Mercedes Vito Viano 2005

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Car service manual

Transcript of 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

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

    ! Always print out complete sections from the current version.

    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. . . .