Conversion Guideline NEW Movano X62

Transcription

1 Conversion Guideline NEW Movano X62 Part 1 - Chapter 1-23 Edition: August 2011 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany

2 CONTENTS Conversion Guideline - Part 1 CHAPTER DESCRIPTION PAGE 3 POWER TRAIN RANGE 3 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE 4 6 REFERENCE SYSTEM AND INTERPRETING DIMENSIONS 7 7 * MAIN VIEWS AND DIMENSIONS 8 8 PARTITIONS BETWEEN CAB AND LOADING COMPARTMENT 26 9 PANEL VAN STANDARD SECTIONS GLAZING LOADING AREA SECTIONS SLIDING DOOR ACCESSIBILITY REAR DOOR, DIMENSIONS AND ACCESS LASHING POINTS PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN * CHASSIS CAB, POSITION OF BODY BRACKETS * CHASSIS CAB, INSTALLATION OF A BODY REAR UNDERRIDE PROTECTION CROSS SECTION OF REAR WHEEL WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB MODIFYING THE REAR OVERHANG 109 * = This chapter is new or has changed, last Edition Feb up-to-date data on body guidelines (online body guidelines).

3 3 POWER TRAIN RANGE 1. Engine Front wheel drive Rear wheel drive Type D1 D2 D3 Noncalibrated D3 D1 D2 D3 Noncalibrated D3 Indices Capacity 2,299 cm³ Power 74 kw 92 kw 92 kw 110 kw 74 kw 92 kw 92 kw 110 kw Emission control Euro 4 and 5 Euro 4 and 5 Euro 5 Euro 4 and 5 Euro 4 and 5 Euro 4 and 5 Euro 5 Euro 4 and 5 2. Gearbox Front wheel drive Rear wheel drive Manual gearbox (BVM) PF 6 ZF 4 Robotised gearbox (BVR) PA 0 (optional) ZF 4R (optional) Clutch Control with BVM Hydraulic clutch control Electric clutch control Clutch Control with BVR Electro-hydraulic control (Easytronic) Electric control (ZF module) Drive axle - 2 axles: one for 3.5 t single wheels and one for 4.5 t twin wheels Automatic differential locking - Optional up-to-date data on body guidelines (online body guidelines). Data status June

4 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE To view the chassis number marking (VIN), use a flat-ended tool (e.g. screwdriver) to lift one of the two flaps located above the right-hand cab side sill. The manufacturer s plate is located on the right-hand cab door frame and has two parts: - the regulatory ID plate, - the oval plate showing data primarily intended to facilitate the ordering of spare parts. VEHICLE IDENTIFICATION : Manufacturer s plate 2: VIN marking 3: Weight and dimensions label The vehicle manufacturer s plate must be replaced if it is damaged or moved, as is inevitable during conversion. This means you will have to order a new plate. This request should be addressed to the country s Quality/Service/After-Sales departments. up-to-date data on body guidelines (online body guidelines). Data status June

5 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE MANUFACTURER'S PLATE Information on identification plate 1 ): 1. = Vehicle identification number 2. = Permissible gross vehicle weight rating 3. = Permissible gross combination weight 4. = Maximum permissible front axle load 5. = Maximum permissible rear axle load 6. = Trim code 7. = Technical specifications of vehicle, including: Vehicle paint code, equipment level and vehicle type 8. = Additional equipment specification 9. = Fabrication number 10. = Interior trim code 1 ) The VIN plate on your vehicle may differ from the illustration shown. The combined total of front and rear axle loads must not exceed the permissible gross vehicle weight. For example, if the front axle is bearing its maximum permissible load, the rear axle can only bear a load that is equal to the gross vehicle weight minus the front axle load. The technical data is determined in accordance with European Community standards. We reserve the right to make modifications. Specifications in the vehicle documents always have priority over those given in this manual. Stamped on a machined surface on the rear of the engine block or stamped on a metal plate on the right side of the engine block, depending on variant. up-to-date data on body guidelines (online body guidelines). Data status June

6 5 CHASSIS MARKING AND READING THE MANUFACTURER S PLATE VIN MARKING : Main VIN engraving 2: Emergency VIN engraving The Vehicle Identification Number is visible through the windscreen. The VIN is also displayed behind a removable plastic cover on the right hand side door step. WEIGHTS AND DIMENSIONS LABEL : Unladen weight 2: Gross authorised train weight 3: Vehicle length 4: Vehicle surface area 5: Vehicle width 6: Gross authorised laden weight up-to-date data on body guidelines (online body guidelines). Data status June

7 6 REFERENCE SYSTEM AND INTERPRETING DIMENSIONS In general, dimensions are expressed as absolute (distance between two points) and positions as relative (location in the reference system). The origin of the reference system is a point situated on the front axle, at the centre of the vehicle, as illustrated on the following view. For laden vehicles, the front axle is fixed at +2 mm along the X axis and mm along the Z axis in relation to the reference system of the unladen vehicle. REFERENCE SYSTEM up-to-date data on body guidelines (online body guidelines). Data status June

8 7 MAIN VIEWS AND DIMENSIONS The figures below show the different versions of the Movano. The main dimensions are given in the tables. 1. PANEL VAN up-todate data on body guidelines (online body guidelines). Data status June

9 7 MAIN VIEWS AND DIMENSIONS PANEL VAN Version drive L1 Front wheel drive Roof H1 H2 GVW 2800 kg 3300 kg 3500 kg 2800 kg 3300 kg 3500 kg V =Z1*Y3*EC18 7,8 m³ 7,8 m³ 7,8 m³ 8,6 m³ 8,6 m³ 8,6 m³ A B C D E F G G H H2 J1 K MVODM Min / Max GVW Min MVODM / GVW MVODM GVW 2290 / Min : 2299 / 2251 Max 2317/ 2264 Min : 546 Max : 560 Min : 189 Max : / Min : 2300 / 2222 Max:2317/ 2235 Min : 546 Max : 560 Min : 182 Max : / Min: 2303/ 2213 Max: 2320/ 2227 Min : 550 Max : 564 Min : 186 Max : / Min: 2515 / 2468 Max: 2533/ 2481 Min : 544 Max : 559 Min : 188 Max : / Min: 2515/ 2439 Max: 2533/ 2452 Min : 544 Max : 559 Min : 182 Max : / Min: 2518/ 2431 Max: 2536/ 2444 Min : 547 Max : 563 Min : 186 Max : 194 HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV EC VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV Y Y Y Y Y Z Z Z1' Z All dimensions are in millimetres unless otherwise specified. up-todate data on body guidelines (online body guidelines). Data status June

10 7 MAIN VIEWS AND DIMENSIONS PANEL VAN Version L2 L3 drive Front wheel drive Front wheel drive Roof H2 H3 H2 H3 GVW 3300 kg 3500 kg 3300 kg 3500 kg 3500 kg 3500 kg V =Z1*Y3*EC18 10,3 m³ 10,3 m³ 11,7 m³ 11,7 m³ 12,5 m³ 14,1 m³ A B C D E F G G H H2 J1 K MVODM Min / Max GVW Min MVODM / GVW MVODM GVW 2482 / Min: 2514/ 2450 Max: 2530/ 2461 Min : 545 Max : 558 Min : 174 Max : / Min: 2517/ 2444 Max:2533/ 2455 Min : 548 Max : 562 Min : 178 Max : / Min: 2513/ 2450 Max: 2529/ 2462 Min : 543 Max : 556 Min : 173 Max : / Min: 2516/ 2444 Max: 2532/ 2455 Min : 547 Max : 560 Min : 178 Max : / Min: 2511/ 2451 Max: 2526/ 2462 Min : 543 Max : 557 Min : 172 Max : / Min: 2511/ 2451 Max: 2524/ 2464 Min : 542 Max : 555 Min : 169 Max : 179 HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV EC VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV Y Y Y Y Y Z Z Z1' Z All dimensions are in millimetres unless otherwise specified. up-todate data on body guidelines (online body guidelines). Data status June

11 7 MAIN VIEWS AND DIMENSIONS PANEL VAN Version L3 L3 L4 drive Heckantrieb (Einzelbereifung) Heckantrieb (Zwillingsbereifung) Heckantrieb (Zwillingsbereifung) Roof H2 H3 H2 H3 H2 H3 GVW 3500 kg 3500 kg 3500/4500kg 3500/4500kg 3500/4500kg 3500/4500kg V =Z1*Y3*EC18 11,8 m³ 13,5 m³ 11,8 m³ 13,5 m³ 13,9 m³ 15,8 m³ A B C D E F G G H H2 J1 K MVODM Min / Max GVW Min MVODM / GVW MVODM GVW 2507 / Min: 2549/ 2490 Max:2574/ 2506 Min : 674 Max : 696 Min : 197 Max : / Min : 2547/ 2490 Max: 2572/ 2506 Min : 672 Max : 694 Min : 197 Max : / Min : 2590/ 2475 Max: 2611/ 2490 Min : 706 Max : 724 Min : 181 Max : / Min : 2588 / 2476 Max: 2609/ 2490 Min : 704 Max : 723 Min : 181 Max : / Min : 2583/ 2487 Max: 2600/ 2502 Min : 701 Max : 717 Min : 167 Max : / Min: 2582/ 2487 Max: 2599/ 2502 Min : 700 Max : 715 Min : 167 Max : 178 HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV EC VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV Y Y Y Y Y Z Z Z1' Z All dimensions are in millimetres unless otherwise specified. up-todate data on body guidelines (online body guidelines). Data status June

12 7 MAIN VIEWS AND DIMENSIONS 2. CREW VAN up-todate data on body guidelines (online body guidelines). Data status June

13 7 MAIN VIEWS AND DIMENSIONS CREW VAN Version L1 L2 drive Front wheel drive Front wheel drive Roof H1 H2 H2 GVW 3300 kg 3500 kg 3300 kg 3500 kg 3300 kg 3500 kg V =Z6*Y3*EC18 4,6 m³ 4,6 m³ 6,7 m³ 6,7 m³ 8,8 m³ 8,8 m³ A B C D E F G G H H2 J1 K MVODM Min / Max GVW Min MVODM / GVW MVODM GVW 2290 / Min : 2300/ 2222 Max:2317/ 2235 Min : 546 Max : 560 Min : 182 Max : / Min: 2303/ 2213 Max: 2320/ 2227 Min : 550 Max : 564 Min : 186 Max : / Min: 2515/ 2439 Max: 2533/ 2452 Min : 544 Max : 559 Min : 182 Max : / Min: 2518/ 2431 Max: 2536/ 2444 Min : 547 Max : 563 Min : 186 Max : / Min: 2514/ 2450 Max: 2530/ 2461 Min : 545 Max : 558 Min : 174 Max : / Min: 2517/ 2444 Max:2533/ 2455 Min : 548 Max : 562 Min : 178 Max : 185 HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV EC VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV Y Y Y Y Y Z Z Z Z All dimensions are in millimetres unless otherwise specified. up-todate data on body guidelines (online body guidelines). Data status June

14 7 MAIN VIEWS AND DIMENSIONS CREW VAN Version L3 L3 drive Front wheel drive Rear wheel drive (single wheels) Rear wheel drive (twin wheels) Roof H2 H2 H2 GVW 3500 kg 3500 kg 3500/ 4500kg V =Z6*Y3*EC18 8,8 m³ 8,4 m³ 8,4 m³ A B C D E F G G H H2 J1 K MVODM Min / Max GVW Min MVODM / GVW MVODM GVW 2475 / Min: 2511/ 2451 Max: 2526/ 2462 Min : 543 Max : 557 Min : 172 Max : / Min: 2549/ 2490 Max:2574/ 2506 Min : 674 Max : 696 Min : 197 Max : / Min : 2590/ 2475 Max: 2611/ 2490 Min : 706 Max : 724 Min : 181 Max : 191 HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV EC VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV Y Y Y Y Y Z Z Z Z All dimensions are in millimetres unless otherwise specified. up-todate data on body guidelines (online body guidelines). Data status June

15 7 MAIN VIEWS AND DIMENSIONS 3. COMBI up-todate data on body guidelines (online body guidelines). Data status June

16 7 MAIN VIEWS AND DIMENSIONS COMBI Version L1 L2 drive Front wheel drive Front wheel drive Roof H1 H2 GVW 3000 kg 3300 kg 3300 kg 3500 kg V =Z6*Y3*EC18 A B C D E F G G H H2 MVODM Max Min: 2303/ 2213 Min: 2303/ 2213 Min: 2517/ 2444 Min: 2517/ 2444 MVODM / GVW Max: 2320/ 2227 Max: 2320/ 2227 Max:2533/ 2455 Max:2533/ 2455 J1 MVODM Max : 564 Max : 564 Max : 558 Max : 562 K GVW HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV EC VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV Y Y Y Y Y Z Z Z Z All dimensions are in millimetres unless otherwise specified. up-todate data on body guidelines (online body guidelines). Data status June

17 7 MAIN VIEWS AND DIMENSIONS 4. CHASSIS CAB up-todate data on body guidelines (online body guidelines). Data status June

18 7 MAIN VIEWS AND DIMENSIONS CHASSIS CAB Version L2 L25 L3 drive Front wheel drive Roof H1 H1 H1 GVW 3500 kg 3500 kg 3500 kg A B B1 * = C+A+D1max C D D1 * E F 1730/ / /1860 G G1 Min / Max 2470 / / / 2654 G2 * Min / Max 2170 / / / 2350 H MVODM Min / Max 2259 / / / 2258 H H J1 MVODM Min / Max 735 / / / 741 HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV ADAP Z3 * Min / Max 3182 / / / 4838 Z4 Min / Max 331 / / / 948 All dimensions are in millimetres unless otherwise specified. These dimensions are maximum values and serve as guidelines for the conversion; according to the centre of gravity it must be adjusted. up-todate data on body guidelines (online body guidelines). Data status June

19 7 MAIN VIEWS AND DIMENSIONS CHASSIS CAB Version L2 L3 L2 L3 L4 drive Rear wheel drive (single wheels) Rear wheel drive (twin wheels) Roof H1 H1 H1 H1 H1 GVW 3500 kg 3500 kg 3500/ 4500 kg 3500/ 4500 kg 3500/ 4500 kg A B B1 * = C+A+D1max C D D1 * E F G G1 Min / Max 2470 / / / / / 2654 G2 * Min / Max 2170 / / / / / 2350 MVODM H Min / Max 2279 / / / / / 2273 H H MVODM J1 Min / Max 771 / / / / / 789 HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV ADAP Z3 * Min / Max 3182 / / / / / 5468 Z4 Min / Max -83 / / / / / 562 All dimensions are in millimetres unless otherwise specified. These dimensions are maximum values and serve as guidelines for the conversion; according to the centre of gravity it must be adjusted. up-todate data on body guidelines (online body guidelines). Data status June

20 7 MAIN VIEWS AND DIMENSIONS 5. CHASSIS CREW CAB up-todate data on body guidelines (online body guidelines). Data status June

21 7 MAIN VIEWS AND DIMENSIONS CHASSIS CREW CAB Version L2 L3 L2 L3 L3 L4 drive Front wheel drive Rear wheel drive (single wheels) Rear wheel drive (twin wheels) Roof H1 H1 H1 H1 H1 H1 GVW 3500 kg 3500 kg 3500 kg 3500 kg 3500/ 4500 kg 3500/ 4500 kg A B B1 * = C+A+D1max C D D1 * E F G G1 Min / Max 2470 / / / / / / 2654 G2 * Min / Max 2170 / / / / / / 2350 MVODM H Min / Max 2266 / / / / / / 2286 H H J1 HV02 MVODM Min / Max 727 / / / / / / (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV ADAP Z3 * Min / Max 2432 / / / / / / 4434 Z4 Min / Max 97 / / / / / / -1 All dimensions are in millimetres unless otherwise specified. These dimensions are maximum values and serve as guidelines for the conversion; according to the centre of gravity it must be adjusted. up-todate data on body guidelines (online body guidelines). Data status June

22 7 MAIN VIEWS AND DIMENSIONS 6. PLATFORM CAB up-todate data on body guidelines (online body guidelines). Data status June

23 7 MAIN VIEWS AND DIMENSIONS PLATFORM-CAB Version L1 L2 L3 drive Front wheel drive Front wheel drive Front wheel drive Roof H1 H1 H2 H1 H2 GVW 3500 kg 3500 kg 3500 kg A B B1 * = C+A+D1max C D D1 * E F / / / /1860 G 2070 / / / / / 2095 G1 Min / Max 2470 / / / / / 2654 G2 * Min / Max 2170 / / / / / 2350 H H1 MVODM Min / Max 2270 / / / / / 2457 H MVODM J 580 / / / / / 583 Min / Max K GVW HV (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) 742 (DAD = 742) W HV VO (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) 365 (DAD = 385) VO HV ADAP Z Z3 * Min / Max 2569 / / / / / 4610 Z4 Min / Max 279 / / / / / 1068 All dimensions are in millimetres unless otherwise specified. These dimensions are maximum values and serve as guidelines for the conversion; according to the centre of gravity it must be adjusted. up-todate data on body guidelines (online body guidelines). Data status June

24 7 MAIN VIEWS AND DIMENSIONS Legend A = Wheelbase ADAP01 = Horizontal distance between front wheel and rear panel of the Cabin B = Overall length B1 * = Maximum overall length of the vehicle ( B1 = C+A+D1max) C = Front overhang D = Rear overhang D1 * = Maximum extension of rear overhang E = Front Track EC18 = Maximal headroom in cargo area F = Rear Track G = Overall width (without rear view mirrors) G1 = Overall width with series rear view mirrors G2 * = Maximum overall cargo area width with long arm rear view mirrors (option) H = Overall height H1 = Maximum overall height of the vehicle H2 = Overall height of open door H3 = Vertical distance between cab roof and rear side member HV01 = Vertical distance between heel point and H-point HV02 = Horizontal distance between accel pedal point and H-point driver seat HV07 = Height under percale at 14 1st row, driver H-point J1 = Loading sill height K = Ground clearance V = Max. cargo volume (V = Z1*Y3*EC18) or (V=Z6*Y3*EC18) VO10 = Horizontal distance between H-point and steering wheel VO11 = Vertical distance between H-point and steering wheel W1 = Front shoulder width Y = Door sill upper portion width (at 1069 mm above floor) Y1 = Door sill lower portion width (at 169 mm above floor) Y2 = Width between wheel arches Y3 = Cargo area width These dimensions are maximum values and serve as guidelines for the conversion; according to the centre of gravity it must be adjusted. up-todate data on body guidelines (online body guidelines). Data status June

25 7 MAIN VIEWS AND DIMENSIONS Legend Y4 = Sliding door sill width (at 1100 mm above floor) Z = Rear door sill height ( Y0 ) Z1 = Cargo area length Y0 on floor Z1 = Cargo area length (at 1100 mm above the floor) Z2 = Sliding door sill height Z3 * = Maximum overall conversion body length Z4 = Load application Z5 = Cargo area length Y0 on floor Z6 = Cargo area length (at 1100 mm above the floor) Z7 = Cargo area length behind the 3rd seat row Z8 = Cargo area length behind the 2nd seat row GVW = Gross vehicle weight MVODM = Kerb weight GVW = Gross vehicle weight These dimensions are maximum values and serve as guidelines for the conversion; according to the centre of gravity it must be adjusted. Other dimensions can be found in the conversion guideline Part 1 to 6. up-todate data on body guidelines (online body guidelines). Data status June

26 8 PARTITIONS BETWEEN CAB AND LOADING COMPARTMENT Panel vans and platform cabs may be delivered with partitions. Depending on the version, the partitions may come as standard or be available as an option. The following partitions are available: Full glazed partition. Full sheet-metal partition. These partitions are limited to H1 versions, the free space in H2 versions between the roof panel and the cab trim being reserved for accessing the roof storage area. The partitions are attached with screws and two rivets to make them theft-resistant. Full partitions are not strictly sealed. These partitions comply with standard DIN and other requirements specific to the different countries. If a partition is included, please refer to the "Sliding side door" sheet for the diagram defining the perfect position for driver's seat clearance and cab ergonomics. It is highly recommended, in case of attack or impact from the rear loading area, to add protection to the partition glazing area. FULL METAL AND GLAZED PARTITION N.B.: Coat hook on partition on the driver's side. Glazed surface area: 14 dm². For more information on dimensions can also be found in Chapter 12 sliding door. up-to-date data on body guidelines (online body guidelines). Data status June

27 8 PARTITIONS BETWEEN CAB AND LOADING COMPARTMENT Their rigidity is ensured by three welded reinforces. The upper reinforce differs between the 3.5t and 4.5t versions (glazed or standard). There are three clothes hooks on the partition. FULL GLAZED AND METAL PARTITIONS; GVW=3.5t (View from the Cockpit) with window without window A B C D FULL GLAZED AND METAL PARTITIONS; GVW=4.5t (View from the Cockpit) with window without window A B C D A = Hooks; B = Upper reinforce; C = Middle reinforce; D = Lower reinforce up-to-date data on body guidelines (online body guidelines). Data status June

28 8 PARTITIONS BETWEEN CAB AND LOADING COMPARTMENT As an option, an additional partition trim to be offered ( with or without windows) for the cockpit. FULL METAL AND GLAZED PARTITION TRIM (View from the Cockpit) with window without window Hooks up-to-date data on body guidelines (online body guidelines). Data status June

29 9 PANEL VAN STANDARD SECTIONS The various standard sections of the van are shown on the diagram below. N.B.: Throughout this document, INT means vehicle interior and EXT means vehicle exterior. PANEL VAN STANDARD SECTIONS up-to-date data on body guidelines (online body guidelines). Data status June

30 9 PANEL VAN STANDARD SECTIONS SECTION 1 "DOOR OPENING PILLAR EXT INT 1 up-to-date data on body guidelines (online body guidelines). Data status June

31 9 PANEL VAN STANDARD SECTIONS SECTION 2 "FRONT DOOR RAIL ROOF-VERSION H1" (X = 1,200) EXT INT 2 up-to-date data on body guidelines (online body guidelines). Data status June

32 9 PANEL VAN STANDARD SECTIONS SECTION 2 "FRONT DOOR RAIL ROOF-VERSION H2" (X = 1,200) EXT 2 INT up-to-date data on body guidelines (online body guidelines). Data status June

33 9 PANEL VAN STANDARD SECTIONS SECTION 2 "FRONT DOOR RAIL ROOF-VERSION H3" (X = 1,200) EXT 2 2 INT up-to-date data on body guidelines (online body guidelines). Data status June

34 9 PANEL VAN STANDARD SECTIONS SECTION 3 REAR CANTRAIL ROOF-VERSION H1 (X = 2,300) EXT INT SECTION 6 "LOWER FRAME CROSS MEMBER 3 up-to-date data on body guidelines (online body guidelines). Data status June

35 9 PANEL VAN STANDARD SECTIONS SECTION 3 REAR CANTRAIL ROOF-VERSIONS H2 AND H3 (X = 2,300) EXT SECTION 7 3 INT up-to-date data on body guidelines (online body guidelines). Data status June

36 9 PANEL VAN STANDARD SECTIONS SECTION 4 LOWER SIDE SILL, FIXED SIDE PANEL (X = 2,106.9) EXT INT 4 up-to-date data on body guidelines (online body guidelines). Data status June

37 9 PANEL VAN STANDARD SECTIONS SECTION 4 LOWER SIDE SILL, SLIDING SIDE DOOR (X = 2,300) INT EXT 4 up-to-date data on body guidelines (online body guidelines). Data status June

38 9 PANEL VAN STANDARD SECTIONS SECTION 5 FUEL FLAP (X = 1,351) INT EXT 5 up-to-date data on body guidelines (online body guidelines). Data status June

39 9 PANEL VAN STANDARD SECTIONS SECTION 6 ROOF PANEL VERSION H1 (Y = 0) EXT INT 6 up-to-date data on body guidelines (online body guidelines). Data status June

40 9 PANEL VAN STANDARD SECTIONS SECTION 6 ROOF PANEL VERSIONS H2 AND H3 (Y = 0) EXT INT 6 up-to-date data on body guidelines (online body guidelines). Data status June

41 9 PANEL VAN STANDARD SECTIONS SECTION 7 AREA UNDER WINDSCREEN (Y = 0) EXT INT 7 up-to-date data on body guidelines (online body guidelines). Data status June

42 9 PANEL VAN STANDARD SECTIONS SECTION 8 REAR UPPER CROSS MEMBER (Y = 122) EXT EXT INT INT 8 up-to-date data on body guidelines (online body guidelines). Data status June

43 9 PANEL VAN STANDARD SECTIONS SECTION 9 REAR LIGHT/DOOR STOP (Z = 740) INT EXT 9 up-to-date data on body guidelines (online body guidelines). Data status June

44 9 PANEL VAN STANDARD SECTIONS SECTION 10 LOWER RIGHT-HAND REAR DOOR STOP, VERSION L2 FRONT WHEEL DRIVE (Y = 114) INT EXT 10 up-to-date data on body guidelines (online body guidelines). Data status June

45 9 PANEL VAN STANDARD SECTIONS SECTION 11 SLIDING SIDE DOOR CENTRE RAIL (X = 3,512) INT EXT 11 up-to-date data on body guidelines (online body guidelines). Data status June

46 10 GLAZING To add glazing to a panel van, it is recommended that you: - remove the vertical tensioners, - cut out an opening in the side panel and get close to the insert shape of the glazed versions of the Movano for bonded windows and the window shape for fitted windows. - protect the cut-outs from corrosion. Please refer to the Corrosion Prevention sheet For bonded windows, it is advisable to separate the horizontal centre strut from the vertical members, turn it around and then weld along the bottom of the cut out insert and on the vertical members. Local reinforcement of the frame structure may be required. Warning: Under no circumstances must the vertical seal of the side bodywork panels be cut out. up-to-date data on body guidelines (online body guidelines). Data status June

47 10 GLAZING BASIC SECTIONS : Lower strut 2: Exterior side panel 3: Upper strut 4: Cantrail up-to-date data on body guidelines (online body guidelines). Data status June

48 10 GLAZING DIFFERENCE BETWEEN PANEL VAN AND GLAZED VAN : Lower strut 2: Exterior side panel 3: Bonded window up-to-date data on body guidelines (online body guidelines). Data status June

49 11 LOADING AREA SECTIONS The main dimensions of the loading area (versions H1, H2, H3) are given in the form of superimposed sections. Details of the wheel arches are also given. 1: Loading area 2: Wheel arch 1 2 PANEL VAN H1, FRONT WHEEL DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

50 11 LOADING AREA SECTIONS PANEL VAN H2, FRONT WHEEL DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

51 11 LOADING AREA SECTIONS PANEL VAN H3, FRONT WHEEL DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

52 11 LOADING AREA SECTIONS PANEL VAN H2, SINGLE WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

53 11 LOADING AREA SECTIONS PANEL VAN H3, SINGLE WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

54 11 LOADING AREA SECTIONS PANEL VAN H2, TWIN WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

55 11 LOADING AREA SECTIONS PANEL VAN H3, TWIN WHEEL REAR DRIVE up-to-date data on body guidelines (online body guidelines). Data status June

56 12 SLIDING DOOR ACCESSIBILITY Access via the sliding door, its clearance and its position along the side of the body are given as overall dimensions. SIDE DOOR DIMENSIONS 1,186 Where a partition is fitted, the diagram below defines the longitudinal travel of the driver s seat. It should be noted that this partition should comply with legislation in the country where the vehicle is marketed. It is highly recommended, in case of attack or impact from the rear loading area, to add protection to the partition glazing area. up-to-date data on body guidelines (online body guidelines). Data status June

57 12 SLIDING DOOR ACCESSIBILITY SLIDING DOOR OPENING 3 C A D B 151 mm 1 2 1: Loading bed 5 4 2: Side door entry 3: Solid partition 4: Position of the backrest as far back as possible 5: Rear seat mounting Vehicle type A (mm) B (mm) C (mm) D (mm) Panel Van L1H1, Front wheel drive 1,581 1, ,050 Panel Van L1H2, Front wheel drive 1,780 1, ,050 Panel Van L2 or L3, Front wheel drive 1,780 1,849 1,147 1,270 Panel Van L3 or L4, Rear wheel drive 1,684 1,849 1,147 1,270 N.B.: A: Useful height of sliding door entry B: Height of sliding door entry above floor C: Useful width of sliding door entry D: Width of sliding door entry 1,100 mm above the floor The tubular partition gives a larger useful width (64 mm) than the solid partition. up-to-date data on body guidelines (online body guidelines). Data status June

58 12 SLIDING DOOR ACCESSIBILITY PIANO SIDE X 1,618 A mini 1 2 1: Solid partition limit 2: Rear wheel arch Wheelbase (mm) A (mm) E1: 3,182 1,150 E2: 3,682 1,650 E3: 4,332 2,300 up-to-date data on body guidelines (online body guidelines). Data status June

59 13 REAR DOOR, DIMENSIONS AND ACCESS 1. Dimensions of rear doors The travel and position along the side of the body are given as overall dimensions and at different heights. The door opening angle is 90 on the first notch and 176 on the second notch. With the 255 opening option, the maximum opening angle is 260 without the sliding side door and 242 with a sliding side door. REAR DOOR TRAVEL up-to-date data on body guidelines (online body guidelines). Data status June

60 13 REAR DOOR, DIMENSIONS AND ACCESS REAR DOOR DIMENSIONS Vehicle length L1 Front wheel drive Roof height H1 H2 MMAC (maximum authorised laden weight) (kg) 2,800 3,300 3,500 2,800 3,300 3,500 1: Door height (mm) 1,815 2,023 2: 3: Minimum height at MMAC (mm) Maximum height at MVODM (mm) ,317 2,317 2,320 2,533 2,533 2,536 up-to-date data on body guidelines (online body guidelines). Data status June

61 13 REAR DOOR, DIMENSIONS AND ACCESS Vehicle length L2 Front wheel drive L3 Front wheel drive Roof height H2 H3 H2 H3 MMAC (maximum authorised laden weight) (kg) 3,300 3,500 3,300 3,500 3,500 1: Door height (mm) 2,023 2: 3: Minimum height at MMAC (mm) Maximum height at MVODM (mm) ,530 2,533 2,529 2,532 2,526 2,524 Vehicle length L3 Rear wheel drive Single wheel L3 Rear wheel drive Twin wheels L4 Rear wheel drive Twin wheels Roof height H2 H3 H2 H3 H2 H3 MMAC (maximum authorised laden weight) 3,500 4,500 3,500 1: Door height (mm) 2,023 2: 3: Minimum height at MMAC (mm) Maximum height at MVODM (mm) ,574 2,572 2,611 2,609 2,600 2,599 MMAC: Maximum authorised laden weight MVODM: Curb weight up-to-date data on body guidelines (online body guidelines). Data status June

62 13 REAR DOOR, DIMENSIONS AND ACCESS 2. Access via the door frame Access via the rear door frame is provided for 3 heights (H1, H2 and H3). REAR DOOR FRAME DIMENSIONS H2 / H3 H1 A A: Maximum height between floor and upper cross member Panel Van H1 Panel Van, Front wheel drive, H2 or H3 Panel Van, Rear wheel drive, H2 or H3 A 1,662 1,847 1,751 N.B.: The rear door frame is the same for versions H2 and H3 up-to-date data on body guidelines (online body guidelines). Data status June

63 14 LASHING POINTS Lashing eyes are mounted in the load compartment to enable cargo to be secured in position using lashing straps or a luggage floor net. The number of lashing points on the floor varies depending on the panel van version: 6 lashing points on the floor and 2 on the far rear pillar for L1 vans 8 lashing points on the floor and 2 on the far rear pillar for L2 vans 10 lashing points on the floor and 2 on the far rear pillar for L3 vans 12 lashing points on the floor and 2 on the far rear pillar for L4 vans These lashing points comply with the requirements of standard DIN (Load per ring: 500 dan with an angle of 30 according to the position of the ring buckle) Their positioning is symmetrical to the body axis (Y = 0). They are attached to the body with M8 x 125 (Art. Nr ) fastening screws, tightening torque: 21 Nm As an option, it is possible to have 8 lashing points on the side panels. up-to-date data on body guidelines (online body guidelines). Data status June

64 14 LASHING POINTS LASHING POINT FASTENING SCREW up-to-date data on body guidelines (online body guidelines). Data status June

65 14 LASHING POINTS PANEL VAN L1, FRONT WHEEL DRIVE C3 C1 C4 C D3 8 D4 6 D2 D1 4 2 PANEL VAN L1 Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 2, on floor 6 2, on floor 7 3, on side panel 8 3, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 3, ,545 on side panel C4 3, on side panel D1 3, ,545 on side panel D2 2, on side panel D3 3, ,545 on side panel D4 3, on side panel up-to-date data on body guidelines (online body guidelines). Data status June

66 14 LASHING POINTS PANEL VAN L2, FRONT WHEEL DRIVE C3 C2 C4 7 5 C D3 10 D4 8 D2 6 D1 2 4 PANEL VAN L2 Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 4, on side panel 10 4, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 4, ,545 on side panel C4 4, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 4, ,545 on side panel D4 4, on side panel up-to-date data on body guidelines (online body guidelines). Data status June

67 14 LASHING POINTS PANEL VAN L3, FRONT WHEEL DRIVE 11 C4 C C1 C D4 D PANEL VAN L3, FRONT WHEEL DRIVE Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 3, on floor 10 3, on floor 11 5, on side panel 12 5, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 5, ,545 on side panel C4 5, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 5, ,545 on side panel D4 5, on side panel 6 D2 D1 4 2 up-to-date data on body guidelines (online body guidelines). Data status June

68 14 LASHING POINTS PANEL VAN L3, REAR WHEEL DRIVE 11 C4 C C2 C D4 D D1 4 2 PANEL VAN L3, REAR WHEEL DRIVE Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 4, on floor 10 4, on floor 11 5, on side panel 12 5, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 5, ,545 on side panel C4 5, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 5, ,545 on side panel D4 5, on side panel D2 up-to-date data on body guidelines (online body guidelines). Data status June

69 14 LASHING POINTS PANEL VAN L4, REAR WHEEL DRIVE C1 1 C2 3 5 C C4 D1 4 2 D3 D D PANEL VAN L4, REAR WHEEL DRIVE Pts X Y Z Comments 1 1, on floor 2 1, on floor 3 2, on floor 4 2, on floor 5 3, on floor 6 3, on floor 7 3, on floor 8 3, on floor 9 3, on floor 10 3, on floor 11 5, on floor 12 5, on floor 13 5, on side panel 14 5, on side panel C1 2, ,545 on side panel C2 2, on side panel C3 5, ,545 on side panel C4 5, on side panel D1 2, ,545 on side panel D2 2, on side panel D3 5, ,545 on side panel D4 5, on side panel up-to-date data on body guidelines (online body guidelines). Data status June

70 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS The cross sections of the floor reinforcement are given for the different vehicle wheelbases. A cross section of the rear lower panel is also available for information. For any modifications to the rear lower panel, please refer to the chapter on rear overhang modifications. It should be noted that the rear skirt performs an important structural function. Details of the main under-floor cross sections are given below. Each overview is an aerial view (floor panel transparent). They show the different side members and cross members in the 3 wheelbase configurations. The principle for going from the L1 wheelbase to the L2 wheelbase chosen for the Movano is elongation behind the exhaust outlet zone (or behind the sliding side door for a panel van). PLATFORM CAB L1 2 E E A B C D 1 A B C D 1: Start of bodywork X = 1,598 2: Vehicle axis Y=0 up-to-date data on body guidelines (online body guidelines). Data status June

71 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION A-A SECTION B-B Distance from start of bodywork = 340 mm Distance from start of bodywork = 840 mm SECTION C-C SECTION D-D Distance from start of bodywork = 1,140 mm Distance from start of bodywork = 2,165 mm SECTION E-E Distance from the vehicle axis Y = 465 mm up-to-date data on body guidelines (online body guidelines). Data status June

72 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS PLATFORM CAB L2 F F 2 A B C D E 1 A B C D E 1: Start of bodywork X = 1,598 2: Vehicle axis Y=0 SECTION A-A SECTION B-B Distance from start of bodywork = 340 mm Distance from start of bodywork = 725 mm up-to-date data on body guidelines (online body guidelines). Data status June

73 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION C-C SECTION D-D Distance from start of bodywork= 1,340 mm Distance from start of bodywork = 1,640 mm SECTION E-E Distance from start of bodywork = 2,665 mm SECTION F-F Distance from the vehicle axis Y = 465 mm up-to-date data on body guidelines (online body guidelines). Data status June

74 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS PLATFORM CAB L3 2 H H A B C D E F G 1 A B C D E F G 1: Start of bodywork X = 1,598 2: Vehicle axis Y=0 SECTION A-A SECTION B-B Distance from start of bodywork = 340 mm Distance from start of bodywork = 725 mm up-to-date data on body guidelines (online body guidelines). Data status June

75 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION C-C SECTION D-D Distance from start of bodywork = 1,340 mm Distance from start of bodywork = 1,640 mm SECTION E-E SECTION F-F Distance from start of bodywork = 1,990 mm Distance from start of bodywork = 2,290 mm SECTION G-G Distance from start of bodywork = 3,315 mm up-to-date data on body guidelines (online body guidelines). Data status June

76 15 PLATFORM CAB, UNDER-FLOOR CROSS SECTIONS SECTION H-H Distance from the vehicle axis Y = 465 mm up-to-date data on body guidelines (online body guidelines). Data status June

77 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL On platform cabs, nuts welded onto the side sill closing can be used to attach bodywork connection supports. When manufacturing the rear bodywork, an inertia equivalent to that of the Movano panel van must be recreated. PLATFORM CAB VERSION L2H1 Start of bodywork up-to-date data on body guidelines (online body guidelines). Data status June

78 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL POSITION OF NUTS ON SIDE SILL CLOSING PANEL The position of the bolts is given in relation to the vehicle reference system L X 1,720 1,720 2,220 2,220 3,070 3,070 3,720 3,720 4,880 4,880 Y Z L X 1,720 1,720 2,220 2,220 3,070 3,070 4,230 4,230 Y Z L X 1,720 1,720 2,220 2,220 3,730 3,730 Y Z up-to-date data on body guidelines (online body guidelines). Data status June

79 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL SECTION - NUTS 1 AND 2 SECTION - NUTS 5 AND 6 SECTION - NUTS 9 AND 10 up-to-date data on body guidelines (online body guidelines). Data status June

80 16 PLATFORM CAB, POSITION OF CONNECTIONS ON SIDE SILL The absence of side sills on the platform cab version means that the hole at the base of the rear pillar needs to be plugged. The aim is to avoid unwanted noise in the passenger compartment and to prevent pollution getting into the hollow sections. REAR CAB PILLAR 1: 1 1: Zone to be plugged up-to-date data on body guidelines (online body guidelines). Data status June

81 17 PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN Platform cabs H1 and H2 are fitted with a connection rim as standard. To this rim are added 6 brackets welded to the body. The start of bodywork dimension is the same for both the H1 and H2 versions. M8 bolts must be used for attachment to the bodywork. The 6 body brackets must be used. After drilling the body brackets, use a corrosion inhibitor, referring to the Specific Corrosion Guidelines. The location of the body brackets is given for both heights (H1 and H2). As the manufacturing variation is ± 3 mm along the Y and Z axes, it would be prudent to test out any bodywork attachment in practice. PLATFORM CAB REAR RING H H : Upper body brackets H2 (x2) 2 : Upper body brackets H1 (x2) 3 : Side body brackets H2 or H2 (x2) 4 : M8 weld nuts, on rear seat floor cross member (x7) 5 : Loading bed up-to-date data on body guidelines (online body guidelines). Data status June

82 17 PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN PLATFORM CAB H1 B A A B C C SECTION A-A SECTION B-B SECTION C-C 1 1: Start of bodywork up-to-date data on body guidelines (online body guidelines). Data status June

83 17 PLATFORM CAB; POSITION OF CONNECTIONS ON CABIN REAR RIM H1 AND H2 D C D C SECTION C-C SECTION D-D 1 1 1: Start of bodywork up-to-date data on body guidelines (online body guidelines). Data status June

84 18 CHASSIS CAB, POSITION OF BODY BRACKETS The start of bodywork dimension, the locations of the body brackets and the location of the connecting cross members between the side members are given for the different chassis cab versions. For fastening anything to these body brackets, see chapter 19 Body brackets sheet. FRONT WHEEL DRIVE CHASSIS CAB, WHEELBASE 2 4,660 3,847 3,265 2,665 2,165 1, ,055 1, ,614 1,899 2,319 2,939 3,440 4,108 4,384 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

85 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS CAB, WHEELBASE 2 5,210 4,601 3,665 2,665 2,165 1, , ,614 1,899 2,319 2,939 3,537 4,108 4,384 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

86 18 CHASSIS CAB, POSITION OF BODY BRACKETS FRONT WHEEL DRIVE CHASSIS CAB, WHEELBASE 3 5,310 4,497 3,915 3,315 2,665 2,165 1, ,055 1, ,614 1,899 2,319 2,939 3,589 4,090 4,758 5,034 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

87 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS CAB, WHEELBASE 3 5,860 5,251 4,315 3,315 2,665 2,165 1, ,936 1,614 1,899 2,319 2,939 3,589 4,187 4, ,034 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

88 18 CHASSIS CAB, POSITION OF BODY BRACKETS FRONT WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 2 4,660 3,847 3,265 2, ,055 1, ,379 2,939 3,440 4,108 4,384 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

89 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 2 5,210 4,601 3,665 2, , ,379 2,938 3,537 4,108 4,384 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

90 18 CHASSIS CAB, POSITION OF BODY BRACKETS FRONT WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 3 5,310 4,497 3,915 3,315 2, ,055 1,936 2,379 2,939 3,589 4,090 4, ,034 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

91 18 CHASSIS CAB, POSITION OF BODY BRACKETS REAR WHEEL DRIVE CHASSIS DOUBLE CAB, WHEELBASE 3 5,860 5,251 4,315 3,315 2, ,936 2,379 2,939 3,589 4,187 4, ,034 1: Wheel shaft up-to-date data on body guidelines (online body guidelines). Data status April

92 19 CHASSIS CAB, INSTALLATION OF A BODY 1. Fixing plates The plates (4) are welded to the upper surfaces of the side members (on chassis cab and double cab versions). These plates are all identical and are intended for the attachment of a subframe. The subframe must be attached with the vehicle parked on a horizontal surface. The subframe must rest on the entire surface of the plates to ensure even load distribution. N.B. Mandatory carry-over of the regulatory tank guard POSITIONS OF THE PLATES, ALL VERSIONS A B C D E F G 1 : Axis of the front axle 2 : Single cab version 3 : Double cab version 4 : Plates welded to the side members 5 : 3.5T or 4.5T single wheel or twin wheel rear drive version The exact distances for each wheel base "A" to "G" can be found in Chapter 18. up-to-date data on body guidelines (online body guidelines). Data status April

93 19 CHASSIS CAB, INSTALLATION OF A BODY When front-wheel drive Fixing plates Section through the longitudinal up-to-date data on body guidelines (online body guidelines). Data status April

94 19 CHASSIS CAB, INSTALLATION OF A BODY 2. Brackets Reinforcing brackets are added to the 4.5T chassis cab and double cab twin wheel rear drive versions. The brackets are angle irons attached to the side members to reinforce the strength of the plates. Comments: A subframe must be fitted Plan a gradual reduction of the section of the subframe in the front, in order to avoid a breakage zone. Use all interior and exterior attachments. Ensure a uniform introduction of force. First bracket with flexible attachment. For the screw disc springs are recommended. The mounting frame must be attached in the same way to all body support brackets Layout and number by version OVERVIEW: DISTRIBUTION OF BRACKETS A B A: Brackets outside the side members B: Brackets inside & outside the side members : Flexible assembly on the back of the cab. : Rigid assembly. up-to-date data on body guidelines (online body guidelines). Data status April

95 19 CHASSIS CAB, INSTALLATION OF A BODY CHASSIS CAB with REAR WHEEL DRIVE, WHEELBASE 2: 14 brackets CHASSIS CREW CAB with REAR WHEEL DRIVE, WHEELBASE 2: 10 brackets up-to-date data on body guidelines (online body guidelines). Data status April

96 19 CHASSIS CAB, INSTALLATION OF A BODY CHASSIS CAB with REAR WHEEL DRIVE, WHEELBASE 3: 16 brackets CHASSIS CREW CAB with REAR WHEEL DRIVE, WHEELBASE 3: 12 brackets up-to-date data on body guidelines (online body guidelines). Data status April

97 19 CHASSIS CAB, INSTALLATION OF A BODY 2.2. Installation of the subframe In order to attach the subframe, all positions available on the side members must be used. The first row (on the back of the cab; point E) must be a flexible assembly. For all other attachments, it must be rigid (points F). The nuts used must be self-locking (radial buckle nuts or nuts with thread locks). The threaded part of the screws must protrude from the nut by at least three threads, regardless of the stack assembly. A B D C A: Cab sidewall B: Subframe with gradual reduction of the section C: Side member D: Back of the cab E: First bracket with flexible attachment (stack of spring washers) F: Bracket with rigid attachment E F up-to-date data on body guidelines (online body guidelines). Data status April

98 19 CHASSIS CAB, INSTALLATION OF A BODY Rigid attachment : Screw thread projection 2 : nut H RDL M10 x 125 (150 permitted) grade : Subframe 4 : Side member + plate assembly 5 : Bracket 6 : Screw H RDL M10 x 125 (150 permitted) grade 10.9 Tightening torque: 52 Nm if thread lock used on the screw or 60 Nm with radial buckle nut. up-to-date data on body guidelines (online body guidelines). Data status April

99 19 CHASSIS CAB, INSTALLATION OF A BODY Flexible attachment : Screw thread projection 2 : nut H M12 x 150 grade : 6 spring washers (Belleville) int. Ø 12.3 mm ext. Ø 34 mm thickness 1.5 mm 4 : Subframe 5 : Side member + plate assembly 6 : Bracket 7 : Plain washer M12x27x2.5 mm 8 : Screw H M12 x grade Value is 15 mm when the spring washers in the stack are touching and free to rotate. The measure is about 12 mm (equivalent to 2 turns of the screw). This results in a spacing of about 1 mm between each pair of spring washer up-to-date data on body guidelines (online body guidelines). Data status April

100 19 CHASSIS CAB, INSTALLATION OF A BODY 2-3 Regulatory tank guard This protective guard around the tank is subject to Regulation ECE 34 and concerns the fire resistance of the fuel circuit. Any modification or removal of this guard must comply with this directive. For information: On all the CHASSIS CAB vehicles (except the double cab), carry-over of the fuel tank guard element. This measure is identical for TRACTION HEADS when the standard fuel tank is carried over onto a specific chassis developed by a coach-builder. Fuel tank guard up-to-date data on body guidelines (online body guidelines). Data status April

101 20 REAR UNDERRIDE PROTECTION The rear underride protection on chassis cab versions is explained hereafter in situ on a vehicle fitted with a drop-side flat bed. The crossmember which acts as an underride protection device is bolted to the end of the sidemembers and has been designed to provide protection to the rear lamps. CROSSMEMBER POSITION A B A: Max. crossmember height: 550mm for N1 and N2 B: Max. crossmember recess: 450mm for N1 and 300mm for N2 up-to-date data on body guidelines (online body guidelines). Data status June

102 20 REAR UNDERRIDE PROTECTION CROSSMEMBER ATTACHMENTS Ansicht von außen Ansicht von innen 2: Rear underride protection 3: Bolts attaching the underride protection to the sidemembers up-to-date data on body guidelines (online body guidelines). Data status June

103 21 CROSS SECTION OF REAR WHEEL The cross section is given with an asymmetrical travel, with first fit tyres and bump stops pressed down as far as possible. A clearance of 10 mm must be added in relation to the tyre for any bodywork positioning. Additional clearance may be needed for fitting snow chains. FRONT WHEEL DRIVE PLATFORM CAB FRONT WHEEL DRIVE CHASSIS CAB OR CHASSIS DOUBLE CAB up-to-date data on body guidelines (online body guidelines). Data status July

104 21 CROSS SECTION OF REAR WHEEL SINGLE WHEEL REAR DRIVE CHASSIS CAB OR CHASSIS DOUBLE CAB TWIN WHEEL REAR DRIVE CHASSIS CAB OR CHASSIS DOUBLE CAB up-to-date data on body guidelines (online body guidelines). Data status July

105 21 CROSS SECTION OF REAR WHEEL TWIN WHEEL REAR DRIVE PANEL VAN up-to-date data on body guidelines (online body guidelines). Data status July

106 22 WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB (FWD) Alteration of the wheelbase is not generally recommended. The Movano range with 3 wheelbase options caters for most application purposes. However, if it is necessary to alter the wheelbase, ensure that the following recommendations are complied with: Modification of the wheelbase with front wheel drive will alter the distribution of load on the vehicle axles. Full allowance must be made for this before the wheelbase is extended to ensure that the maximum loads per axle are not exceeded. (Also see chapter 79: Maximum authorised load per axle) Impacts related to the changes on the basic vehicle are the responsibility of the converter. The following instructions must be followed with regard to the braking control system: No changes to the hoses No change to the handbrake cables, but lengthened control rod. Compliance with the handbrake adjustment procedure. Important: OPEL/ VAUXHALL do not allow any modification to the wheelbase on rear wheel drive vehicles. OPEL/ VAUXHALL do not allow any modification to the wheelbase on vehicles with ESP. For front-wheel drive vehicles with a 4332mm wheelbase, lengthening by 10% is possible, except on the version with ESP. For safty reasons it is not allowed to shorten or extend the ABS cable. The permissible axle loads, gross vehicle weights and centre of gravity locations must be complied with. Further information regarding permissible weights is contained on the vehicle type identification plates on the vehicle itself. The minimum front axle load must be complied with in all load states. On no account should modifications be made to the vehicle width, vehicle height or vehicle length if they exceed the threshold values specified in the current version of the Conversion Guideline (also see chapter 7). up-to-date data on body guidelines (online body guidelines). Data status September

107 22 WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB (FWD) 1. CHASSIS SINGLE CAB and CREW CAB without ESP The recommended splice line has been determined based on considerations of structural soundness (maintenance of the tank and exhaust interfaces) and the location of cross members and reinforcements. The overlap between the longitudinal beam and reinforcement must be at least 300 mm on each side. CHASSIS SINGLE CAB and CREW CAB rear axle 2615 mm X front axle rear axle X = Wheelbase extension The position of the cut is determined with regard to the location of already fitted components such as the exhaust, cross member and reinforcing: for the Chassis Cab and Crew Cab this point lies 2615 mm from the Front axle. up-to-date data on body guidelines (online body guidelines). Data status September

108 22 WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB (FWD) 2. PLATFORM CAB without ESP The recommended splice line has been determined based on considerations of structural soundness (maintenance of the tank and exhaust interfaces) and the location of cross members and reinforcements. For a large extension to the wheelbase (10% max.), depending on the floor panel used, one or two under floor reinforcement cross members may be added between the main side members The overlap between the longitudinal beam and reinforcement must be at least 200 mm on each side. PLATFORM CAB rear axle 2460 mm X front axle rear axle X = Wheelbase extension The position of the cut is determined with regard to the location of already fitted components such as the exhaust, cross member and reinforcing: for the Platform Cab this point lies 2460 mm from the front axle. 3. MAXIMUM POSSIBLE EXTENSION This converted vehicle (Modification of the wheelbase / rear overhang) shall not exceed the maximum vehicle length. See Chapter 7 MAIN VIEWS AND DIMENSIONS ". up-to-date data on body guidelines (online body guidelines). Data status September

109 23 MODIFYING THE REAR OVERHANG Modification of the rear overhang will alter the distribution of load on the vehicle axles. Make sure that you do not exceed the permissible axle loads. Doing so would prevent the ESP system from functioning correctly on vehicles which are equipped with this feature. Further information regarding permissible weights is contained on the vehicle type identification plates on the vehicle itself. (Also see chapter 79 "Maximum load per axle") The extension to the rear overhang must not exceed the maximum authorized body limit. The dimensions of the basic vehicle are available in chapter 7. An extended overhang prevents: - The installation of a lift tailgate - The installation of a platform on this overhang - The assembly of a classic coupling device. If installing a new trailer coupling device, ensure validation in accordance with the regulatory requirements. Conversions (extension or shortening of the overhang) must not disrupt the correct operation of the ESP (load distribution variation). Important: The permissible axle loads, gross vehicle weights and centre of gravity locations must be complied with. Further information regarding permissible weights is contained on the vehicle type identification plates on the vehicle itself. On no account should modifications be made to the vehicle width, vehicle height or vehicle length if they exceed the threshold values specified in the current version of the body / equipment When installing a new coupling, plan for a validation, in compliance with regulatory requirements up-to-date data on body guidelines (online body guidelines). Data status June

110 23 MODIFYING THE REAR OVERHANG 1. CHASSIS SINGLE CAB AND CREW CAB 1.1. Extension of the rear overhang The recommended extension area (4) is determined according to structural constraints (Rear leaf spring attachment, etc.) and the existence of cross members or reinforcements. The extension area is located between the rear suspension attachments (3) and the rear end cross member (5). The reinforcements in the side members (point 6) must be kept. If a modification is made, these side members must be reinforced by equivalent parts. An extension of more than 385 mm requires one or more cross members to be added. The rear tow eye function must be kept. REAR CHASSIS: AERIAL VIEW (WITH CLOSURE ELEMENTS REMOVED) : Rear axle front attachment 2: Rear axle + wheel 3: Rear axle rear attachment 4: Cutting area 5: Rear end cross member 6: Side member internal reinforcement 5 6 It is essential that the extension to the overhang keep or add additional reinforcements to each side member (see 6, view above), located in line with the rear leaf spring attachments (see 3, view above). up-to-date data on body guidelines (online body guidelines). Data status June

111 23 MODIFYING THE REAR OVERHANG CHASSIS SINGLE CAB and CREW CAB front axle rear axle 1 F Z4 D1 D 2 1 = Crew Cab 2 = Extension of rear overhang D = Standard rear overhang D1 = Maximum rear overhang Z4 = Application of the load F The dimensions ( D; D1; Z4) of the vehicle see Chapter 7. up-to-date data on body guidelines (online body guidelines). Data status June

112 23 MODIFYING THE REAR OVERHANG 1.2. Shortening of the rear overhang The shortening of the rear overhang shall apply to the versions with single and crew cab and rear-wheel drive. The shortening area is located between the rear bracket of the rear suspension (3) and the rear cross member (5). See first picture REAR CHASSIS: AERIAL VIEW in this chapter 23. If a coupling is installed, reinforcements should be planned accordingly. CHASSIS SINGLE CAB and CREW CAB (with RWD) front axle rear axle 1 F Z4 D D 2 1 = Crew Cab 2 = Shortened rear overhang D = Standard rear overhang Z4 = Application of the load F The dimensions (D; Z4) of the vehicle, see Chapter 7. up-to-date data on body guidelines (online body guidelines). Data status June

113 23 MODIFYING THE REAR OVERHANG 2. PLATFORM CAB The conversion must under no circumstances alter the spring blade supports. Depending on the overhang extension, one or more under-floor reinforcing cross members may be added between the main side members. front axle rear axle F Z4 D 2 D1 2 = Extension of rear overhang D = Standard rear overhang D1 = Maximum rear overhang Z4 = Application of the load F The dimensions (D; D1; Z4) of the vehicle, see Chapter MAXIMUM EXTENSION The maximum extension (2) is limited by the maximum vehicle length. See Chapter 7 - MAIN VIEWS AND DIMENSIONS ". up-to-date data on body guidelines (online body guidelines). Data status June