the conversion of vehicles in Germany, appropriate bulletins can be ordered from the relevant technical test-ing centres for motor vehicles (e.g. TÜV, DEKRA).

Particular attention must be paid to the following sec-tions of the Body/Equipment Mounting Directives:

� Dimensions and weights (� page 23).

� Notes on modifying the basic vehicle (� page 52).

� Electrical system/electronics (� page 70).

� Wings and wheel arches (� page 58).

Modifications or conversions to standard vehicles which are subject to approval (e.g. the installation of a raised roof, etc.) will invalidate the operating permit. In Germa-ny, modifications to the vehicle must therefore be in-spected by the relevant testing centre in accordance with Section 19, Paragraph 2 of the German road traffic licensing regulations (StVZO).

The vehicle log book and registration document must be presented. After the modifications have been entered, submit the vehicle log book and registration document to the relevant registration office so that a new general operating permit can be issued.

The interior fittings must be designed in such a way that there are no sharp edges or corners (accident preven-tion).

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, edg-es or corners which could cause injury in the area of the seats.

You can find further information on the electrical system and additional equipment in the "Electrical system/

electronics" (� page 70) and "Additional equipment" sections (� page 85).



7 Conversion work

93

7.5 Retrofitting a raised roof

7.5 Retrofitting a raised roof Comply with the guidelines in the "Panel van/Traveliner roof" section when retrofitting raised roofs (� page 60).



7 Conversion work

94

7.6 Increasing the roof height

7.6 Increasing the roof heightComply with the guidelines in the "Panel van/Traveliner roof" section when increasing the height of the vehicle roof (� page 60).

8.1 Vito 109 CDI

Mercedes-Benz body/equipment mounting directives for Vito/Viano as at: 20.07.2004


95

8 Technical data

8.1 Vito 109 CDI6396113 63960313 63960513

Panel van Traveliner Panel van Traveliner Panel van Traveliner

Normal High Normal Normal High Normal Normal High Normal

Dim

ensi

ons

Wheelbase [mm] 3,200 3,200 3,200 3,200 3,200 3,430 3,430

Turning circle [m] 11.8 11.8 11.8 11.8 11.8 12.5 12.5

Vehicle length [mm] 4,748 4,748 4,993 4,993 4,993 5,223 5,223

Vehicle height [mm] 1,901 1,875 1,901 2,329 1,875 1,901 1,872

Interior height [mm] 1,350 1,350 1,350 1,760 1,350 1,350 1,350

Wei

ghts

Weight code - XA2 XA2 - XA2 - XA2 XA2 - XA2 XA2

Permissible front axle load

[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550

Permissible rear axle load

[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550

Permissible gross vehicle weight

[kg] 2,770 2,940 2,940 2,770 2,940 2,770 2,940 2,940 2,770 2,940 2,940

Permissible tractor-trailer gross weight

[kg] 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940

Front-axle load, unladen vehicle

[kg] 1,100 1,100 1,120 1,095 1,095 1,105 1,105 1,115 1,150 1,150 1,180

Rear-axle load, unladen vehicle

[kg] 720 720 795 750 750 780 780 825 720 720 785

Unladen vehicle (including driver, tank 90% full)

[kg] 1,820 1,820 1,915 1,845 1,845 1,885 1,885 1,940 1,870 1,870 1,965

Payload [kg] 950 1,120 1,025 925 1,095 885 1,055 1,000 900 1,070 975

Engi

ne

Engine code M0C1 M0C1 M0C1 M0C1 M0C1 M0C1 M0C1

Engine designation OM646LA OM646LA OM646LA OM646LA OM646LA OM646LA OM646LA

Displacement [ccm] 2,148.0 2,148.0 2,148 2,148.0 2,148.0 2,148.0 2,148.0

Output [kW] 65 65 65 65 65 65 65

Output [bhp] 88 88 88 88 88 88 88

At rated engine speed

[rpm] 3,800 3,800 3,800 3,800 3,800 3,800 3,800

Torque [Nm] 220 220 220 220 220 220 220

From engine speed [rpm] 1,400 1,400 1,400 1,400 1,400 1,400 1,400

To engine speed rpm] 2,500 2,500 2,500 2,500 2,500 2,500 2,500

Emissions level Euro3 EU3Gr.3 Euro3 Euro3 EU3Gr.3 Euro3 EU3Gr.3

Minimum engine oil quantity

[l] 8.00 8.00 8.00 8.00 8.00 8.00 8.00

Maximum engine oilquantity

[l] 8.50 8.50 8.50 8.50 8.50 8.50 8.50

Tank capacity [l] 75 75 75 75 75 75 75



8 Technical data

96

8.1 Vito 109 CDI

*Well-base rim

6396113 63960313 63960513Panel van Traveliner Panel van Traveliner Panel van Traveliner


Dri

ve t

rain

Transmission NSG250 NSG250 NSG250 NSG250 NSG250 NSG250 NSG250

Transmission oil quantity

[l] 1.50 1.50 1.50 1.50 1.50 1.50 1.50

Transmission designation

G250-6 (4.99-0.82)

G250-6 (4.99-0.82)

G250-6 (4.99-0.82)

G250-6 (4.99-0.82)

G250-6 (4.99-0.82)

G250-6 (4.99-0.82)

G250-6 (4.99-0.82)

Rear-axle code A0C2 A0C2 A0C2 A0C2 A0C2 A0C2 A0C2

Rear-axle ratio 4.111 4.111 4.111 4.111 4.111 4.111 4.111

Cha

ssis

Front suspension Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs

Rear suspension Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs

Tyres 195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

Rims* 6 J x 6.5 J 6.5 J 6 J x 6.5 J 6 J x 6.5 J 6.5 J 6 J x 6.5 J 6.5 J



8 Technical data

97

8.2 Vito 111 CDI

8.2 Vito 111 CDI6396113 63960313 63960513



Dim

ensi

ons

Wheelbase [mm] 3,200 3,200 3,200 3,200 3,200 3,430 3,430

Turning circle [m] 11.8 11.8 11.8 11.8 11.8 12.5 12.5




Wei

ghts



[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 2,770 2,940 2,940 2,770 2,940 2,770 2,940 2,940 2,770 2,940 2,940


[kg] 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940


[kg] 1,100 1,100 1,120 1,095 1,095 1,105 1,105 1,115 1,150 1,150 1,180


[kg] 720 720 795 750 750 780 780 825 720 720 785


[kg] 1,820 1,820 1,915 1,845 1,845 1,885 1,885 1,940 1,870 1,870 1,965

Payload [kg] 950 1,120 1,025 925 1,095 885 1,055 1,000 900 1,070 975

Engi

ne



Displacement [ccm] 2,148.0 2,148.0 2,148.0 2,148.0 2,148.0 2,148.0 2,148.0

Output [kW] 80 80 80 80 80 80 80

Output [bhp] 109 109 109 109 109 109 109


[rpm] 3,800 3,800 3,800 3,800 3,800 3,800 3,800

Torque [Nm] 270 270 270 270 270 270 270


To engine speed [rpm] 2,500 2,500 2,500 2,500 2,500 2,500



[l] 8.00 8.00 8.00 8.00 8.00 8.00 8.00


[l] 8.50 8.50 8.50 8.50 8.50 8.50 8.50

Tank capacity [l] 75 75 75 75 75 75 75



8 Technical data

98

8.2 Vito 111 CDI

*Well-base rim



Dri

ve t

rain



[l] 1.80 1.80 1.80 1.80 1.80 1.80 1.80


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)

G370-6 (5.01-0.80)

G370-6 (5.01-0.80)


Rear-axle ratio 3.727 3.273 3.727 3.727 3.273 3.727 3.273

Cha

ssis



Tyres 195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

Rims* 6 J x 5 J x 6.5 J 6 J x 6.5 J 6 J x 6.5 J 6.5 J 6 J x 6.5 J 6.5 J



8 Technical data

99

8.3 Vito 115 CDI

8.3 Vito 115 CDI6396113 63960313 63960513



Dim

ensi

ons

Wheelbase [mm] 3,200 3,200 3,200 3,200 3,200 3,430 3,430

Turning circle [m] 11.8 11.8 11.8 11.8 11.8 12.5 12.5




Wei

ghts



[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 2,770 2,940 2,940 2,770 2,940 2,770 2,940 2,940 2,770 2,940 2,940


[kg] 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940


[kg] 1,100 1,100 1,120 1,095 1,095 1,105 1,105 1,115 1,150 1,150 1,180


[kg] 720 720 795 750 750 780 780 825 720 720 785


[kg] 1,820 1,820 1,915 1,845 1,845 1,885 1,885 1,940 1,870 1,870 1,965

Payload [kg] 950 1,120 1,025 925 1,095 885 1,055 1,000 900 1,070 975

Engi

ne




Output [kW] 110 110 110 110 110 110 110

Output [bhp] 150 150 150 150 150 150 150


[rpm] 3,800 3,800 3,800 3,800 3,800 3,800 3,800

Torque [Nm] 330 330 330 330 330 330 330





[l] 8.00 8.00 8.00 8.00 8.00 8.00 8.00


[l] 8.50 8.50 8.50 8.50 8.50 8.50 8.50

Tank capacity [l] 75 75 75 75 75 75 75



8 Technical data

100

8.3 Vito 115 CDI

*Well-base rim



Dri

ve t

rain



[l] 1.80 1.80 1.80 1.80 1.80 1.80 1.80


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)

G370-6 (5.01-0.80)

G370-6 (5.01-0.80)


Rear-axle ratio 3.455 3.273 3.455 3.455 3.273 3.455 3.273

Cha

ssis



Tyres 195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16




8 Technical data

101

8.4 Vito 119

8.4 Vito 1196396113 63960313 63960513



Dim

ensi

ons

Wheelbase [mm] 3,200 3,200 3,200 3,200 3,200 3,430 3,430

Turning circle [m] 11.8 11.8 11.8 11.8 11.8 12.5 12.5




Wei

ghts



[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 2,770 2,940 2,940 2,770 2,940 2,770 2,940 2,940 2,770 2,940 2,940


[kg] 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940


[kg] 1,100 1,100 1,120 1,095 1,095 1,105 1,105 1,115 1,150 1,150 1,180


[kg] 720 720 795 750 750 780 780 825 720 720 785


[kg] 1,820 1,820 1,915 1,845 1,845 1,885 1,885 1,940 1,870 1,870 1,965

Payload [kg] 950 1,120 1,025 925 1,095 885 1,055 1,000 900 1,070 975

Engi

ne


Engine designation M112Ered M112Ered M112Ered M112Ered M112Ered M112Ered M112Ered


Output [kW] 140 140 140 140 140 140 140

Output [bhp] 190 190 190 190 190 190 190


[rpm] 5,600 5,600 5,600 5,600 5,600 5,600 5,600

Torque [Nm] 270 270 270 270 270 270 270


To engine speed [rpm] 4,750 4,750 4,750 4,750 4,750 4,750 4,750

Emissions level EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1


[l] 9.50 9.50 9.50 9.50 9.50 9.50 9.50


[l] 10.00 10.00 10.00 10.00 10.00 10.00 10.00

Tank capacity [l] 75 75 75 75 75 75 75



8 Technical data

102

8.4 Vito 119

*Well-base rim



Dri

ve t

rain

Transmission NAGW5A NAGW5A NAGW5A NAGW5A NAGW5A NAGW5A NAGW5A


[l] 9.00 9.00 9.00 9.00 9.00 9.00 9.00


W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)


Rear-axle ratio 3.727 3.727 3.727 3.727 3.727 3.727 3.727

Cha

ssis



Tyres 195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16




8 Technical data

103

8.5 Vito 122

8.5 Vito 1226396113 63960313 63960513



Dim

ensi

ons

Wheelbase [mm] 3,200 3,200 3,200 3,200 3,200 3,430 3,430

Turning circle [m] 11.8 11.8 11.8 11.8 11.8 12.5 12.5




Wei

ghts



[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 1,470 1,550 1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,550


[kg] 2,770 2,940 2,940 2,770 2,940 2,770 2,940 2,940 2,770 2,940 2,940


[kg] 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940 4,940


[kg] 1,100 1,100 1,120 1,095 1,095 1,105 1,105 1,115 1,150 1,150 1,180


[kg] 720 720 795 750 750 780 780 825 720 720 785


[kg] 1,820 1,820 1,915 1,845 1,845 1,885 1,885 1,940 1,870 1,870 1,965

Payload [kg] 950 1,120 1,025 925 1,095 885 1,055 1,000 900 1,070 975

Engi

ne


Engine designation M112E M112E M112E M112E M112E M112E M112E


Output [kW] 160 160 160 160 160 160 160

Output [bhp] 217 217 217 217 217 217 217


[rpm] 5,600 5,600 5,600 5,600 5,600 5,600 5,600

Torque [Nm] 305 305 305 305 305 305 305


To engine speed [rpm] 4,750 4,750 4,750 4,750 4,750 4,750 4,750

Emissions level EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1 EU4Gr.1


[l] 9.50 9.50 9.50 9.50 9.50 9.50 9.50


[l] 10.00 10.00 10.00 10.00 10.00 10.00 10.00

Tank capacity [l] 75 75 75 75 75 75 75



8 Technical data

104

8.5 Vito 122

*Well-base rim



Dri

ve t

rain

Transmission NAGW5A NAGW5A NAGW5A NAGW5A NAGW5A NAGW5A NAGW5A


[l] 9.00 9.00 9.00 9.00 9.00 9.00 9.00


W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)

W5A380 (3.59-0.83)


Rear-axle ratio 3.727 3.727 3.727 3.727 3.727 3.727 3.727

Cha

ssis



Tyres 195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

195/65 R 16

205/65 R 16

205/65 R 16

Rims* 6 J x 6.5 J 6.5 J 6 J x 6.5 J 6 J x 6.5 J 6.5 J 6 J x 6.5 J Drop centre rims, 6.5 J



8 Technical data

105

8.6 Viano CDI 2.0/CDI 2.2

8.6 Viano CDI 2.0/CDI 2.22.0 CDI 2.2 CDI

63981113 63981313 63981513 63981113 63981313 63981513

Dim

ensi

ons

Wheelbase [mm] 3,200 3,200 3,430 3,200 3,200 3,430

Turning circle [m] 11.8 11.8 12.5 11.8 11.8 12.5

Vehicle length [mm] 4,748 4,993 5,223 4,748 4,993 5,223

Vehicle height [mm] 1,875 1,875 1,872 1,875 1,875 1,872

Interior height [mm] 1,350 1,350 1,350 1,350 1,350 1,350

Wei

ghts

Weight code XA2 XA2 XA2 XA2 XA2 XA2


[kg] 1,550 1,550 1,550 1,550 1,550 1,550


[kg] 1,550 1,550 1,550 1,550 1,550 1,550


[kg] 2,940 2,940 2,940 2,940 2,940 2,940


[kg] 4,940 4,940 4,940 4,940 4,940 4,940


[kg] 1,180 1,170 1,240 1,180 1,170 1,240


[kg] 890 925 880 890 925 880


[kg] 2,070 2,095 2,120 2,070 2,095 2,120

Payload [kg] 870 845 820 870 845 820

Engi

ne

Engine code MOC2 MOC2 MOC2 MOC3 MOC3 MOC3

Engine designation OM646LA OM646LA OM646LA OM646LA OM646LA OM646LA

Displacement [ccm] 2,148.0 2,148.0 2,148.0 2,148.0 2,148.0 2,148.0

Output [kW] 80 80 80 110 110 110

Output [bhp] 109 109 109 150 150 150


[rpm] 3,800 3,800 3,800 3,800 3,800 3,800

Torque [Nm] 270 270 270 330 330 330

From engine speed [rpm] 1,600 1,600 1,600 1,800 1,800 1,800


Emissions level EUGr.3 EUGr.3 EUGr.3 EUGr.3 EUGr.3 EUGr.3


[l] 8.00 8.00 8.00 8.00 8.00 8.00


[l] 8.50 8.50 8.50 8.50 8.50 8.50

Tank capacity [l] 75 75 75 75 75 75



8 Technical data

106

8.6 Viano CDI 2.0/CDI 2.2

*Well-base rim

2.0 CDI 2.2 CDI63981113 63981313 63981513 63981113 63981313 63981513

Dri

ve t

rain

Transmission NSG370 NSG370 NSG370 NSG370 NSG370 NSG370


[l] 1.80 1.80 1.80 1.80 1.80 1.80


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) G370-6 (5.01-0.80)

Rear-axle code A0C7 A0C7 A0C7 A0C7 A0C7 A0C7

Rear-axle ratio 3.273 3.273 3.273 3.273 3.273 3.273

Cha

ssis

Front suspension Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs

Rear suspension Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs

Tyres 205/65 R 16 205/65 R 16 205/65 R 16 205/65 R 16 205/65 R 16 205/65 R 16

Rims* 6.5 J 6.5 J 6.5 J 6.5 J 6.5 J 6.5 J



8 Technical data

107

8.7 Viano 3.0/3.2

8.7 Viano 3.0/3.23.0 3.2

63981113 63981313 63981513 63981113 63981313 63981513

Dim

ensi

ons

Wheelbase [mm] 3,200 3,200 3,430 3,200 3,200 3,430

Turning circle [m] 11.8 11.8 12.5 11.8 11.8 12.5

Vehicle length [mm] 4,748 4,993 5,223 4,748 4,993 5,223

Vehicle height [mm] 1,875 1,875 1,872 1,875 1,875 1,872

Interior height [mm] 1,350 1,350 1,350 1,350 1,350 1,350

Wei

ghts

Weight code XA2 XA2 XA2 XA2 XA2 XA2


[kg] 1,550 1,550 1,550 1,550 1,550 1,550


[kg] 1,550 1,550 1,550 1,550 1,550 1,550


[kg] 2,940 2,940 2,940 2,940 2,940 2,940


[kg] 4,940 4,940 4,940 4,940 4,940 4,940


[kg] 1,180 1,170 1,240 1,180 1,170 1,240


[kg] 890 925 880 890 925 880


[kg] 2,070 2,095 2,120 2,070 2,095 2,120

Payload [kg] 870 845 820 870 845 820

Engi

ne

Engine code MOC8 MOC8 MOC8 MOC7 MOC7 MOC7

Engine designation M112Ered M112Ered M112Ered M112E M112E M112E

Displacement [ccm] 3,199.0 3,199.0 3,199.0 3,199.0 3,199.0 3,199.0

Output [kW] 110 110 110 140 140 140

Output [bhp] 190 190 190 217 217 217


[rpm] 3,800 3,800 3,800 3,800 3,800 3,800

Torque [Nm] 270 270 270 305 305 305

From engine speed [rpm] 2,750 2,750 2,750 2,800 2,800 2,800


Emissions level EUGr.4Gr.1 EUGr.4Gr.1 EUGr.4Gr.1 EUGr.4Gr.1 EUGr.4Gr.1 EUGr.4Gr.1


[l] 9.50 9.50 9.50 9.50 9.50 9.50


[l] 10.00 10.00 10.00 10.00 10.00 10.00

Tank capacity [l] 75 75 75 75 75 75


! Always print out the complete section from the current version.

108

Index

AAccident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Additional battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Additional equipment. . . . . . . . . . . . . . . . . . . . . . . . . . 85Additional equipment threshold values . . . . . . . . . 43Aerial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63Airbag control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Anti-corrosion protection for welding . . . . . . . . . . . 31Attachment above cab. . . . . . . . . . . . . . . . . . . . . . . . . 86Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

BBattery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Battery isolating switch . . . . . . . . . . . . . . . . . . . . . . . 70Belt tensioners. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63Bodies for motor caravans . . . . . . . . . . . . . . . . . . . . . 92Bodies for refrigerated vehicles . . . . . . . . . . . . . . . . 91Body/equipment approval . . . . . . . . . . . . . . . . . . . . . 12Bodyshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56, 58Bodyshell threshold values . . . . . . . . . . . . . . . . . . . . 39Bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 53

CCab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Cable duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77, 78Cables and lines . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 53CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 78, 79Centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Certificate of endorsement . . . . . . . . . . . . . . . . 12, 13Chassis end cross-member . . . . . . . . . . . . . . . . . . . . 58Checking the entire vehicle . . . . . . . . . . . . . . . . . . . . 34Clearance dimensions, trailer coupling . . . . . . . . . 87Closed panel van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Conversion work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Corrosion protection . . . . . . . . . . . . . . . . . . . . . . 31, 46

DDamage prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Damage prevention by painting . . . . . . . . . . . . . . . . 48Damage prevention when storing and delivering the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 36Disc brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Drilling holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Drilling work on the chassis. . . . . . . . . . . . . . . . . . . . 57Drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 61Drive train threshold values. . . . . . . . . . . . . . . . . . . . 40Dust/dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

EElectrical interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Electrical wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Electromagnetic compatibility . . . . . . . . . . . . . . . . . 83EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Engine air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Engine periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Engine periphery threshold values . . . . . . . . . . . . . 40ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 82Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

FFaxback system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Floor assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 61Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 77

GGeneral operating permit . . . . . . . . . . . . . . . . . . . . . . . 6

IIncreasing the roof height . . . . . . . . . . . . . . . . . . . . . 94Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63

LLegal claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Line cross-sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23



Index

109

MMaintenance and repairs . . . . . . . . . . . . . . . . . . . . . . 33Mercedes star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Mercedes-Benz body/equipment manufacturer sy-stem (MB-AS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14MIG plug welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Mobile communications systems . . . . . . . . . . . 42, 76Model designation. . . . . . . . . . . . . . . . . . . . . . . . 8, 9, 11Model overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 11Modifications to closed panel vans . . . . . . . . . . . . . 89Modifications to mobile communications systems . 76Modifications to the basic vehicle . . . . . . . . . . . . . . 52Modifications to the bodyshell . . . . . . . . . . . . . . . . . 39Motor caravans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

NNoise in the vehicle interior . . . . . . . . . . . . . . . . . . . . 69Noise insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Noise level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

OOperational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Overview of Vito models . . . . . . . . . . . . . . . . . . . . . . . . 9

PPainting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Panel van/Traveliner roof. . . . . . . . . . . . . . . . . . . . . . 59Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57, 89PC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Permissible tyre sizes . . . . . . . . . . . . . . . . . . . . . . . . . 37Pneumatic suspension . . . . . . . . . . . . . . . . . . . . . . . . 54Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Power take-offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Product liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 15Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62PSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 72, 73

QQuality assurance system . . . . . . . . . . . . . . . . . . . . . 20

RRaised roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 92, 93Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Reducing noise in the vehicle interior. . . . . . . . . . . 69Refrigerated vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 91Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Reprocessing components . . . . . . . . . . . . . . . . . . . . . 19Retrofitting electrical equipment . . . . . . . . . . . . . . . 76Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

SSafety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 88Securing points on the frame . . . . . . . . . . . . . . . . . . 39Shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 52Side-impact sensors . . . . . . . . . . . . . . . . . . . . . . . 65, 66Sidewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 52Steerability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Storing and delivering the vehicle . . . . . . . . . . . . . . 50Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TTack welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Technical advice for body/equipment manufactur-ers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Tender drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Third-party trademarks . . . . . . . . . . . . . . . . . . . . . . . . 17Towing and tow-starting . . . . . . . . . . . . . . . . . . . . . . . 49Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Tyre load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27, 55

UUnderbody panelling . . . . . . . . . . . . . . . . . . . . . . . . . . 59



Index

110

VVehicle approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Vehicle dimension threshold values . . . . . . . . . . . . 36Vehicle dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Vehicle frame threshold values . . . . . . . . . . . . . . . . 39Vehicle identification data . . . . . . . . . . . . . . . . . . . . . 25Vehicle identification plate . . . . . . . . . . . . . . . . . . . . 25Vehicle modifications . . . . . . . . . . . . . . . . . . . . . . . . . 22Vehicle outline lamps. . . . . . . . . . . . . . . . . . . . . . . . . . 42Vehicle overhang. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Vehicle overhang threshold values . . . . . . . . . . . . . 39Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Vehicle selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Vehicle width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

WWarranty claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Weight distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Welded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 36Welding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Welding work on the bodyshell . . . . . . . . . . . . . . . . . 56Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Wheel arch lowering threshold values . . . . . . . . . . 39Wheel arches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 81Workshop Information System (WIS) . . . . . . . . . . . 14

Mercedes Vito Viano 2005

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Transcript of Mercedes Vito Viano 2005