Mercedes Vito Viano 2005

Vito/Viano Body/Equipment Mounting Directives
Contents
1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.2.1 2.3 2.4 2.4.1 2.4.2 2.4.3 2.5 2.5.1 2.5.2 2.5.3 2.6 2.7 2.8 2.9 2.10 2.11 3 3.1 3.2 3.3 3.3.1 3.4 3.5 3.6 3.7 3.7.1 3.7.2 3.8 3.9 3.9.1 3.9.2 3.9.3 3.10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 4 The aim of these Directives . . . . . . . . . . . . . . . 4 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operational safety . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Vehicle and model designations . . . . . . . . . . . 8 Overview of Vito models . . . . . . . . . . . . . . . . . 9 Seating options in the Vito. . . . . . . . . . . . . . . 10 Overview of Viano models . . . . . . . . . . . . . . . 11 Technical advice for body/equipment manufacturers . . . . . . . . . . . . . . . . . . . . . . . . 12 Certificate of endorsement . . . . . . . . . . . . . . 12 Issuing a certificate of endorsement . . . . . . . 13 Legal claims . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tender drawings, technical data, product information/Mercedes-Benz body/ equipment manufacturer system (MB-AS). . . 14 PC program (ISDN/modem) . . . . . . . . . . . . . 14 Faxback system . . . . . . . . . . . . . . . . . . . . . . . 14 Workshop Information System (WIS) . . . . . . . 14 Product liability . . . . . . . . . . . . . . . . . . . . . . . 15 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . 16 Mercedes star and logo . . . . . . . . . . . . . . . . . 17 Accident prevention . . . . . . . . . . . . . . . . . . . . 18 Reprocessing components recycling . . . . . 19 Quality assurance system . . . . . . . . . . . . . . . 20 Planning conversions . . . . . . . . . . . . . . . . . 21 Vehicle selection . . . . . . . . . . . . . . . . . . . . . . 21 Vehicle modifications. . . . . . . . . . . . . . . . . . . 22 Dimensions and weights . . . . . . . . . . . . . . . . 23 Weight distribution. . . . . . . . . . . . . . . . . . . . . 23 Vehicle identification data . . . . . . . . . . . . . . . 25 Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . 26 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Bolted and welded connections . . . . . . . . . . . 28 Bolted connections . . . . . . . . . . . . . . . . . . . . 28 Welded connections. . . . . . . . . . . . . . . . . . . . 29 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . 32 Maintenance and repairs . . . . . . . . . . . . . . . . 33 Preparation for storing the vehicle. . . . . . . . . 33 Battery maintenance and storage . . . . . . . . . 34 Preparation for handing over the converted vehicle. . . . . . . . . . . . . . . . . . . . . . 34 Optional equipment . . . . . . . . . . . . . . . . . . . . 35
4 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.5 4.5.1 4.5.2 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.7 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7
Technical threshold values for planning . . 36 Basic vehicle threshold values . . . . . . . . . . . . 36 Steerability. . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Extreme permissible positions of centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Parts which must not be welded . . . . . . . . . . 36 Parts which must not be welded . . . . . . . . . . 36 Parts in which holes may not be drilled . . . . . 36 Chassis threshold values . . . . . . . . . . . . . . . . 37 Permissible axle loads . . . . . . . . . . . . . . . . . . 37 Approved tyre sizes . . . . . . . . . . . . . . . . . . . . 37 Turning circle diameter . . . . . . . . . . . . . . . . . 37 Modifications to the axles . . . . . . . . . . . . . . . 37 Modifications to the steering system. . . . . . . 37 Modifications to the brake system . . . . . . . . 38 Modifications to the springs/spring mountings/ shock absorbers . . . . . . . . . . . . . . . . . . . . . . 38 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . 38 Bodyshell threshold values . . . . . . . . . . . . . . 39 Modifications to the bodyshell. . . . . . . . . . . . 39 Vehicle roof/roof load. . . . . . . . . . . . . . . . . . 39 Engine periphery/drive train threshold values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Modifications to the engine/drive train parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Interior threshold values . . . . . . . . . . . . . . . . 41 Modifications to the airbags and belt tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Modifications to the seats . . . . . . . . . . . . . . . 41 Electrical system/electronics threshold values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electrical lines/fuses . . . . . . . . . . . . . . . . . . 42 Vehicle outline and side marker lamps . . . . . 42 Retrofitting electrical equipment ("e" mark). . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Mobile communications systems. . . . . . . . . . 42 CAN bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electronic Stability Program . . . . . . . . . . . . . 42 Additional equipment threshold values . . . . . 43 Damage prevention . . . . . . . . . . . . . . . . . . . 44 Brake hoses/cables and lines. . . . . . . . . . . . 44 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . 45 Corrosion protection measures . . . . . . . . . . . 46 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Towing and tow-starting. . . . . . . . . . . . . . . . . 49 Storing and delivering the vehicle . . . . . . . . . 50 Electromagnetic compatibility (EMC). . . . . . . 51
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 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7 6.5.8 6.5.9 6.5.10 6.5.11
Modifications to the basic vehicle . . . . . . . 52 Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Basic chassis . . . . . . . . . . . . . . . . . . . . . . . . . 52 Springs/shock absorbers . . . . . . . . . . . . . . . 52 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . 53 Pneumatic suspension . . . . . . . . . . . . . . . . . . 54 Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . 55 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Bodyshell/bodywork . . . . . . . . . . . . . . . . . . . 56 General notes on the bodyshell/ bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Modifying the partition. . . . . . . . . . . . . . . . . . 57 Sidewall, windows, doors and flaps . . . . . . . . 57 Wings and wheel arches . . . . . . . . . . . . . . . . 58 Chassis end cross-member . . . . . . . . . . . . . . 58 Bodyshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Underbody panelling . . . . . . . . . . . . . . . . . . . 59 Roof of panel van/Traveliner . . . . . . . . . . . . 59 Engine periphery/drive train . . . . . . . . . . . . . 61 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 61 Engine cooling . . . . . . . . . . . . . . . . . . . . . . . . 61 Engine air intake . . . . . . . . . . . . . . . . . . . . . . 62 Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . 62 Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Safety equipment. . . . . . . . . . . . . . . . . . . . . . 63 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Reducing noise in the vehicle interior . . . . . . 69 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Electrical system/electronics . . . . . . . . . . . . 70 General notes. . . . . . . . . . . . . . . . . . . . . . . . . 70 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Power supply interfaces . . . . . . . . . . . . . . . 71 Retrofitting electrical equipment . . . . . . . . . . 76 Mobile communications systems. . . . . . . . . . 76 Electrical lines/CAN bus . . . . . . . . . . . . . . . . 77 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . 81 Electronic Stability Program (ESP) . . . . . . . . 82 Electromagnetic compatibility (EMC). . . . . . . 83 Retrofitting an alternator . . . . . . . . . . . . . . . . 83
6.6 6.6.1 6.6.2 6.6.3 6.7 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 7 7.1 7.1.1 7.1.2 7.2 7.3 7.4 7.5 7.6 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7
Additional equipment. . . . . . . . . . . . . . . . . . . 85 Retrofitting the air conditioning . . . . . . . . . . . 85 Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . 85 Power take-offs . . . . . . . . . . . . . . . . . . . . . . . 85 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 86 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Attachment above cab. . . . . . . . . . . . . . . . . . 86 Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . 86 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . 87 Conversion work . . . . . . . . . . . . . . . . . . . . . 88 Modifications to the interior . . . . . . . . . . . . . 88 Modifications to the cockpit . . . . . . . . . . . . . 88 Retrofitting additional seats. . . . . . . . . . . . . . 88 Modifications to closed panel vans . . . . . . . . 89 Refrigerated vehicles . . . . . . . . . . . . . . . . . . . 91 Motor caravans . . . . . . . . . . . . . . . . . . . . . . . 92 Retrofitting a raised roof . . . . . . . . . . . . . . . . 93 Increasing the roof height . . . . . . . . . . . . . . . 94 Technical data . . . . . . . . . . . . . . . . . . . . . . . 95 Vito 109 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 95 Vito 111 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 97 Vito 115 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 99 Vito 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Vito 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Viano CDI 2.0/CDI 2.2 . . . . . . . . . . . . . . . . 105 Viano 3.0/3.2 . . . . . . . . . . . . . . . . . . . . . . . 107
1 Introduction
These Body/Equipment Mounting Directives provide the body manufacturers with important technical information about the basic vehicle. This information must be observed by the body manufacturer in the production of bodies and their equipment, fittings and conversions. Due to the great number of body manufacturers and body types, DaimlerChrysler AG cannot foresee all possible changes, e.g. to road performance, stability, load distribution, the vehicle's centre of gravity and its handling characteristics, caused by bodies and their equipment, fittings and conversions. For this reason, DaimlerChrysler AG can assume no liability for accidents or injuries caused by such modifications to your vehicle, even if these modifications have an adverse affect on the complete vehicle. As a manufacturer, DaimlerChrysler AG is accordingly only liable for its own designs and products. The body manufacturer itself, as manufacturer of the complete vehicle, is obliged to make sure that bodies and their equipment, fittings and conversions are not faulty and that they cannot lead to faults or hazards on the complete vehicle. If this obligation is violated in any way, the body manufacturer will assume full product liability. By drawing up these Body/ Equipment Mounting Directives, DaimlerChrysler AG fulfils its obligation to brief the body manufacturers and inform them of important aspects to observe when carrying out conversions. These Body/Equipment Mounting Directives are intended primarily for professional manufacturers of bodies and add-on equipment and who carry out fittings and conversions of our vehicles. For this reason, these Body/Equipment Mounting Directives assume that the body manufacturer possesses the necessary background knowledge. If you intend to carry out work on bodies and their equipment, fittings or conversions, please be aware that certain types of work (e.g. welding work on load-bearing components) may only be carried out by qualified personnel. This will avoid the risk of injury and will attain the degree of quality required for bodies and their equipment, fittings and conversions.
1.1
The aim of these Directives
The following Body/Equipment Mounting Directives are divided into 8 related sections to help you to find information quickly: 1. Introduction 2. General 3. Planning conversions 4. Technical threshold values for planning 5. Damage prevention 6. Modifications to the basic vehicle 7. Conversion work 8. Technical data Appendix: - Index You can obtain further information and technical data from the tender drawings in the Mercedes-Benz body/ equipment manufacturer system ( page 14). The index, in PDF format, is linked to help you find information quickly. The threshold values chosen in section 4 must be adhered to and must form the basis of planning. The sections entitled "Modifications to the basic vehicle" and "Conversions specifications" are the main source of technical information contained in these Body/ Equipment Mounting Directives.
1 Introduction 1.2 Symbols

1.2 Symbols
You will find the following symbols used in these directives: Warning
A warning draws your attention to possible risks of accident and injury to yourself and others.
Environmental note
An environmental note gives you tips on the protection of the environment.
!
This note draws your attention to possible hazards to your vehicle.
i
This tip contains advice or further information you may find useful.
page
This symbol indicates the page on which you will find further information on the subject. This continuation symbol indicates an interrupted sequence of actions that will be continued on the next page.
! Always print out complete section from the current version.
1 Introduction 1.3 Vehicle safety

1.3 Vehicle safety
Risk of accident
Before installing non-Mercedes-Benz bodies or attaching, fitting or converting assemblies, please read the relevant section of the detailed Owner's Manual/ Operating Instructions. You could otherwise fail to recognise dangers and endanger yourself or others. Notes on vehicle safety We recommend the following: Use only parts and assemblies or recommended conversion parts and accessories that have been recommended by Mercedes-Benz for the type of vehicle concerned. Parts that modify the vehicle such that they: change the vehicle type approved in the general operating permit can be expected to endanger road users, or adversely affect exhaust emissions or noise levels will invalidate the vehicle's general operating permit in many countries The use of parts, assemblies or conversion parts and accessories which have not been recommended may jeopardise the safety of the vehicle.
!
Observe the national specifications since attachments, installation of bodies, conversion and installation work on the vehicle could change the approved vehicle type and may invalidate the general operating permit.
1 Introduction 1.4 Operational safety

1.4 Operational safety
Risk of accident
Work incorrectly carried out on electronic equipment and its software could prevent this equipment from working. Since the electronic systems are networked, this might also affect systems that have not been modified. Malfunctions in the electronic systems could seriously jeopardise the operational safety of the vehicle. Have work on or modifications to electronic components carried out at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required. Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose. In particular, work relevant to safety or on safety-related systems must be carried out at a qualified specialist workshop. Some of the safety systems only function when the engine is running. For this reason, do not switch off the engine when the vehicle is in motion.
2 General 2.1 Vehicle and model designations

2.1 Vehicle and model designations
Private use: Viano (BM 639.7 (Fun)/8) Trend Ambiente Vito 119 Vito 122 Vito 123 Vito 109 CDI Vito 111 CDI Vito 115 CDI 140 kW/190 bhp 160 kW/218 bhp 170 kW/231 bhp 65 kW/88 bhp 80 kW/109 bhp 110 kW/150 bhp Model designation according to permissible gross vehicle weight Engine code MQ3 MQ4 MQ5 MQ6 MR8 Engine OM611 DE22LA OM611 DE22LA OM611 DE22LA OM611 DE27LA M111 E23 Output [kW] 60 80 95 115 105 214 2,590 [kg] 208 CDI 211 CDI 213 CDI 2,800 [kg] 208 CDI 211 CDI 213 CDI 216 CDI 214 3,500 [kg] 308 CDI 311 CDI 313 CDI 316 CDI 314 4,600 [kg] 408 CDI 411 CDI 413 CDI 416 CDI 414 616 CDI 5,990 [kg] Viano 3.0 Viano 3.2 Viano 3.5 Viano CDI 2.0 Viano CDI 2.2 Fun Marco Polo 140 kW/190 bhp 160 kW/218 bhp 170 kW/231 bhp 80 kW/109 bhp 110 kW/150 bhp These Body/Equipment Mounting Directives apply to the following vehicle model designation numbers: Commercial use: Vito (BM 639.6/7)
2 General
2.2 Overview of Vito models
Long Short wheelbase, long overhang, length 4,993 mm Extra long Long wheelbase, long overhang, length 5,223 mm
Compact Short wheelbase, short overhang, length 4,748 mm Panel van
Dualiner
Traveliner
You will find explanations of models and engine codes in the table ( page 8)
2 General
2.2.1 Seating options in the Vito
N23.00-2019-00
Double seat next to the driver option Easy entry option
10
2 General
2.3 Overview of Viano models
2.3 Overview of Viano models
Long Short wheelbase, long overhang, length 4,993 mm Extra long Long wheelbase, long overhang, length 5,223 mm
Compact Short wheelbase, short overhang, length 4,748 mm Trend, Ambiente
Fun
Marco Polo
You will find explanations of models and engine codes in the table ( page 8)
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2 General
2.4 Technical advice for body/equipment manufacturers
Technical advice regarding the basic vehicle Herr Enrique Giminez Castro and his team at the order processing centre in the Vitoria factory are available to answer any questions you may have about the basic vehicle. Telephone: Fax: Postal address: +34 (945)-18 55 44 +34 (945)-18 55 40 Mercedes Benz Espaa S.A. Avda. de los Huetos. 73 y 75 E-01010 Vitoria, Spain Technical advice outside Germany The body/equipment manufacturer advisors at the DaimlerChrysler AG organisation in your country are available to offer technical advice and to answer questions about conversions.
Technical advice regarding the feasibility of the conversion Herr Leipner and his team are available to offer technical advice to body/equipment manufacturers and to issue certificates of endorsement. The relevant members of staff can be contacted on: Telephone: +49 (0)711-17-58438 +49 (0)711-17-50810 Fax: Postal address: +49 (0)711-17-32323 DaimlerChrysler AG HPC (in-house postcode) C103 Department ET/3M 70546 Stuttgart, Germany Body/equipment manufacturer information and certification Herr Pflger and his team are available for any questions and suggestions you may have regarding the sale of existing and new products, as well as about the ABH Portal and the qualified supplier list. The relevant members of staff can be contacted on: Telephone: +49 (0)711-17-90819 +49 (0)711-17-90591 +49 (0)711-17-90507 Fax: Postal address: +49 (0)711-17-90868 DaimlerChrysler AG HPC (in-house postcode) Z602 Department VT/P3 70546 Stuttgart, Germany
2.4.1
Certificate of endorsement
DaimlerChrysler AG does not issue body/equipment approval certificates for non-Mercedes-Benz conversions. It only provides body manufacturers with important information and technical guidelines for the correct handling of the product by means of these Directives. DaimlerChrysler AG therefore recommends that conversions are carried out in accordance with these Mercedes-Benz Body/Equipment Mounting Directives. DaimlerChrysler AG advises against bodies and their equipment, fittings and conversions which: are not completed in accordance with the Mercedes-Benz body/equipment mounting directive exceed the permissible gross vehicle weight would exceed the permissible axle loads DaimlerChrysler AG issues certificates of endorsement on a discretionary basis, based on the following requirements:
12
2 General
DaimlerChrysler AG bases its assessment solely on the documents presented (by the company which carries out the conversion). It checks and declares safe only the explicitly described scopes and their general compatibility with the vehicle specified and its connection points or, in the case of vehicle modifications, the basic constructional permissibility for the specified vehicle. The certificate of endorsement does not apply to the design of the conversion as a whole, nor its functions or intended use. The endorsement is only valid if the design, production and installation carried out by the company is effected to the state of the art and in accordance with the valid DaimlerChrysler AG Body/Equipment Mounting Directives unless deviations have been endorsed in these Directives. The certificate of endorsement does not absolve the company which is carrying out the modifications from its product liability or the obligation to carry out its own calculations, checks and tests of the entire vehicle to ensure the operating safety, road safety and handling characteristics of the entire vehicle it has manufactured. Accordingly, the body manufacturer has the sole responsibility for ensuring the compatibility of the body and its equipment, fittings and conversion with the basic vehicle, as well as for the operating and road safety of the entire vehicle. Conditions of vehicle operation, e.g. on poor roads in very dusty conditions at high altitude at extremely high or low ambient temperatures Certification (e mark, seat tension test, etc.) Queries can be avoided and processing accelerated by providing complete documentation.
2.4.3
Legal claims
No legal claim can be made as to the issue of a certificate of endorsement. DaimlerChrysler AG reserves the right to refuse an endorsement certificate due to ongoing technical development and the knowledge gained from it, even if a similar certificate was granted in the past. The certificate of endorsement may be limited to single vehicles. Subsequent granting of a certificate of endorsement for vehicles already completed or delivered may be refused. The body manufacturer alone is responsible for: the functionality and compatibility of the body and its equipment, fittings and conversion with the basic vehicle the operating and road safety all bodies and their equipment, fittings and conversion and other installed parts
!
Comply with all national laws, guidelines and vehicle registration regulations.
2.4.2
Issuing a certificate of endorsement
In particular cases, the conversion drawings may be presented to the responsible department ( page 12) before the work is commenced. The drawings must contain the following information: All deviations from the Mercedes-Benz Body/ Equipment Mounting Directives Complete data on dimensions, weights and centre of gravity (weight certificates).
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2 General
2.5 Tender drawings, technical data, product information/Mercedes-Benz body/ equipment manufacturer system (MB-AS)
2.5 Tender drawings, technical data, product information/Mercedes-Benz body/equipment manufacturer system (MB-AS) 2.5.2 Faxback system
Vehicle data can be called up and printed out using a fax machine with "faxback" function. Additional information on this is provided in the user's manual for the fax machine. After selecting the faxback function and entering the number +49 (0)7 1117-86 40 40, you will receive the MB-AS title page containing a summary of the information categories available and their faxback numbers. A total of approximately 1,500 technical data sheets and over 3,000 tender drawings as well as additional information for body/equipment manufacturers is available on faxback. All vehicle information available, the PC program and all services associated with the faxback system are free of charge. For further information about MB-AS, call +49 (0)711-17-3 33 22.
You can obtain tender drawings and technical data from the Mercedes-Benz body/equipment manufacturer system (MB-AS) at: http://mbas.mercedes-benz.com MB-AS is a modern communications system for exchanging tender drawings, technical data and product information for all commercial vehicles. Make sure that work is only carried out in accordance with the current body/equipment mounting directive, which you can find on the Internet. Current commercial vehicle information and data can be called up with minimum effort, either in fax or data processing format, by modem or by ISDN data transfer, and can then be printed and processed. You are thus optimally equipped to provide your customers with quick, low-cost and comprehensive advice, feasibility studies and plans to determine the final vehicle design, to compile quotations and to prepare designs.
2.5.3
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: Fax: Postal address: +49 (0)711-17-83170 +49 (0)711-17- 40082 DaimlerChrysler AG HPC (in-house postcode) R800 Department GSP/TIM 70546 Stuttgart, Germany
2.5.1
PC program (ISDN/modem)
The vehicle information required can be selected and ordered directly from easy-to-use selection catalogues on your PC using this Windows program. This program is available to you free of charge. The following are available: Tender drawings in DXF, DWG and bitmap formats (DIN A4) Technical data sheets Body/Equipment Mounting Directives Body/equipment manufacturer information Information about power take-offs The data can be transferred within a few minutes via ISDN or modem.
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2 General
2.6 Product liability
2.6 Product liability
Product liability (under civil law) means the liability of a manufacturer for any consequential damage arising to the user of the product or a third party if the product does not possess the degree of operating safety or reliability which can reasonably be expected by the injured party. Please note the following points with regard to product liability: Each manufacturer is liable for the products it manufactures. As a manufacturer, DaimlerChrysler AG is accordingly only liable for its own designs and products. DaimlerChrysler AG does not therefore accept any liability for damage resulting from defects in retrofitted products produced by third-party manufacturers. The body/equipment manufacturer shall bear sole responsibility for: the operating and road safety of the conversion the operating and road safety of parts and conversion parts testing and maintaining the operating and road safety of the entire vehicle after the conversion (handling, braking and steering characteristics must not be adversely affected by the conversion) the effects of parts or conversion parts on the vehicle consequential damage resulting from the attachment, installation or conversion consequential damage resulting from retrofitted electrical and electronic systems the operational reliability and freedom of movement of all moving parts of the vehicle after the conversion (e.g. axles, springs, propeller shafts, steering, transmission linkage, etc.) even in the case of diagonal torsion Work carried out on or modifications made to the vehicle must be entered in the "Confirmations by the body manufacturer" section of the Maintenance Booklet.
15
2 General
2.7 Warranty claims
2.7 Warranty claims
Warranty claims can only be made within the framework of the contract of sale between purchaser and seller. This means that each seller is liable to the purchaser for the items supplied by the former to the latter. In the following cases in particular, DaimlerChrysler AG will assume no liability: if the vehicle used does not correspond to the equipment version for the country in question and field of application if damage was caused by the conversion
16
2 General
2.8 Mercedes star and logo
2.8 Mercedes star and logo
The Mercedes star and Mercedes-Benz logo are trademarks of DaimlerChrysler AG. They may not be removed or attached to another point without approval. Mercedes-Benz stars and Mercedes-Benz logos supplied separately must be attached at the points specified by Mercedes-Benz. Appearance of the entire vehicle If the vehicle fails to comply with the vehicle image and the quality standards required by Mercedes-Benz, the DaimlerChrysler AG trademarks must be removed. Third-party trademarks may not be affixed next to Mercedes-Benz trademarks may only be affixed to other points on the vehicle with permission from the relevant department of DaimlerChrysler AG ( page 12)
17
2 General
2.9 Accident prevention
2.9 Accident prevention
The conversion and attached or installed equipment must comply with all applicable laws and directives and with health and safety and accident prevention regulations, safety regulations and information sheets issued by accident insurers. All technical means shall be used to avoid operating conditions that may be unsafe or liable to cause an accident. In Germany, information is provided to commercial carriers by the "Vehicles" Working Group of the "Traffic" Technical Committee at the following address: Telephone: Fax: E-mail: Postal address: +49 (0) 40 39 80- 0 +49 (0) 40 39 80-19 99 info@bgf.de Berufsgenossenschaft fr Fahrzeughaltungen (German Trade Association of Vehicle Owners) Ottenser Hauptstrae 54 22765 Hamburg, Germany National laws, guidelines and registration regulations must be complied with. The body and equipment manufacturer is responsible for compliance with these laws and regulations.
18
2 General
2.10 Reprocessing components recycling
2.10 Reprocessing components recycling
Components in areas at risk from accidents must be designed in such a way that they are damage-tolerant, repairable and easy to replace. All plastic parts are to be marked in accordance with VDA code of practice 260, e.g. "PP GF30R". EU Directive 2000/53/EC must be complied with. Environmental note
Environmental note
When planning conversions, the following principles for environmentally-compatible design and material selection shall be taken into account, in particular with regard to EU Directive 2000/53/EC. Materials with risk potential, such as halogen additives, heavy metals, asbestos, CFCs and CHCs, are to be avoided. It is preferable to use materials which permit recycling and closed material cycles. Materials and production processes that generate only low quantities of waste during production must be selected such that this waste can be easily recycled. Plastics are to be used only where they provide advantages in terms of cost, function or weight. In the case of plastics, and composite materials in particular, only compatible substances within one material family are to be used. For components which are relevant to recycling, the number of different types of plastics used must be kept to a minimum. It must be assessed whether a component can be made from recycled material or admits the addition of recycled components. It must be ensured that components can be dismantled easily for recycling, e.g. by snap connections, artificially weakened points, easy accessibility, and using standard tools. It must be ensured that service products can be removed simply and in an environmentally-compatible manner by means of drain plugs, etc. Painting and coating components is to be avoided wherever possible; coloured plastic parts should be used instead.
Additional information is provided in the "Commercial vehicle recycling, ecology and economy" brochure, Order no. 6702 6187 00-00/0952 ( page 14).
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2 General
2.11 Quality assurance system
2.11 Quality assurance system
Global competition, more stringent quality standards demanded by the customer of the entire van product, national and international product liability laws, new forms of organisation and increasing cost pressures require effective quality assurance systems in all areas of the automotive industry. To be able to meet these requirements, a work group of the VDA (Association of German Automobile Manufacturers) has developed a "Guide to quality assurance for the manufacturers of trailers, bodies and containers" as VDA volume 8, based on DIN EN ISO 9000 ff. For the reasons stated above, we strongly recommend that body manufacturers set up a quality management system with the following minimum requirements: Development, implementation and monitoring of a quality assurance system in each company Details of responsibilities in an organigram Appointment of member of staff responsible for quality management Guarantee of the availability and current validity of the process, work and inspection instructions in all the departments and at all workplaces Fulfilment of the proofs of qualification for the members of staff concerned
20
3 Planning conversions 3.1 Vehicle selection

!
As well as a user-friendly and easy-to-maintain design, selection of the correct materials and subsequent observation of the corrosion protection measures are important when planning conversions ( page 46).
3.1
Vehicle selection
Careful selection of the vehicle for the required field of application is necessary to ensure that it is used safely. In particular, the: wheelbase engine/transmission axle ratio permissible gross vehicle weight centre of gravity and permissible axle loads should be taken into consideration and be appropriate for the intended use.
!
Before carrying out modification work, the delivered vehicle must be submitted to a check to verify whether it fulfils the necessary requirements. Further information about the vehicle models available can be found in the "Overview of models" section ( page 9) or can be obtained from the relevant department ( page 12).
i
Visit the Mercedes-Benz home page at: http://mbks2.mercedes-benz.com/ van_konfigurator/vp.dll to configure your vehicle and view the available items of optional equipment.
21
3 Planning conversions 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 relevant department or retrieved from the communications system ( page 14). Furthermore, attention must be paid to optional equipment fitted ex works ( page 35). As supplied ex works, all vehicles comply with EC directives and national regulations (except for some vehicles for non-European countries). The vehicles must still comply with EC directives or national regulations after modifications have been carried out. Vehicle approval The body/equipment manufacturer must inform the officially recognised technical expert or inspector of any modifications to the vehicle.
!
Comply with all national laws, guidelines and vehicle registration regulations.
!
Adequate clearances must be maintained in order to ensure the function and operational safety of assemblies.
Risk of accident
Do not make any modifications to the steering or brake systems. Modifications to the steering or brake systems could result in these systems no longer functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident.
!
Modifications to sound proofing are not permitted.
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3 Planning conversions 3.3 Dimensions and weights

3.3 Dimensions and weights
Risk of accident 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 equipment. 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 threshold values for planning" section ( page 36) and in the "Technical data" section ( page 95). Risk of accident
The permissible axle loads must be complied with. If the permissible axle loads are exceeded on vehicles with ESP, this system may no longer function. The driver could lose control of the vehicle as a result and cause an accident. Information about changes in weight is available from your contact at Mercedes-Benz ( page 12).
!
The individual axle loads and the permissible gross vehicle weight must be observed for all conversions. The permissible number of vehicle occupants and an adequate margin for the payload must also be observed. The payload may consist of luggage, optional equipment, etc. Take the weight of optional equipment into consideration when making calculations. National regulations and guidelines shall apply.
The tyre load capacity of the vehicle must not be exceeded by overloading the vehicle above the specified gross vehicle weight. The tyres could otherwise overheat and be damaged. The driver could lose control of the vehicle as a result and cause an accident. The braking distance could be considerably longer if the vehicle is overladen. Details of the permissible weights can be found in the vehicle identification data on the vehicle ( page 25) and in the Technical data ( page 95).
3.3.1
Weight distribution
Avoid placing excessive loads on one side of the vehicle. The wheel load (1/2 the axle load) should not be exceeded by more than 4%. Observe the tyre load-bearing capacity. The maximum rear-axle load must not exceed 53% of the permissible vehicle load.
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3 Planning conversions 3.3 Dimensions and weights

Vehicle weights Weight in kg Unladen weight in accordance with 92/91 EEC1 Panel van Traveliner Luxury Traveliner Permissible gross weight2
2
Compact body
Long body
Extra-long body
1,790 1,900 2,070 2,770/2,940 1,470/1,550 1,470/1,550
1,845 1,925 2,095 2,770/2,940 1,470/1,550 1,470/1,550
1,870 1,950 2,120 2,940 1,470/1,550 1,470/1,550
Permissible front axle load Permissible rear axle

1 2
load2
Values apply to vehicles with an OM646 DE LA engine and manual transmission with standard equipment; the unladen weight increases by 20 kg for a petrol engine and automatic transmission Data applicable depending on vehicle operating permit (without/with load increase, code XA2)
Trailer loads/payload Weight in kg Permissible trailer load, braked Permissible trailer load, unbraked Maximum trailer drawbar noseweight Maximum payload2 Panel van2 Traveliner
2 2 3
Compact body 2,000 750 100

1
Long body 2,000 750 100

1
Extra-long body 2,0001 750 100
950 1,120 1,040 700 870 100/150 45
925 1,095 1015 675 845 50/100/150 45
900 1,070 990 820 100/150 45
Luxury Traveliner
Permissible roof load

1 2 3
Maximum tailgate rack load 2,500 kg as option, code D44
Dependent on unladen weight and permissible gross weight of vehicle; reduced when additional equipment is fitted 150 kg for 6 attachment points or 100 kg for 4 attachment points; maximum 50 kg for a high roof
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3 Planning conversions 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
25
3 Planning conversions 3.5 Vehicle stability

3.5 Vehicle stability
Risk of accident During approval of the vehicle with body/equipment, a calculation of the centre of gravity height of the laden vehicle must be provided in accordance with EC Brakes Directive 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 unfavourablylocated centre of gravity (e.g. either at the rear, or very high or to one side) as conversions will have a considerable impact on the above characteristics and can therefore only be assessed by the body manufacturer. Risk of accident
The permissible axle loads must be complied with. If the permissible axle loads are exceeded on vehicles with ESP, this system may no longer function. The driver could lose control of the vehicle as a result and cause an accident.
On vehicles with ESP and unfavourably-located centres of gravity (e.g. either at the rear, or very high or to one side), the effectiveness of ESP may be limited depending on the attachments, body, installations or conversion and the intended use. The vehicle must therefore be driven with a suitably adapted driving style (slower cornering speed, smooth steering wheel movements). The permissible axle loads, gross vehicle weights and location of the centre of gravity must be observed. Neither in kerb condition nor with equipment installed nor with modifications having been carried out may the permissible wheel, axle, or gross vehicle weight ever be exceeded.
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3 Planning conversions 3.6 Tyres

3.6 Tyres
The body/equipment manufacturer must ensure that: the clearance between the tyre and the wing or wheel housing is sufficient even when snow or antiskid 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 documents) Risk of accident
!
Further information ( see page 14) and ( see page 35).
Exceeding the specified tyre load capacity or maximum permissible speed for the tyre can lead to tyre damage or cause the tyres to fail. You could thus lose control of the vehicle and cause an accident, injuring yourself or others. For this reason, only use tyre types and sizes which have been approved for your vehicle and observe the tyre load capacity and speed index required for your vehicle. In particular, you must also observe the national specifications for tyres. These specifications may specify a certain tyre type or prohibit the use of certain tyre types which are approved in other countries. If you have other tyres fitted: the wheel brakes or chassis components may be damaged wheel and tyre clearance can no longer be guaranteed the wheel brakes or chassis components can no longer function correctly
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3 Planning conversions 3.7 Bolted and welded connections

3.7 3.7.1 Bolted and welded connections Bolted connections
Fuel line bolted connections. Tank fastening strap mountings. Rear-axle drive shaft mountings (side shafts). Brake disc to wheel hub and sliding calliper to rearaxle semi-trailing arm. Rear-axle semi-trailing arm mounting to the substructure. 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 Risk of accident
Bolted connections with particular relevance to safety (class "A" according to VDI 2862) The following bolted connections of the vehicle's safety and restraint systems, chassis and fuel supply may only be loosened and retightened in accordance with Mercedes-Benz service literature and regulations: Mountings for the airbags on the dashboard and steering wheel. Mountings for the windowbags underneath the roof trim. Mountings of the thorax bag to the seat. Attachment of driver's seat and front-passenger seat to their respective frames, and attachment of seat frames to the bodyshell, and, where applicable, partition cross member. Connections between the steering wheel and steering column. Bolted connections for the rear seat rails or seat pans. Connection between the parking brake adjuster and the longitudinal member. Brake unit and expansion tank mountings in the engine compartment. All bolted connections of the brake lines. Brake disc mounting on the wheel hub and brake calliper mounting on the front-axle swivel bearing. Bolted connection between the high-pressure oil line and the power-steering pump. High and low-pressure oil lines to the steering system. Steering system to the suspension subframe and drag link to the swivel bearing. Wishbone to suspension subframe. Suspension strut to the swivel bearing and vehicle body.
All bolt connections relevant to safety, e.g. wheel location, steering and braking functions, must not be altered, otherwise they may no longer function correctly. The driver could lose control of the vehicle as a result and cause an accident. Parts must be refitted in accordance with Mercedes-Benz after-sales service instructions and using suitable standard parts. We recommend the use of genuine Mercedes-Benz parts. VDI guideline 2862 must be applied to all installation work. A shortening of the free length of the clamping bolts, a substitution with stretch-shank bolts or the use of bolts with a shorter thread will definitely not be approved.
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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. Choice of welding procedure 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. Accessible sides 1 MIG plug welding 2 Resistance spot welding
i
Information is available from any Mercedes-Benz Service Centre. Additional tensioned parts must be of equal or greater strength than the preceding tensioned assembly. The use of Mercedes-Benz tightening torques assumes coefficients of friction for the bolts within the tolerance range [=0.08 0.14]. We recommend the use of standard Mercedes-Benz parts.
Resistance spot welding Resistance spot welding is a suitable procedure for welding overlapping parts when both sides are accessible. Avoid spot welding more than two sheets. Distance between the spot welds: You must observe the specified distances between welds (d=10e+10 mm) to avoid shunt effects.
3.7.2
Welded connections
General To maintain the high quality of welding required by Mercedes Benz, you should ensure that it is carried out by qualified personnel (certified according to DIN 8560 B1m). The following is recommended for achieving high-quality welds: Thorough cleaning of the areas to be welded Several short welding beads rather than one long one Symmetrical beads to restrict shrinkage Avoiding more than 3 welding seams in one place Avoiding welding in work-hardened areas d e Distance between the spot welds Sheet thickness
29

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). MIG plug welding If overlapping sheets are accessible from one side only, they can be welded using MIG plug welding or tack welding. If the parts are joined using punched or drilled holes and then plug welded, the drilling area must be deburred before welding.
e L
Sheet thickness Distance to the edge of the sheet
D = plug hole diameter [mm]
4.5
5 0.7
5.5 1
6.5
7 2
e = sheet thick- 0.6 ness [mm]
1.25 1.5
30

The mechanical properties can also be improved by using "slots" (l=2*b). Do not perform welding work on: assemblies such as the engine, transmission, axles, etc. the vehicle frame
i
Further information on welding work can be taken from the "Technical threshold values for planning" and "Damage prevention" sections ( page 44), the "Bodyshell" section ( page 56) and from the Mercedes Benz Workshop Information System (WIS). Anti-corrosion protection after welding Observe the corrosion protection measures ( page 46) specified after all welding work on the vehicle.
b I
Slot width Slot length
!
The information given by Mercedes-Benz in the "Damage prevention" ( page 45) and "Modifications to the basic vehicle" ( page 56) sections must be observed when welding.
Tack welding If the sheet is thicker than 2 mm, overlapping sheets can also be joined using tack welding (30 mm < L < 40 x e; d > 2 L).
d e L
Distance between tack weld centres Sheet thickness Length of tack weld
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3 Planning conversions 3.8 Noise insulation

3.8 Noise insulation
If modifications are carried out on any parts whose operation 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 regulations (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 affected.
!
If any modifications are made to the vehicle, the exterior noise of the vehicle must comply with the values specified in EC Directive 70/157/EEC.
!
In order not to affect the noise level of the vehicle when modifications are made, it must be ensured that noise levels in the vehicle interior are kept to a minimum when planning conversions ( page 69).
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3 Planning conversions 3.9 Maintenance and repairs

3.9 Maintenance and repairs
Maintenance and repair of the vehicle must not be hindered by the conversion. Maintenance points and assemblies must remain easily accessible. Observe the Owner's Manual/Operating Instructions. 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 recommends that the scope of maintenance work to be carried out on the conversion parts corresponds to the Mercedes-Benz maintenance 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 maintenance instructions for conversion work and for any additional equipment installed must be included with the vehicle in the language of the country of use on delivery by the body/equipment manufacturer.
!
The battery may be damaged if not used for long periods. This must be avoided by disconnecting the battery and storing it appropriately ( page 34). DaimlerChrysler AG will not carry the costs for any additional work which is made necessary by the conversion and is to be carried out during warranty, maintenance or repair work. The following must be observed by the body/equipment manufacturer before delivery of the vehicle: Check the headlamp adjustment or have this checked at a qualified specialist workshop. We recommend a Mercedes-Benz Service Centre. Retighten the wheel nuts to the specified torque.
3.9.1
Preparation for storing the vehicle
Storage in enclosed spaces: Clean the entire vehicle Check the oil and coolant levels Increase the specified tyre pressures by 0.5 bar Release the handbrake and chock the wheels Disconnect the battery and lubricate the cable lugs and terminals Storage in the open (less than 1 month): Perform the same tasks as for storage in enclosed spaces Close all air inlets and switch the heater to "Off" Storage in the open (more than 1 month): Perform the same tasks as for storage in enclosed spaces Fold the windscreen wipers away from the windscreen Close all air inlets and switch the heater to "Off" Remove the battery and store it according to the manufacturer's instructions ( page 34)
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3 Planning conversions 3.9 Maintenance and repairs

Maintenance of stored vehicles (in storage for more than 1 month) Check the oil level monthly Check the coolant level monthly Check the tyre pressure monthly Taking the vehicle out of storage 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
3.9.3
Preparation for handing over the converted vehicle
The work and modifications carried out must be entered in the Service Booklet by the body manufacturer. Checking the entire vehicle The vehicle should be checked for faults and any damage repaired. If it is not known how long a vehicle with a hydraulic brake system has been out of use, the brake fluid must be renewed. The brake fluid must be renewed every two years. Checking the battery The battery charge must be tested before delivering the vehicle ( page 34). Checking the tyres The tyres must be checked for the correct pressure and for damage before the vehicle is delivered. Damaged tyres must be replaced. Checking the wheel alignment If is recommended that the wheel alignment is checked if modifications have been made by a bodyshop. You will find further information in the Mercedes-Benz Workshop Information System (WIS).
3.9.2
Battery maintenance and storage
To avoid damage to the battery, disconnect the battery if the vehicle is to be parked up for a period longer than 1 week. If the vehicle is parked up for periods longer than 1 month, remove the battery and store it in a dry place at a temperature between 0 C and 30 C. The battery must be stored in an upright position. The battery charge must be above 12.55 V. If the voltage drops below 12.55 V, but is still above 12.1 V, the battery should be charged.
!
If the battery voltage drops below 12.1 V, it will be damaged and will have to be replaced.
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3 Planning conversions 3.10 Optional equipment

3.10 Optional equipment
To convert the vehicle in the best possible way, we recommend 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 available items of optional equipmen. Optional equipment (e.g. reinforced springs, frame reinforcement, auxiliary tanks, anti-roll bars, etc.) and retrofitted equipment increases the unladen weight of the vehicle. The actual vehicle weight and axle loads must be determined by weighing before conversion work. Not all optional equipment can be installed in any vehicle without problems. This applies particularly to retrofitting.
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4 Technical threshold values for planning 4.1 Basic vehicle threshold values
4.1 Basic vehicle threshold values 4.1.3 Parts which must not be welded
!
This section contains the most important technical threshold values required for planning the basic vehicle. Furthermore, you will also find information in the other sections in the current body/equipment mounting directives.
Vehicle width Without additional headlamps: 1,981mm (ECE R48) in general: 2,550 mm (Section 42, Paragraph 3 of the German road traffic licensing regulations (StVZO))
4.1.4
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 prevention" ( page 45) and "Planning conversions" sections ( page 28).
4.1.1
Steerability
In all vehicle load states, the front axle load must be at least 25% of the gross vehicle weight. Comply with the permissible axle loads.
4.1.5
Parts in which holes may not be drilled
A and B-pillars chassis the vicinity of load application points (e.g. axle connections) front-axle or rear-axle supporting points the vicinity of the airbags
4.1.2
Extreme permissible positions of centre of gravity

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)
x direction:
!
Holes in the longitudinal frame member are a result of the production process and are not suitable for all bodies and their equipment, fittings and conversions. The use of holes from the production process is not permitted, as such use could result in damage to the chassis frame. You can obtain further information in the "Planning conversions" section ( page 28).
y direction:
When the vehicle is laden, the wheel load (1/2 the axle load) must not be exceeded by more than 4%.
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4 Technical threshold values for planning 4.2 Chassis threshold values

4.2 4.2.1 Chassis threshold values Permissible axle loads
See the "Technical data" section ( page 95).
4.2.2
Approved tyre sizes

Rim Tyres 195/65R16 C 100/98T Load (kg) 800 Comments only panel van and only for permissible gross vehicle weight 2.77tons only steel rims (as summer and winter tyres) the use of snow chains is only possible with winter tyres series production with steel rims for Traveliner, panel van with a permissible gross vehicle weight of 2.94tons aluminium rims fitted as optional equipment the use of snow chains is only possible on winter tyres with steel rims series production with steel rims aluminium rims fitted as optional equipment the use of snow chains is not possible series production with steel rims aluminium rims fitted as optional equipment the use of snow chains is not possible only aluminium rims the use of snow chains is not possible
6J x 16" ET54 steel
6J x 16" ET60 steel/ aluminium
205/65R16 C 103/101T (99H)
875 (775)
6J x 16" ET60 steel/ aluminium 6J x 16" ET60 steel/ aluminium 7J x 17" ET56 aluminium
225/60R16 C 101/99H Summer tread and all season tread 225/60R16 Rf 102H Summer tread 225/55R17 Rf 101H (-V) Summer tread
825
850
825
4.2.3
See:
Turning circle diameter
4.2.4
Modifications to the axles
Section 32d of the German road traffic licensing regulations (StVZO) European Union: 97/27/EC European Union: 96/53/EC
Modifications to the chassis and axles are not permitted ( page 52).
4.2.5
Modifications to the steering system
Modifications to the steering system are not permitted ( page 52).
37
4 Technical threshold values for planning 4.2 Chassis threshold values

4.2.6 Modifications to the brake system
Modifications 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 regulations (StVZO) for vehicles with a permissible gross vehicle 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 alignment
Modification of the wheel alignment is not permitted ( page 52).
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4 Technical threshold values for planning 4.3 Bodyshell threshold values

4.3 4.3.1 Bodyshell threshold values Modifications to the bodyshell
See the "Modifications to the basic vehicle" section ( page 56). Lowering the wheel arches is not permitted. No modifications to the cross member structure from the front of the vehicle to behind the B-pillar are permitted. Modifications to the rear portal, including the roof area, are not permitted. If any modifications are made to the load-bearing structure, a resulting structural rigidity equal to that of the basic vehicle must be achieved. The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained. It is not permissible to drill holes in or perform welding work on the A-pillar or B-pillar. In the event of modifications to the sidewall, the rigidity of the modified body must be equal to that of the basic vehicle.
4.3.2
Vehicle roof/roof load

Maximum roof loads High roof [kg] 50
Normal roof [kg] 150
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.
39
4 Technical threshold values for planning 4.4 Engine periphery/drive train threshold values
4.4 4.4.1 Engine periphery/drive train threshold values Fuel system
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 permitted. Propeller shafts cannot be extended or shortened. It is not possible to retrofit any engine speed control equipment, other than that which is available as optional equipment.
40
4 Technical threshold values for planning 4.5 Interior threshold values

4.5 4.5.1 Interior threshold values Modifications to the airbags and belt tensioners 4.5.2 Modifications to the seats
Risk of accident
Risk of injury
Modifications to the airbag system and the belt tensioner system are not permitted. Modifications to or work incorrectly carried out on a restraint system (seat belt and its anchorages, belt tensioners or airbags) or their wiring could result in the restraint systems no longer functioning correctly. Airbags or belt tensioners, could then, for instance, fail in accidents with sufficient deceleration or could be activated unintentionally. Modifications to airbag components, or in the vicinity of the airbags, are not permitted. Subsequent modifications to the roof lining are not permissible on vehicles equipped with windowbags. The vehicle interior must be designed in such a way that airbags can fully deploy without impediment. Modifications to the area around the airbag control unit are not permitted. You can obtain further information in the "Modifications to the basic vehicle" section ( page 63).
Modifications to the driver's and front-passenger seat are not permitted. Seats may not be mounted on the wheel housing. The seats could be torn out of their anchorages in an accident. You can obtain further information in the "Modifications to the basic vehicle" ( page 52) and "Modifications to the interior" sections ( page 88).
41
4 Technical threshold values for planning 4.6 Electrical system/electronics threshold values
4.6 Electrical system/electronics threshold values 4.6.3 Retrofitting electrical equipment ("e" mark)
See the "Modifications to the basic vehicle" section ( page 70).
All electrical equipment installed must be tested in accordance with EC Directive 94/54/EEC and must bear the "e" mark.
4.6.1
Electrical lines/fuses
Rated fusing current [A] 5 10 20 30 40 50 70 100 125 150 Wire crosssection [mm2] 0.5 1 2.5 4 6 10 46 25 35 50
Maximum permanent current [A] 0 4.9 5 9.9 10 18 19 28 29 35 36 48 49 69 70 98 99 123 124 148
4.6.4
Mobile communications systems
The maximum transmission output must not be exceeded. Frequency range Short wave < 50Mhz 4 m waveband 2 m waveband 70 cm waveband 25 cm waveband Maximum transmission output [W] 100 20 50 35 10
4.6.5
CAN bus
It is not permitted to tamper with the CAN bus or components connected to it.
4.6.2
Vehicle outline and side marker lamps
4.6.6
Electronic Stability Program
Under Section 51b, Paragraph 2 of the German road traffic licensing regulations (StVZO), all vehicles with a total width of 2.10 m or over are required to be equipped with vehicle outline lamps.
The location, spatial orientation and attachment of the ESP yaw rate sensor must not be modified. Modifications to the lines and ESP components are not permitted. Modifications to the area around the ESP yaw sensors are not permitted.
42
4 Technical threshold values for planning 4.7 Additional equipment threshold values
4.7 Additional equipment threshold values
Additional equipment must never obstruct vehicle components nor impair their clearance and operation.
43
5 Damage prevention 5.1 Brake hoses/cables and lines

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Accident prevention regulations must be observed when working on the vehicle. Warning
!
Specific national guidelines and laws must be observed.
Work carried out incorrectly on the brake hoses or cables may impair their function. This may lead to failure of components or parts relevant to safety.
5.1
Brake hoses/cables and lines
Plastic lines and brake hoses must be covered, or removed if necessary before welding, drilling, grinding or working with cutting discs.
Check the system for pressure loss and leaks after installing hydraulic lines. No other lines may be secured to the brake hoses. Lines must be protected from heat with appropriate insulation. The lines must be routed in such a manner that pressure loss is not increased.
44
5 Damage prevention 5.2 Welding work

5.2 Welding work
The following safety measures must be observed to prevent damage to components caused by overvoltage during 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 protect them from welding spatter. Do not touch springs with welding electrodes or welding tongs. Cover the fuel tank and fuel system (lines, etc.) before carrying out welding work. The earth terminal of the arc welder must be connected 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 electrode 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 angular sections to prevent notching from welding penetration. Avoid welds in bends. A distance of at least 15 mm should be present between the weld and the outer edges.
!
Do not connect the arc welder earth clamp terminal to assemblies such as the engine, transmission or axles.
!
Welding work is not permitted on assemblies such as the engine, transmission or axles.
Warning
If in spite of the warning not to, welding work is performed in the vicinity of the airbags, this can lead to a malfunction of the restraint systems. For this reason, it is not permitted to perform welding work near the airbags. In Germany, the handling, transportation and storage of airbag units is subject to the law concerning hazardous explosive substances (Gesetz ber explosionsgefhrliche Stoffe).
!
Further information on welding work can be taken from the "Planning conversions" ( page 28), "Modifications to the basic vehicle" ( page 52) and "Bodyshell" ( page 56) sections and from the Mercedes-Benz Workshop Information System (WIS).
45
5 Damage prevention 5.3 Corrosion protection measures

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. Planning measures 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
!
If two different metals are connected through an electrolyte (e.g. atmospheric humidity), a galvanic connection is created. Electrochemical corrosion occurs, with the baser of the two metals being damaged. The further apart the two metals are in the electrochemical potential series, the more intense electrochemical corrosion becomes. Electrochemical corrosion must therefore be prevented by treating the components appropriately or isolation, or it must be kept to a minimum by selecting suitable materials.
1 2
Insulating washers Insulating sleeves
The use of electrical insulation such as washers, sleeves or bushings can prevent contact corrosion. Avoid welding work on inaccessible cavities.
46
5 Damage prevention 5.3 Corrosion protection measures

Component design measures Corrosion can be reduced by design measures, in particular by the arrangement of the joints between the same or different materials. There is a risk of dirt or humidity accumulating in corners, edges, beads and folds. Corrosion protection can be implemented at the design stage by using suitable surfaces and run-offs and avoiding gaps where components are joined. Gaps at welded connections caused by the design and how to avoid them Coating measures 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). After all work on the vehicle Remove drilling swarf. Deburr sharp edges. Remove any burned paintwork and thoroughly prepare surfaces for painting. Prime and paint all unprotected parts. Preserve cavities with wax preservative. Carry out corrosion protection measures on the underbody and frame parts.
suitable (welded through)
unsuitable (gaps)
47
5 Damage prevention 5.4 Painting

5.4 Painting
Check the compatibility of the paint before painting over. To prevent colour deviations when painting, we recommend 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
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Do not exceed a temperature of 80 C for drying the paint.
48
5 Damage prevention 5.5 Towing and tow-starting

5.5 Towing and tow-starting
Warning
Before towing or tow-starting, please make sure that you read the section on towing in the detailed Owner's Manual/Operating Instructions. You could otherwise fail to recognise dangers, which could result in injury to yourself or others.
!
Failure to observe the Owner's Manual/Operating Instructions can result in damage to the vehicle.
49
5 Damage prevention 5.6 Storing and delivering the vehicle

5.6 Storing and delivering the vehicle
Storage To prevent damage when storing vehicles, we recommend that you maintain and store the vehicle as described in the manufacturer's instructions ( page 33). Delivery To prevent damage to the vehicle or to repair any existing damage, we recommend that the vehicle be subjected to a full function check and a complete visual inspection before it is handed over ( page 34).
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5 Damage prevention 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 compatibility in the vehicle. When electric or electronic systems are retrofitted, they must be tested in terms of their electromagnetic compatibility, 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
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6 Modifications to the basic vehicle 6.1 Chassis

6.1.2 Springs/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. We recommend the use of genuine Mercedes-Benz springs. Do not damage the surface or corrosion protection of the springs during installation work.
6.1 6.1.1
Chassis Basic chassis
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
Modifications to chassis components are not permitted. Risk of accident
Unauthorised modifications to chassis components can adversely affect the vehicle's handling characteristics, even leading to unstable handling characteristics. Modifications to chassis components are therefore not permitted. This is especially valid for: Front transverse link: modification of the wheel alignment is not permitted. Front axle subframe: no changes to the front-axle subframe may be made when attaching additional equipment and making other modifications. Anti-roll bars: modifications to the front and rear anti-roll bars (diameter, material) and retrofitting require a certificate of endorsement from the relevant department. Rear axle: modifications are not permitted. Brakes: modifications are not permitted. Equipment, sensors, line routing for ESP/ABS Modifications are not permitted.
The use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permitted. On vehicles with ESP, this may otherwise result in the ESP system not functioning correctly and failing.The driver could lose control of the vehicle as a result and cause an accident.
!
Observe the items of optional equipment available at the factory as codes ( page 35).
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6.1.3 Brake system
Routing lines
Risk of accident
Risk of accident
Work carried out incorrectly on the brake hoses, lines or cables may impair their function. This may lead to failure of components or parts relevant to safety. Have work on the brake hoses, lines or cables carried out only at a qualified specialist workshop. When the work is complete, check that the brake system is working properly. We recommend that the brake system be inspected and approved by a technical inspection centre. If the routing has to be altered, avoid routing across sharp edges and through narrow cavities or near moving components. Hydraulic brake system Hydraulic brake lines are to be completely replaced by approved 4.75 mm x 0.7 up to 6 mm x 0.7 mm rolled laminated tube. The bending radius must be > 17.5 mm. Lines must only be shaped in a bending machine. The cross-section must not be reduced. Attach nuts (part no. 000 428 04 72) to the ends of the lines and prepare a flange (F DIN 74234). The inside of the lines must be cleaned before installation. The use of plastic lines in hydraulic systems is not permissible. If the standing time of a vehicle with hydraulic brake system is not known, the brake fluid must be renewed. The brake fluid must be renewed every two years.
An adequate distance between brake lines and heat sources, sharp-edged and moving parts must be maintained. Otherwise, the brake system function could be impaired or the brake system could even suffer total failure due to the formation of bubbles in the brake fluid or from chafing points in the brake lines. For securing, we recommend using Mercedes-Benz genuine brake line support brackets to clip in the brake line. The maximum permissible distance between loops is 500 mm. Routing the lines along the brake hoses No other lines may be secured to the brake hoses.
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Disc brakes Cooling must not be impaired by attaching spoilers below the bumper, additional hub caps or brake disc covers, etc. Risk of accident
6.1.4
Pneumatic suspension
Risk of accident
No modifications may be made to the air inflow and outflow of the brake system. Modifications to the steering and brake system could result in this system no longer functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident. Overheating of the brake system may cause tyre damage and will also impair braking ability. For this reason, make sure there is a sufficient supply of cooling air at all times.
The use of springs and shock absorbers which do not correspond to the characteristics of standard parts or parts available as optional equipment is not permitted. This applies to the retrofitting of pneumatic suspension in particular. This may otherwise result in ESP, for example, not functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident.
Risk of accident
Modifications to parts of the brakes (e.g. brake callipers, discs, etc.) are not permitted. Modifications to parts of the brakes could result in this system no longer functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident. Additional brakes/retarder A certificate of endorsement from the relevant department is required when retrofitting additional brakes.
54

6.1.5 Wheels/tyres 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
For this reason, only use tyre types and sizes which have been approved for your vehicle and observe the tyre load capacity and speed index required for your vehicle. In particular, comply with national regulations for tyres. These regulations may specify a certain type of tyre for your vehicle or forbid the use of certain tyre types which may be permitted in other countries. If you fit tyres other than these: the wheel brakes or chassis components may be damaged free movement of the wheels and tyres can no longer be guaranteed the wheel brakes or chassis components may no longer function correctly The body/equipment manufacturer must ensure that: the distance between the tyre and the wing or wheel housing is sufficient even when snow or anti-skid chains are fitted, with the suspension fully compressed (including any axle twist). Specifications in the tender drawings must be observed only permissible tyre sizes are used (see vehicle documents) ( page 14) ( page 37) only approved wheels are used ( page 14)
i
Further information on wheels/tyres can be obtained from any Mercedes-Benz Service Centre or in the "Optional equipment" section ( page 35).
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6 Modifications to the basic vehicle 6.2 Bodyshell/bodywork

6.2 6.2.1 Bodyshell/bodywork General notes on the bodyshell/ bodywork
Welding work on the bodyshell Welding work may only be performed by skilled personnel.
Conversions must not have a negative effect on the operation or strength of the vehicle's assemblies or controls or on the strength of load-bearing elements. In the case of vehicle conversions, it is not permissible to make modifications that affect the operation or freedom of movement of vehicle parts (e.g. during maintenance and inspection work) or ease of access to these parts. Observe the following: Modifications to the wheelbase are not permitted. No modifications to the cross member structure from the front of the vehicle to behind the B-pillar are permitted. On no account are modifications to be made to the roof area or to the rear portal. The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained ( page 61). Avoid sharp-edged corners. It is not permissible to drill holes in or perform welding work on the A-pillar or B-pillar. The maximum permissible axle loads must not be exceeded. Trailer connections must be checked for correct operation. If a trailer coupling is installed, the necessary reinforcements must be present ( page 87). Holes in the longitudinal frame member are a result of the production process and are not suitable for all bodies and their equipment, fittings and conversions The use of holes from the production process is not permitted, as such use could result in damage to the chassis frame.
i
Further information on welding work can be found in the sections entitled "Planning of conversions" ( page 28), "Damage prevention" ( page 45) and "Bodyshell" ( page 56) and in the Mercedes-Benz Workshop Information System (WIS). Welding work may not be performed on the lower chord of the frame. Plug welding is only permissible in the vertical frame of the longitudinal frame member. Do not perform welding work in bends. Risk of accident
If welding work is performed in the vicinity of the airbags, this can lead to a malfunction of the airbag units (e.g. unintentional deployment during operation; total failure) ( page 63). For this reason, it is not permitted to perform welding work near the airbags. In Germany, the handling, transportation and storage of airbag units is subject to the law concerning hazardous explosive substances (Gesetz ber explosionsgefhrliche Stoffe).
56

Drilling work on the chassis
6.2.3
Sidewall, windows, doors and flaps
Do not drill holes: on the lower chord of the frame in areas with a supporting function for the rear axle or parts fastened to the frame at load application points After drilling, deburr and countersink all holes, remove as much swarf as possible and treat the holes with body cavity sealing.
Sidewall If any modifications are made to the sidewall on the panel van or Traveliner, a resulting structural rigidity equal to that of the basic vehicle must be achieved. The function of the roof frame must not be impaired and must be maintained. A certificate of endorsement from the relevant department is required ( page 12).
!
Observe the corrosion protection measures ( page 46) specified after all work on the vehicle. Windows Windows must be set in a stable frame. This frame must be positively joined to other bodywork components. If the retrofitting of windows (panoramic glass sunroof) affects the load-bearing structure of the basic vehicle, (pillars, reinforcements, connection to roof arches), a resulting structural rigidity equal to that of the basic vehicle must be achieved. Doors and flaps If modifications are made to the doors which affect the load-bearing structure, (cross members, frames, pillars, reinforcements, connection to roof arches), a resulting structural rigidity equal to that of the basic vehicle must be achieved.
6.2.2
Modifying the partition
If the partition is to be cut out due to conversion or installation work, this is possible in conjunction with a continuous frame. Partitions can be fully or partially removed. Observe the "Modifications to closed panel vans" section for notes on how to do this ( page 89). Risk of accident
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags).
!
Modifications to the rear portal including the roof area are only permitted in extreme cases and with a certificate of endorsement from the relevant department ( page 12).
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6.2.4 Wings and wheel arches
Risk of accident
Lowering the wheel arches is not permitted. The vehicle (e.g. wheel arches and tyres) could otherwise be damaged.
6.2.5
Chassis end cross-member
Modifications to the chassis end cross-member are only possible after consultation with the relevant department ( page 12).
6.2.6
N23.00-2031-00
Bodyshell
Rear portal area (certificate of endorsement required)
Observe the following: Modifications to the wheelbase, windscreen, windscreen frame, the A-pillar or the B-pillar and tampering with the longitudinal member structure, are not permitted. No modifications to the cross member structure from the front of the vehicle to behind the B-pillar are permitted. All modifications must be depicted in their entirety in advance by drawings and calculations and must be approved by the vehicle manufacturer. The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained. Avoid sharpedged corners. The seat mounting brackets for the 1st and 2nd rear seat rows and the standard lashing eyelets and their mounting points must be used where possible to secure retrofitted installations in the vehicle interior. Brackets (plug welds) must be used to secure additional equipment to the longitudinal and cross members and require approval. It is not permissible to drill holes in or perform welding work on the A-pillar or B-pillar. The maximum permissible axle loads must not be exceeded.
The seats must be directly accessible from the outside through a door or from the cab. It must be possible to open locked doors quickly and easily from the inside. The doors must open wide enough and the door entrances must be shaped in such a way as to enable persons to get in and out of the vehicle safely and comfortably. The distance between the road surface and the lowest step must be no greater than 400 mm. Fittings must allow sufficient clearance to the interior door handles regardless of the position of the load compartment sliding door (trap guard). Modifications to the central locking system in the immediate area around the door or in the area of the pillars or cross members are not permitted.
!
Observe the corrosion protection measures ( page 46) specified after all work on the vehicle.
58

Trailer connections must be checked for correct operation. If a trailer coupling is installed, the necessary reinforcements must be present. If the vehicle is equipped with driver's and front-passenger windowbags, it is prohibited to cut into the partition ( page 57) for the purposes of conversion or attachment 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. Location of roof arches: behind the front doors (B-pillar) in the middle of the vehicle behind the load compartment sliding door (C-pillar) The new roof structure must be as rigid as the standard roof. The minimum moment of inertia required per roof arch is Ix = 4,000 mm4.
The arches must be connected to the side panels in such a way that a force-locked connection is guaranteed (bend-resistant connection of arch and roof frame). Plastic roofs have limited suitability for installing roof hatches. The roof load-bearing capacity is limited. In the event of any deviation from these specifications, approval is required from the relevant department ( page 12). If a raised roof is fitted, at least 2/3 of the original roof area must be retained. Pillars or other load-bearing components must not be removed. The height of the roof may only be increased in conjunction with integrated arches and reinforcement frames. The vehicle's centre of gravity must not be displaced upwards. No roof load is permissible if the increase in roof height is permanently connected to the body. When fitting a structural support system direct to the rivet nuts, use only mounting brackets that have been approved by DaimlerChrysler or brackets conforming to drawings issued by DaimlerChrysler which provide a direct attachment to the roof. It is only permissible to fit other roof support systems to these brackets. A load of 25 kg for each support point may not be exceeded. However, it is not permissible to exceed a maximum total load of 150 kg for a normal roof and 50 kg for a high roof.
6.2.7
Underbody panelling
It is necessary to treat the entire underbody with additional anti-corrosion protection if parts of the standard underbody panelling are removed. Removing parts of the panelling could create additional airflow noise.
6.2.8
Roof of panel van/Traveliner
Risk of accident
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). Number of roof arches If the roof skin is separated from the roof arches and it is not possible to fit a continuous sectional frame, at least two additional roof arches must be fitted to the front and rear of the area from which the arch was removed.
59

Superstructure Observe the permissible centre of gravity location and axle loads. Increasing the roof height The height of the roof may only be increased in conjunction with integrated arches and reinforcement frames.
!
If roof arches or load-bearing parts are removed or damaged, they must be replaced ( page 60). Maximum roof load Normal roof [kg] 150 High roof [kg] 50
!
The new roof structure must be as rigid as the standard roof.
The threshold values for the maximum vehicle centre of gravity location must not be exceeded. Modifications to the cab roof Risk of accident
Risk of accident
The maximum permissible centre of gravity location must not be exceeded. On vehicles with ESP, this may otherwise result in the ESP system not functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident ( page 82). Retrofitting a raised roof Risk of accident
Modifications to the cab must not impair the function of parts relevant to safety (such as airbag units, sensors, pedals, gear lever, lines, etc.). This may lead to failure of components or parts relevant to safety. No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). The "Cab sliding/tilting glass sunroof" code DS1 can be supplied as optional equipment from the factory ( page 35). Plastic roofs have limited suitability for installing roof hatches. The roof load capacity is limited ( page 39).
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). Plastic roofs have limited suitability for installing roof hatches. The roof load-bearing capacity is restricted (see the following table). If a raised roof is fitted, at least 2/3 of the original roof area must be retained.
!
If roof arches or load-bearing parts are removed or damaged, they must be replaced. Observe the permissible centre of gravity location and maintain the permissible axle loads.
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6 Modifications to the basic vehicle 6.3 Engine periphery/drive train

6.3 6.3.1 Engine periphery/drive train Fuel system 6.3.3 Engine cooling
It is not permissible to modify the cooling system (radiator, 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 objects 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. Risk of accident
Modifications to the fuel system may only be carried out with the approval of the relevant department ( page 12). The free space for the fuel filler neck, the fuel tank and fuel lines must be maintained
!
Inadmissible modifications to the fuel system (tank, lines, etc.) may impair the vehicle's driving characteristics and lead to engine emergency running mode. For connections supplying fuel for auxiliary heating, the procedure for design approval must be followed. Environmental note
Incorrectly performed modifications to the fuel system can cause damage to the environment.
Changes to the air flow in the brake system may impair braking performance. In extreme cases, overheating of the brake system may cause tyre damage and will also impair braking ability. The permission of DaimlerChrysler AG must therefore be sought for modifications which impair the flow of cooling air to the brake system ( page 13).
6.3.2
Exhaust system
No modifications may be made to the exhaust system. In the case of all conversions, the following minimum distances to plastic lines, electric cables and spare wheels must be maintained: 200 mm when the exhaust system is without shielding 80 mm when there is sheet metal shielding 40 mm when there is sheet metal shielding and additional insulation Additional shielding is required Around the control units. Around the assemblies, equipment and fittings, if they are not made from heat-resistance material.
61
6 Modifications to the basic vehicle 6.3 Engine periphery/drive train

6.3.4 Engine air intake
Modifications 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. Warm air 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: Engine kW Air requirement (m3 /min) Filter area Specific filter area (cm2 /m3 /min) with standard filter paper (cm2) Euro 4 19,100 19,100 19,100 19,100 2,110 4,032 3,623 3,012 -EU4/III -3,333 3,048 --
Euro 4 OM 646 DE22LA 65 80 110 M 112 E32 165 6.2 6.9 8.3 9.0
EU4/III -7.5 8.2
Water Make sure that water cannot reach the intake points through any fresh-air intakes. The flow rate at the intake points must not be increased by modifications to the opening of the intake points. Dust/dirt The area of the air intake chamber must be protected against dust being thrown up from the wheel housing. Increased dust intake will lead to shorter maintenance intervals for the air cleaner.
6.3.5
Propeller shafts
!
Modifications to the drive train are not permitted.
62
6 Modifications to the basic vehicle 6.4 Interior

6.4 6.4.1 Interior General 6.4.2 Safety equipment
Seat belts 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 legislation must be observed in all other countries. Airbags and belt tensioners The driver's and front-passenger airbag units, the windowbags and the belt tensioners are pyrotechnic components. Handling, transportation and storage are subject to legislation concerning hazardous explosive substances (for example, the "Gesetz ber explosionsgefhrliche Stoffe" in Germany) and must therefore be reported to the relevant 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 accordance with the relevant safety regulations.
On no account may modifications be made in the cockpit and above the vehicle body waistline. Risk of injury
Modifications to the airbag system and the seat belt system are not permitted. Modifications to or work incorrectly carried out on a restraint system (seat belt and its anchorages, belt tensioners or airbags) or their wiring could result in the restraint systems no longer functioning correctly. Airbags or belt tensioners, for example, could thenfore fail in accidents with sufficient deceleration or could be activated unintentionally. This applies in particular to the inflation areas of the airbags (wooden trim, additional attachments, mobile phone holders, bottle holders, etc.). See the illustrations of airbag deployment areas for more information ( page 64). The permissible centre of gravity location and maximum permissible axle loads may not be exceeded. You will find information on motor caravan conversion in the "Motor caravan" section ( page 92). For the conversion of vehicles in Germany, appropriate bulletins can be ordered from the relevant technical testing centres for motor vehicles (e.g. TV, DEKRA). The interior fittings must be designed in such a way that there are no sharp edges or corners (accident prevention). Fittings must be made of flame-resistant materials and be fitted securely. Unimpeded access to the seats must be ensured. There must not be any protruding parts, edges or corners which could cause injury in the area of the seats.
63

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 deployment area of the thorax bags, driver's and front-passenger airbags and windowbags. Driver's seat backrest with cover panel
Deployment area of the thorax bag in the front-passenger seat Driver's airbag deployment area
Front-passenger airbag deployment area
64

Airbag control unit and side-impact sensors It is not permitted to change the installation point, spatial orientation and attachment of the occupant-safety airbag control units and the side-impact sensors on vehicles with windowbags from those of the standard vehicle. It is not permitted to attach or locate other vehicle components on the airbag control unit, nor on the sideimpact sensors and their points of attachment. Risk of injury Deployment and coverage area of the front-passenger windowbag Front of vehiclel The airbag units fitted in the Vito/Viano include a driver'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 approval has been granted by DaimlerChrysler AG.
Vehicle parts that produce vibrations must not be attached in the vicinity of airbag control units or sensor mounting points, otherwise the reliable functioning of the front airbags, windowbag and belt tensioners is no longer guaranteed. This could result in personal injury. The airbag control unit, including the trigger sensors and the ESP yaw rate sensor, is installed in the footwell/ centre console behind the trim.
!
It is not permissible to modify the floor structure in the area of the airbag control unit.
Risk of injury
In the event of modifications to the vehicle structure by the body manufacturer, such as: Modifications to the seats and thus changes to the kinematics of the occupants in the event of an impact Modifications to the front end Installation of parts in the vicinity of airbag inflation points or airbag deployment areas Installation of non-Mercedes-Benz seats Modifications to the A-pillar and B-pillar, the roof frame and its lining reliable operation of the front airbags, windowbags and belt tensioners can no longer be guaranteed. This could result in personal injury.
3
N54.21-2111-00
ESP yaw rate sensor Airbag control unit Front of vehicle The ESP yaw rate sensor is susceptible to shocks and must be stored where it is free from vibrations.
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Risk of accident
If you drop the ESP yaw rate sensor, it must not be refitted to the vehicle for safety reasons. In such cases, a genuine Mercedes-Benz replacement must be fitted. The side-impact sensors are located on either side of the vehicle behind the trim at the bottom of the B-pillar (the same on the left side of the vehicle).
Storing airbag and belt tensioner units Airbag and belt tensioner units must be stored in accordance with the Second Ordinance to the German Explosives Law (Zweite Verordnung zum Sprengstoffgesetz) dated 17/04/86. This ordinance allows small amounts of substances and materials to be stored in secure areas as specified in the German Explosives Law without requiring special storage permission. Class T1 pyrotechnic materials may only be stored in limited quantities on premises used for commercial purposes. Under Section 6 of the appendix to the Second Ordinance to the German Law on Hazardous Explosive Substances, the following maximum storage quantities are permissible without obtaining special approval from the relevant authority, where materials are stored on premises used for commercial purposes and certain conditions are fulfilled (e.g. steel cabinet). General storage space: 20 kg gross weight The gross mass of the component which has been approved in accordance with the law on explosive substances is used to calculate the actual stored mass.
N54.21-2110-00
Side-impact sensor Front of vehicle Transporting airbag and belt tensioner units For in-plant transport these sensors should always be kept in their spare parts packaging and in the vehicle luggage or load compartment.
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It is strictly forbidden to transport any sort of airbag units in the passenger compartment. The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag and windowbag.
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The weights of the individual components are: Driver's airbag Front-passenger airbag Windowbag Thorax bag Belt tensioners 1.6 kg 3.2 kg 0.6 kg 0.7 kg 1.2 kg (integrated in belt reel) 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 exposed 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 tensioner units may only be subjected to electrical tests using the prescribed testers when the airbag and tensioner 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 disconnected prior to removal of the airbag and belt tensioner unit. Disposing of airbag and belt tensioner units The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag and windowbag. 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 pyrotechnic materials could cause injury if activated incorrectly.
Fitting and removing airbag and belt tensioner units The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag, windowbag and thorax bag as optional equipment. Test and installation work may only be carried out and supervised by specialist personnel. The airbag and belt tensioner units must be fitted without delay and immediately on removal from storage. The vehicle battery must have been disconnected, negative pole covered or negative terminal covered and test coupling/connection disconnected. If work is interrupted, the airbag and belt tensioner units must be locked away again. Precautionary measures for the handling of airbag and belt tensioner units Risk of injury
Risk of injury
Removed airbag units must always be stored in such a way that the upholstered side faces upwards. If the upholstered side faces down, the airbag control unit could be thrown through the air if it is triggered unexpectedly. The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag and windowbag.
Disposing of the airbag and belt tensioner units is carried out by qualified personnel. Comply with the accident prevention regulations. Hazards arise from disposal by cutting torch, smelting, or if primed components are disposed of on open fires or on smouldering fires on waste disposal sites, for example.
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To prevent these safety measures from resulting in an increased workload, we recommend that pyrotechnic materials 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 responsibly for disposal must sign a declaration containing the obligation to dispose of the pyrotechnic materials in accordance with accident prevention regulations. Agreements of this kind must ensure that it is not possible to sort out pyrotechnic materials after disposal and to forward hand them on for reconditioning. Handling airbag and belt tensioner units The airbag units fitted in the Vito/Viano include a driver's airbag, front-passenger airbag and windowbag. 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 factory is only valid if the seats are secured in original mountings. Any deviation from these specifications must be approved by the relevant department. Any rear bench seat with 2-point or 3-point belts that deviates from the standard seating must conform to the requirements of ECE R14. It is not permissible to fit seats without belts. The ECE R14 test certificate (tensile test including floor assembly) must be submitted to DaimlerChrysler AG for approval. Test certificates for seats mounted on rigid panels are not accepted. Risk of accident
It is not permissible to re-cover seats protected by thorax bags (observe the relevant notes in the Owner's Manual/Operating Instructions).
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Information on retrofitting seats can be obtained in the "Conversion work" section ( page 88).
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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. Floor area A structure as shown in the illustration is advisable for insulation and soundproofing. An additional covering with heavy-duty insulating foil may be provided in the area of the wheel arches. Roof and side panels Rock wool, glass wool, fibrous web or soft, open-pore, PE- or PU-based foam are well suited for providing effective insulation. The inside must be covered with a sound-transmissive material (perforated card, plastic, fabric). Risk of accident
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Insulating films, e.g. bituminous felt, possess limited temperature resistance. They should therefore not be installed in the immediate vicinity of the engine or exhaust system.
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags). Seals Openings, gaps and slots between the engine compartment, the underside of the vehicle, the front bulkhead and the vehicle interior must be carefully sealed with a resilient material. Airing and ventilation openings may not be positioned in the immediate vicinity of sources of noise. In addition, manufacturers or suppliers of soundproofing materials should be consulted. They will be able to provide you with suggestions on how to design optimum noise insulation for your particular conversion.
6.4.5
Ventilation
The passenger compartment and the driver's seat must have adequate ventilation with provision for air to enter and exit. 1 2 3 4 Carpet (bonded underside) Wooden floor (12 mm plywood) Heavy-duty insulating foil (weight per unit area: 8 10 kg/m2) Load-bearing construction The windscreen and side windows demisting function must remain operational, especially if the driver's area forms part of the passenger compartment or if the layout and design of the interior does not correspond to that of the standard equipment.
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6 Modifications to the basic vehicle 6.5 Electrical system/electronics

6.5 6.5.1 Electrical system/electronics General notes 6.5.2 Lighting
Adjusting the headlamps Country-specific regulations shall apply. The headlamp basic setting must be observed (see vehicle identification plate). Only check the headlamp setting with the vehicle unladen (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 second 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.
Do not loosen or disconnect the battery terminals when the engine is running. Rapid-charge the batteries only after disconnecting both the positive and negative terminals from the vehicle's electrical system. A positive total charge balance must be ensured when additional electrical consumers are installed ( page 76).
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More detailed information can be obtained from the relevant department ( page 12). Electrical and electronic components must fulfil the test requirements of ISO 16750. Observe the notes on ( page 71) when installing additional batteries. Cables routed in the vicinity of exhaust systems must be covered with fireproof sleeves ( page 53). Cables must be routed such that there are no chafing points ( page 53). The battery must be disconnected if the vehicle is not in use for extended periods (more than 10 days). The battery must have sufficient charge when the vehicle is put into operation again ( page 34). Observe the Owner's Manual/Operating Instructions. Retrofitting a battery isolating switch Installation is only permissible after consulting the relevant department ( page 12).
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Headlamp basic setting: 1.0% = 10 cm 1.5% = 15 cm 2.0% = 20 cm etc. Installing lighting 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. Vehicle outline lamps/perimeter lamps Perimeter lamps increase passive safety and are required 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).
6.5.4
Power supply interfaces
Please observe the following if auxiliary electrical consumers are retrofitted: Batteries and alternators with higher power ratings can be supplied on request. Do not connect any additional consumers to fuses already in use. Do not connect any additional lines to existing lines (e.g. using insulation piercing connecting devices (IPCDs)). Provide for adequate fusing of extra equipment by installing additional fuses. Auxiliary electrical consumers must be connected via the + battery terminal installed ex works. Additional lines can be secured to the 6 mm threaded connection if additional fusing is provided.
6.5.3
Battery
Retrofitting an additional battery An additional battery may only be installed in the righthand seat base in conjunction with a cutoff relay. This battery may only be used to power specified auxiliary consumers such as the auxiliary heating, loading aids or electrical equipment in motor caravans (fridge, etc.). Maintenance and storage of the batteries Even low-maintenance batteries require care. Low-maintenance simply means that the fluid level does not need to be checked. All batteries are subject to self-discharge, and if it this inadequately monitored it could lead to battery damage due to deep discharging. Information on maintaining and storing batteries can be found in the "Planning conversions" section ( page 34).
If the vehicle's electrics/electronics are tampered with or impermissible installation work is carried out on them, operational safety may be jeopardised and the vehicle warranty/operating permit may be invalidated. Tampering of any kind with the vehicle electronics is not permitted for reasons concerning the warranty and operation of the vehicle, and to ensure that no faults occur (e.g. electromagnetic compatibility). The programmable special module (PSM) can be ordered or retrofitted using the code ED5. The fuses are located in the box under the seat (2 x 25 A), and the earth connection and CAN are near the PSM (front-passenger footwell).
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Information Rotary light switch position right-hand parking lamp Rotary light switch position automatic Rotary light switch position off Rotary light switch position side lamps Rotary light switch position dipped-beam headlamps Tailgate open Rotary light switch position front foglamps Rotary light switch position rear foglamp Rear window heating switched on Left-hand sliding door unlocked Right-hand sliding door unlocked Tailgate unlocked Hazard warning lamps active Left-hand turn signal active Right-hand turn signal active Rear window heating switch operated Hazard warning lamp switch operated Rear window wipe/wash switch operated Rear window intermittent wipe switch operated Anti-theft alarm system primed Front right-hand door unlocked Front left-hand door unlocked Air-conditioning compressor Terminal 58D (pwm) V signal (pwm) Daylight driving lights activated Crash event occurred Brake lamp controlled Load compartment centrally locked Front doors centrally locked Entire vehicle centrally locked Immobiliser deactivated Immobiliser activated Front left-hand door open Front right-hand door open Left-hand sliding door open Right-hand sliding door open Side lamps switched on Dipped-beam headlamps switched on Rear foglamp switched on Handbrake applied
N00.00-2638-20
PSM installation location Direction of travel The following information can be made available from the "signal pool" via the PSM by reprogramming the PSM parameters using Star Diagnosis. Information Terminal 15C Terminal 15R Terminal 15 Terminal 15X Terminal 50 Terminal 61 Distance covered Engine speed Stable idle Reverse gear engaged Left-hand turn signal operated Right-hand turn signal operated Main-beam headlamps operated Headlamp flasher operated Horn operated Single wipe operated Wipers operated Intermittent wipe operated Wipe stage 1 operated Wipe stage 2 operated Front fog lamps switched on Main-beam headlamps switched on Horn active Left-hand parking lamp switched on Right-hand parking lamp switched on Rotary light switch position left-hand parking lamp
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The following parameters can be determined via the PSM interface Designation Alarm functions ! Alarm functions have the highest priority. They must only be used in accordance with all legal regulations. PSM_NSW_EIN PSM_FL_EIN PSM_NSF_FL_INT PSM_IL_ALARM PSM_WBL_EIN PSM_SGH_EIN Steering column switch functions PSM_SGH_LENK PSM_BLI_LI_LSS PSM_BLI_RE_LSS PSM_FL_LSS PSM_LH_LSS PSM_WBL_EIN_OBF PSM_IL_VO_EIN PSM_IL_HI_EIN PSM_TIPP_WISCH_LSS PSM_WASCHEN_LSS PSM_SCH_W_INT_LSS PSM_SCH_W_1_LSS PSM_SCH_W_2_LSS PSM_HECK_WISCH PSM_HECK_INT PSM_HHS_EIN Horn Left-hand turn signal Right-hand turn signal Main-beam headlamps Headlamp flasher Hazard warning lamps Front interior light Rear interior light Windscreen wipers "single wipe"1) Windscreen wipers "wash" Windscreen wipers "intermittent" Windscreen wipers "stage 1" Windscreen wipers "stage 2" Activates rear window wiper 2) Rear window wiper intermittent wipe Rear window heating Flashes/alarm flashes front fog lamps (programmable) Flashes/alarm flashes main-beam headlamps (programmable) Flashes main-beam headlamps/front fog lamps synchronously/asynchronously (default: asynchronously) Interior light alarm Hazard warning lamp alarm Horn alarm (intermittent) Function
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Designation Rotary light switch functions PSM_PL_LDS PSM_PR_LDS PSM_AUTO_LDS PSM_AUS_LDS PSM_STL_LDS PSM_ABL_LDS PSM_NSF_LDS PSM_NSL_LDS
Central locking functions
PSM_V_ENTRI PSM_V_VERRI PSM_LR_ENTRI PSM_LR_VERRI PSM Gesamtfahrzeug entriegeln PSM Gesamtfahrzeug verriegeln Unlocks front of vehicle (driver's + front-passenger doors)3) Locks front of vehicle (driver's + front-passenger doors) Unlocks load compartment (all rear doors) Locks load compartment (all rear doors) Unlocks entire vehicle Locks entire vehicle
Function
Left-hand parking lamp1) Right-hand parking lamp Lights automatic (only in combination with rain sensor) Lights "off" Lights "side lamps" Lights "dipped-beam headlamps" Lights "front fog lamps"1) Lights "rear foglamp"
Sliding sunroof functions

PSM_SD_MH PSM_SD_AH PSM_SD_MSE PSM_SD_ASE PSM_SD_MOE PSM_SD_AOE PSM_SD_MSCH PSM_SD_ASCH PSM_PD_MH PSM_PD_AH PSM_PD_MSE PSM_PD_ASE PSM_PD_MOE PSM_PD_AOE PSM_PD_MSCH PSM_PD_ASCH Front sliding sunroof raises manually Front sliding sunroof raises automatically Front sliding sunroof lowers manually Front sliding sunroof lowers automatically Front sliding sunroof opens manually Front sliding sunroof opens automatically Front sliding sunroof closes manually Front sliding sunroof closes automatically Panorama sunroof raises manually Panorama sunroof raises automatically Panorama sunroof lowers manually Panorama sunroof lowers automatically Panorama sunroof opens manually Panorama sunroof opens automatically Panorama sunroof closes manually Panorama sunroof closes automatically
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Designation
Seat functions
PSM_SVL_VOR PSM_SVL_ZUR PSM_SVL_HI_AUF PSM_SVL_HI_AB PSM_SVL_LE_VOR PSM_SVL_LE_ZUR PSM_SVL_VO_AUF PSM_SVL_VO_AB PSM_SVL_KST_AUF PSM_SVL_KST_AB PSM_SVR_VOR PSM_SVR_ZUR PSM_SVR_HI_AUF PSM_SVR_HI_AB PSM_SVR_LE_VOR PSM_SVR_LE_ZUR PSM_SVR_LE_ZUR PSM_SVR_VO_AUF PSM_SVR_VO_AB PSM_SVR_KST_AUF Front left-hand seat adjusts forwards Front left-hand seat adjusts backwards Front left-hand seat raises height at rear Front left-hand seat lowers height at rear Front left-hand seat backrest forwards Front left-hand seat backrest backwards Front left-hand seat raises height at front Front left-hand seat lowers height at front Front left-hand seat raises headrest Front left-hand seat lowers headrest Front right-hand seat adjusts forwards Front right-hand seat adjusts backwards Front right-hand seat raises height at rear Front right-hand seat lowers height at rear Front right-hand seat backrest forwards Front right-hand seat backrest backwards Front right-hand seat backrest backwards Front right-hand seat raises height at front Front right-hand seat lowers height at front Front right-hand seat raises headrest
Function
Other functions
LADEN_AKT
1
Disables terminal 50 (e.g. if a battery charger is connected)
Important: Only one signal may be active at any time; therefore, use either the rotary switch or the electronics. 2 Important: Use buttons, not switches. 3 Important: Function requires approximately 750 ms; no contrary action is possible during this time. You can obtain further information about the PSM from MB-AS ( page 14).
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6.5.5 Retrofitting electrical equipment 6.5.6 Mobile communications systems
Please observe the following if auxiliary electrical consumers 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 devices (IPCDs)). Provide for adequate fusing of extra equipment by installing additional fuses. All electrical equipment installed must be tested in accordance with EC Directive 95/54/EU and must bear the "e" mark ( page 51). Auxiliary electrical consumers must be connected as described in the "Power supply interfaces" section ( page 71). When mobile communication systems (e.g. telephone, CB radio) are retrofitted ( page 42), the following requirements must be fulfilled in order to avoid malfunctions 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). Equipment The maximum transmission output must not be exceeded. Frequency range Short wave < 50Mhz 4 m waveband 2 m waveband 70 cm waveband 25 cm waveband Maximum transmission output [W] 100 20 50 35 10
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If the vehicle's electrics/electronics are tampered with or impermissible installation work is carried out on them, operational safety may be jeopardised and the vehicle warranty/operating permit may be invalidated.
The mobile communications systems and brackets must not be positioned in the deployment area of the airbags ( page 64). The equipment must be permanently installed. Operation of portable or mobile equipment inside the vehicle is permissible only when connected to a reflexion-free exterior aerial. The transmitter unit must be installed as far away from the vehicle's electronic system as possible. Protect the unit from moisture and heavy mechanical vibration; observe the permissible operating temperature.
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Connection and cable routing for the aerial (radio) 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 cable). 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 transmitter, 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 hazardous goods (GGVS: German Law on the Road Transport of Hazardous Goods), and ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road). Line cross-sections/fuses The wires must be dimensioned and safeguarded by fuses adequate to the strength of the current drawn. Maximum permanent current [A] 0 4.9 5 9.9 10 18 19 28 29 35 36 48 49 69 70 98 99 123 124 148 Rated fusing current [A] 5 10 20 30 40 50 70 100 125 150 Wire crosssection [mm2] 0.5 1 2.5 4 6 10 46 25 35 50
6.5.7
Electrical lines/CAN bus
If it is necessary to change the routing, avoid routing over sharp edges and routing through narrow cavities or in the vicinity of moving components. Additional circuits If additional circuits are installed, safeguard these from the main circuit using suitable fuses. The wires must be dimensioned in such a manner that they are adequate to the strength of the current drawn, they must be protected against shocks and heat.
Both cable ducts must be taken into consideration when modification or installation work is carried out in the load compartment or passenger compartment. The position of the cable duct on the transmission tunnel depends on the location of the steering wheel, i.e. in a left-hand-drive vehicle, the cable duct is on the righthand side and vice versa. The cable duct must neither be damaged nor relocated in the event of installation or modification work in the area of the transmission tunnel.
N54.00-2210-20
Cable duct Front of vehicle
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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 panel Cable duct Front of vehicle
The electronic systems in the engine and passenger compartments are interconnected via networks. Data is exchanged between the individual networks via gateways. The individual networks include: Class C engine CAN Class B passenger compartment CAN D2B network (digital domestic bus)
As all consumers are networked via CAN network and internally monitored, cables and wiring harnesses may neither be disconnected nor lengthened. Any modifications to the wiring harness, e.g. length, cross-section or resistance may lead to fault messages appearing in the instrument cluster.
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The control units in the CLASS B network are still available when the ignition is switched off and the key is removed. The D2B ring network installed in the vehicle uses an optical waveguide as data carrier for transmitting audio and control signals. This system allows data to be transferred synchronously at high baud rates. It is immune to electromagnetic interference (EMC), produces no electromagnetic 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 activated 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 established using the STAR Diagnosis tester and the software developed for this unit. Risk of accident Risk of accident
On no account should any modifications be made to the CAN bus (e.g. interruptions or "tapping"). Unauthorised modifications to the CAN bus may adversely affect the standard vehicle. In addition to causing inconvenience, this may also lead to failure of components or parts relevant to safety.
Any interruption or tapping of these networks may result in malfunctions which affect the operational and road safety of the vehicle. The programmable special module ( page 71) is designed for connecting electronic components. CAN bus All Mercedes-Benz Vito/Viano vehicles are equipped with a Class C engine CAN as standard.
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A B C
6 1 2 3 4 7 8 12
30 5 9 10 14 15 16 17 18 13 19 20 21 22 23 24 25
5400-2211.00
11 28
29
26
31
27
Schematic overview of networks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Meaning/abbreviation Electronic Stability Program (ESP) Engine electronics Electronic transmission control (EGS) Signal receiver and control module (SAM) E box Front right door control panel (TVR) Voice control system (SBS) CD changer (TA) (RLS) Overhead control panel (DBE) Front passenger seat control unit Auxiliary heating (STH) Upper control panel (OBF) Programmable special module (PSM) Heater booster system (PTC) Head unit (radio/navigation system) (HU) Electric selector lever module (EWM)
N54.00-2237-00
19 20 21 22 23 24 25 26 27 28 29 30 31 A B C D
Meaning/abbreviation Heatmatic/Tempmatic (KLA) Restraint system (SRS) Parktronic (PTS) Electronic ignition switch (EZS) Steering angle sensor (LWS) Instrument cluster (INS) Tachograph Driver's seat control unit Front left door control panel (TVL) Rear passenger compartment air-conditioning (FKLA) Rear sliding sunroof (SDE) Trailer control unit (AAG) Pneumatic suspension (ENR) Engine bus (CAN C) Interior bus (Can B) D2B Optional equipment
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Risk of accident
6.5.8
Wiring diagrams
As all consumers are networked and internally monitored, cables and wiring harnesses of the C-class engine CAN may neither be disconnected nor lengthened. Any modifications to the length, cross-section or resistance of the wiring harness can lead to malfunction messages appearing in the instrument cluster and the failure of components relevant to safety. Communication with the control unit can be established using the STAR Diagnosis tester and the software developed for this unit. Risk of accident
Wiring diagrams can be made available to body manufacturers. Enquiries should be addressed to: E-mail: Service.Information@DaimlerChrysler.com Fax: +49 (0)7 11-17-8 34 17
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Further information is available from your Mercedes-Benz Service Centre.
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6.5.9 Electronic Stability Program (ESP)
ESP is a dynamic driving control system which actively regulates the longitudinal dynamics and transverse dynamics 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. Installation instructions for the ESP yaw rate sensor The location, spatial orientation and attachment of the ESP yaw rate sensor (yaw rate/lateral acceleration sensor) must not be different from that of the standard vehicle. 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.
3
N00.00-2639-20
Installation location of ESP yaw rate sensor Airbag control unit Front of vehicle Together with the signals of other sensors, a processor monitors whether the direction desired by the driver is maintained. If the vehicle deviates from the correct path (oversteering or understeering), the system produces a stabilising counteraction by applying the brakes on individual wheels. To guarantee operating safety: on no account should modifications be made to the CAN bus, nor may CAN bus signals be tapped any additional equipment (e.g. a DVD player) may only be installed without interfering with the onboard electronics Risk of accident
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It must be ensured that the sensor is easily accessible at all times.
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Risk of accident
Further important notes can be found in the "Damage prevention" section ( page 51).
On no account may the following modifications be carried out on vehicles equipped with ESP: Modifications to the wheelbase Modifications to the sensor system (steering angle sensor, yaw rate sensor, wheel rotational speed sensor) Changes to the vibration characteristics in the vicinity of the yaw rate sensor point of installation due to modifications to the body Modifying the position of components Modifications to the chassis Modifications to the permissible wheels and tyres Modifications to the engine Modifications to the steering system Modifications to the brake system Conversion to a semitrailer tractor vehicle On vehicles with ESP, modifications may result in the ESP system not functioning correctly and failing. The driver could lose control of the vehicle as a result and cause an accident.
6.5.11 Retrofitting an alternator

If additional electrical consumers are retrofitted, the increase in power requirement can be supplied by using a more powerful alternator. All electrical equipment installed must be tested in accordance 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 sufficient 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 manufacturer'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 adequately dimensioned. Additional protection of the alternator circuit (-> page 80). The additional pulleys (code N62, available as optional equipment from the factory), are available to drive the refrigerant compressors. Make sure that the electrical lines are routed correctly (-> page 80). Access to installed components and ease of maintenance must be not impaired.
Risk of accident
If you drop the ESP yaw rate sensor, it must not be refitted to the vehicle for safety reasons. In such cases, a genuine Mercedes-Benz replacement must be fitted.
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 affecting them adversely through its operation nor suffering any adverse effects itself through the operation of these systems.
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The operating instructions and the maintenance manual for the additional equipment is to be supplied with the vehicle when it is handed over. The air supply required and engine cooling must not be adversely affected (-> page 64).
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6 Modifications to the basic vehicle 6.6 Additional equipment

6.6 Additional equipment
If additional equipment is fitted, factory-fitted power take-offs must be used ( page 85). When assembling compact systems (evaporator, condensor and blower) on the cab roof, the permissible roof loads must not be exceeded ( page 60). Connections to the roof require a certificate of endorsement from the relevant department ( page 12).
6.6.1
Retrofitting the air conditioning
All electrical equipment installed must be tested in accordance with EC Directive 95/54/EU and must bear the "e" mark. We recommend the relevant versions available as optional equipment at the factory for retrofitting air conditioning. If other air-conditioning systems are retrofitted, the following points relating to compatibility with the basic vehicle must be observed in addition to the equipment manufacturer's specifications: Damage to vehicle parts and their function caused by installation of an air conditioning system is not permitted. The battery must have sufficient capacity ( page 71) and the alternator ( page 83) must generate sufficient power. Additional fuse protection for the air-conditioning power circuit ( page 77). The additional pulley (code N60) is available from the factory as optional equipment to drive air-conditioning compressors. Make sure that lines and ( page 44) electrical lines ( page 77) are routed correctly. Access to installed components and ease of maintenance must be not impaired. The operating instructions and the maintenance manual for the additional equipment must be supplied with the vehicle when it is handed over. The air supply required and engine cooling must not be adversely affected ( page 61)
6.6.2
Auxiliary heating
The floor of the vehicle must be air-tight if exhaust gases are routed out under the vehicle. Openings in the vehicle floor provided for control elements must be sealed with rubber sleeves.
6.6.3
Power take-offs
General Power take-off models supplied from the factory: Engine power take-off at front Information on maximum transferable torques (Nm) for the individual power take-offs are guide values for operation without impact or vibration. The gear ratio of the power take-off should be selected such that a minimum engine speed of 1,000 1,200 rpm is maintained when the power take-off is under load. The power output should be within the range of the maximum engine torque. Exposed propeller shafts, fan wheels or pulleys must be covered.
85
6 Modifications to the basic vehicle 6.7 Attachments

6.7 Attachments 6.7.3 Roof rack
Attachments to the frame require a certificate of endorsement 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 attachments. Comply with national legal requirements. 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. Roof rack threshold values Maximum roof loads Low roof High roof 150 kg 50 kg Minimum number of support points 5 4
6.7.1
Winch
The attachment of winches requires a certificate of endorsement from the relevant department ( page 12). If winches are attached to the basic vehicle, the permissible axle loads must be adhered to. Winch on the front of the frame Carry out the attachment as described in the "Bodyshell/bodywork" section ( page 56). Observe the guidelines on drilling work on the chassis ( page 57). The use of spacers is required. Provide also for additional support on the longitudinal frame member for temporary support.
6.7.4
Fitted shelving
Fitted shelving must: be sufficiently strong and self-supporting rest on the cross and longitudinal members of the vehicle floor distribute forces evenly
!
The airbag units may need to be deactivated if attachments are fitted to the front of the frame, as these may change the impact structure. The relevant department can provide you with information on this ( page 12).
!
On no account should attachments transfer forces only to the vehicle sidewalls.
6.7.2
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).
86
6 Modifications to the basic vehicle 6.7 Attachments

6.7.5 Trailer coupling
Only secure trailer couplings that have been approved 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 fitted (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 consideration. 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 fittings, 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 programmed by a Mercedes-Benz diagnostic tool at a Mercedes-Benz specialist workshop. Otherwise malfunctions cannot be ruled out.
87
7 Conversion work 7.1 Modifications to the interior

7.1 7.1.1 Modifications to the interior Modifications to the cockpit
Further information on code V40 optional equipment can be obtained from your Mercedes-Benz Service Centre, the relevant department ( page 12) or in the "Optional equipment" section ( page 35). Any rear bench seat with 2-point or 3-point belts that deviates from the standard seating must conform to the requirements of EC Directives 76/115/EEC and 74/ 408/EEC. Seat belt anchorages may be retrofitted. Aftermarket solutions have been developed for this. An appropriate report may be requested from the relevant department ( page 12). Risk of accident
Modifications to the cockpit above the waistline are not permitted. This applies in particular to the inflation areas of the airbags (wooden trim, additional attachments, mobile phone holders, bottle holders, etc.). See the illustrations of airbag inflation points for more information ( page 64).
7.1.2
Retrofitting additional seats
DaimlerChrysler AG will issue a certificate of endorsement at their discretion ( page 12) for modifications to the seat attachments (including seat bases) and seat belt anchorages or for the installation of seats other than those available from the factory. Proof of the strength of the seats delivered from the factory is only valid if the seats are secured in their original mountings. When the seat belts are fastened again, the specified bolts must be tightened to the original torque. Risk of accident
Seats may not be mounted on the wheel housing. Persons could be injured in an accident if seats are torn out of their anchorages and the vehicle could be further damaged. Any rear bench seat with 2-point or 3-point belts that deviates from the standard seating must conform to the requirements of ECE R14. It is not permissible to fit seats without belts. The ECE R14 test certificate (tensile test including floor assembly) must be submitted for approval by DaimlerChrysler AG. Test certificates for seats mounted on rigid panels are not accepted. Risk of injury
Modifications to the driver's and front-passenger seat are not permitted. Seats may not be mounted on the wheel housing. The seats could be torn out of their anchorages in an accident. Passenger/cargo area On panel vans, the bodyshell floor assembly is available from the factory as optional equipment under Code V40 (Traveliner floor assembly) for retrofitting bench seats. The number of attachment options for the Traveliner floor assembly depends on the model series and the equipment and registration variants (the mounting shells for the bench seats are not included in the scope of delivery).
It is not permissible to retrofit covers on seats with thorax bags (see notes in the Owner's Manual/ Operating Instructions).
88
7 Conversion work 7.2 Modifications to closed panel vans

7.2 Modifications to closed panel vans
Floor assembly 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. Partitions If the partition is to be cut out due to conversion or installation work, this is possible in conjunction with a continuous frame. Partitions can be fully or partially removed. Observe the "Modifications to closed panel vans" section for notes on how to do this ( page 89). Risk of accident
No modifications to the roof lining or roof skin may be made on vehicles equipped with windowbags, as otherwise the windowbags could no longer inflate correctly (e.g. delayed or incomplete inflation of windowbags).
Areas that must be retained Designation of partition level with B-pillar View in the direction of travel
89
7 Conversion work 7.2 Modifications to closed panel vans

Further information on optional equipment can be obtained from your Mercedes-Benz Service Centre, the relevant department ( page 12) or in the "Optional equipment" section ( page 35). Vehicle roof Information on modifications to the roof can be found in the "Panel van/Traveliner roof" section ( page 59).
90
7 Conversion work 7.3 Refrigerated vehicles

7.3 Refrigerated vehicles
Conversions for refrigerated vehicles require a certificate 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).
91
7 Conversion work 7.4 Motor caravans

7.4 Motor caravans
Prior to conversion into a motor caravan, please make sure that: legal requirements are observed (German road traffic licensing regulations (StVZO) or relevant EC directives) the minimum requirements for interior design and motor caravan equipment are fulfilled the permissible centre of gravity location and maximum permissible axle loads are not exceeded For the conversion of vehicles in Germany, appropriate bulletins can be ordered from the relevant technical testing centres for motor vehicles (e.g. TV, DEKRA). Particular attention must be paid to the following sections 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 Germany, modifications to the vehicle must therefore be inspected 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 prevention). Fittings must be made of flame-resistant materials and be fitted securely. Unimpeded access to the seats must be ensured. There must not be any protruding parts, edges or corners which could cause injury in the area of the seats. 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).
92
7 Conversion work 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).
93
7 Conversion work 7.6 Increasing the roof height

7.6 Increasing the roof height
Comply with the guidelines in the "Panel van/Traveliner roof" section when increasing the height of the vehicle roof ( page 60).
94
8 Technical data 8.1 Vito 109 CDI

8.1 Vito 109 CDI
6396113
Panel van
Normal Wheelbase [mm] [m] [mm] [mm] [mm] [kg] [kg] [kg] 3,200 11.8 4,748 1,901 1,350 XA2 1,470 1,550 1,470 1,550 2,770 2,940 4,940 4,940 1,100 1,100 720 720 High
63960313
Traveliner
Normal 3,200 11.8 4,748 1,875 1,350 XA2 Normal 3,200 11.8 4,993 1,901 1,350 XA2
63960513
Traveliner
Normal 3,200 11.8 4,993 1,875 1,350 Normal 3,430 12.5 5,223 1,901 1,350 XA2 XA2 1,550 1,470 1,550 1,550 1,470 1,550 2,940 2,770 2,940 4,940 4,940 4,940 1,115 1,150 1,150 825 720 720
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 EU3Gr.3 8.00 8.50 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
Permissible gross vehicle weight
Permissible tractor- [kg] trailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l] [ccm] [kW] [bhp] [rpm] [Nm] rpm] [kg] [kg] [kg] [kg]
1,820 1,820 950 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 1,120 M0C1
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C1 OM646LA 2,148 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 EU3Gr.3 8.00 8.50 75 1,095 885 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 1,055 M0C1
1,940 1,870 1,870 1,000 900 M0C1 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 Euro3 8.00 8.50 75 OM646LA 2,148.0 65 88 3,800 220 1,400 2,500 EU3Gr.3 8.00 8.50 75 1,070
Engine
From engine speed [rpm]
Mercedes-Benz body/equipment mounting directives for Vito/Viano as at: 20.07.2004
95

6396113
Panel van
Normal Transmission NSG250 [l] 1.50 G250-6 (4.99-0.82) A0C2 4.111 Coil springs Coil springs 195/ 205/ 65 R 65 R 16 16 6 J x 6.5 J Transmission oil quantity Transmission designation Rear-axle code Rear-axle ratio Front suspension Rear suspension Tyres Rims* *Well-base rim High
63960313
Traveliner
Normal NSG250 1.50 Normal NSG250 1.50
63960513
Traveliner
Panel van
High NSG250 1.50 G250-6 (4.99-0.82) A0C2 4.111
Panel van
High
Traveliner
Normal NSG250 1.50 G250-6 (4.99-0.82) A0C2 4.111 Coil springs Coil springs 205/65 R 16 6.5 J
Drive train
G250-6 G250-6 (4.99-0.82) (4.99-0.82) A0C2 4.111 A0C2 4.111
G250-6 G250-6 (4.99-0.82) (4.99-0.82) A0C2 4.111 A0C2 4.111
Coil springs Coil springs Coil springs Coil springs 205/65 R 16 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 205/65 R 65 R 16 16 6.5 J 6.5 J 195/ 205/ 65 R 65 R 16 16 6 J x 6.5 J
Chassis
96

8.2 Vito 111 CDI
6396113
Panel van
63960313
Traveliner
63960513
Traveliner
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Dimensions
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
Permissible tractor- [kg] trailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l] [ccm] [kW] [bhp] [rpm] [Nm] [rpm] [kg] [kg] [kg] [kg]
1,820 1,820 950 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 Euro3 8.00 8.50 75 1,120 M0C2
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 Euro3 8.00 8.50 75 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EU3Gr.3 8.00 8.50 75 1,095 885 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 Euro3 8.00 8.50 75 1,055 M0C2
1,940 1,870 1,870 1,000 900 M0C2 OM646LA 2,148.0 80 109 3,800 270 1,600 Euro3 8.00 8.50 75 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EU3Gr.3 8.00 8.50 75 1,070
Engine
97

6396113
Panel van
Normal Transmission NSG370 [l] 1.80 G370-6 (5.01-0.80) A0C6 3.727 Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 65 R 16 5Jx Transmission oil quantity Transmission designation Rear-axle code Rear-axle ratio Front suspension Rear suspension Tyres Rims* *Well-base rim High
63960313
Traveliner
63960513
Traveliner
Panel van
High NSG370 1.80 G370-6 (5.01-0.80) A0C6 3.727
Panel van
High
Traveliner
Drive train
G370-6 G370-6 (5.01-0.80) (5.01-0.80) A0C7 3.273 A0C6 3.727
G370-6 G370-6 (5.01-0.80) (5.01-0.80) A0C7 3.273 A0C6 3.727
Coil springs Coil springs Coil springs Coil springs Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 205/65 R 65 R 16 16 6.5 J 6.5 J 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J
Chassis
98

8.3 Vito 115 CDI
6396113
Panel van
Normal Wheelbase [mm] [m] [mm] [mm] [mm] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] 3,200 11.8 4,748 1,901 1,350 XA2 1,470 1,550 1,470 1,550 2,770 2,940 4,940 4,940 1,100 1,100 720 720 High
63960313
Traveliner
63960513
Traveliner
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
1,820 1,820 950 M0C3 OM646LA 1,120 M0C3
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 Euro3 8.00 8.50 75 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EU3Gr.3 8.00 8.50 75 1,095 885 M0C3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 Euro3 8.00 8.50 75 1,055 M0C3
1,940 1,870 1,870 1,000 900 M0C3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EU3Gr.3 8.00 8.50 75 Euro3 8.00 8.50 75 OM646LA 2,148.0 110 150 3,800 330 1,800 1,070
[ccm] [kW] [bhp] [rpm] [Nm] [rpm]
2,148.0 110 150 3,800 330 1,800 2,400 Euro3 8.00 8.50 75
Engine
Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l]
99

6396113
Panel van
Normal Transmission NSG370 [l] 1.80 G370-6 (5.01-0.80) A0C1 3.455 Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J Transmission oil quantity Transmission designation Rear-axle code Rear-axle ratio Front suspension Rear suspension Tyres Rims* *Well-base rim High
63960313
Traveliner
63960513
Traveliner
Panel van
High NSG370 1.80 G370-6 (5.01-0.80) A0C1 3.455
Panel van
High
Traveliner
Drive train
G370-6 G370-6 (5.01-0.80) (5.01-0.80) A0C7 3.273 A0C1 3.455
G370-6 G370-6 (5.01-0.80) (5.01-0.80) A0C7 3.273 A0C1 3.455
Chassis
100
8 Technical data 8.4 Vito 119

8.4 Vito 119
6396113
Panel van
63960313
Traveliner
63960513
Traveliner
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75
Dimensions
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
Permissible tractor- [kg] trailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l] [ccm] [kW] [bhp] [rpm] [Nm] [rpm] [kg] [kg] [kg] [kg]
1,820 1,820 950 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,120 M0C8
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,095 885 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,055 M0C8
1,940 1,870 1,870 1,000 900 M0C8 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 M112Ered 3,199.0 140 190 5,600 270 2,750 4,750 EU4Gr.1 9.50 10.00 75 1,070
Engine
101

6396113
Panel van
Normal Transmission NAGW5A [l] 9.00 W5A380 (3.59-0.83) A0C6 3.727 Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J Transmission oil quantity Transmission designation Rear-axle code Rear-axle ratio Front suspension Rear suspension Tyres Rims* *Well-base rim High
63960313
Traveliner
Normal NAGW5A 9.00 Normal NAGW5A 9.00
63960513
Traveliner
Panel van
High NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727
Panel van
High
Traveliner
Normal NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727 Coil springs Coil springs 205/65 R 16 6.5 J
Drive train
W5A380 W5A380 (3.59-0.83) (3.59-0.83) A0C6 3.727 A0C6 3.727
W5A380 W5A380 (3.59-0.83) (3.59-0.83) A0C6 3.727 A0C6 3.727
Chassis
102

8.5 Vito 122
6396113
Panel van
Normal Wheelbase [mm] [m] [mm] [mm] [mm] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] 3,200 11.8 4,748 1,901 1,350 XA2 1,470 1,550 1,470 1,550 2,770 2,940 4,940 4,940 1,100 1,100 720 720 High
63960313
Traveliner
63960513
Traveliner
Panel van
High 3,200 11.8 4,993 2,329 1,760 XA2
Panel van
High
Traveliner
Normal 3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,180 785 1,965 975 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code Permissible front axle load Permissible rear axle load Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle Unladen vehicle (including driver, tank 90% full) Payload Engine code Engine designation Displacement Output Output At rated engine speed Torque To engine speed Emissions level
1,550 1,470 1,550 1,470 1,550 1,550 1,470 1,550 1,470 1,550 2,940 2,770 2,940 2,770 2,940 4,940 4,940 4,940 4,940 4,940 1,120 1,095 1,095 1,105 1,105 795 750 750 780 780
Weights
1,820 1,820 950 M0C7 M112E 1,120 M0C7
1,915 1,845 1,845 1,885 1,885 1,025 925 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 1,095 885 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 1,055 M0C7
1,940 1,870 1,870 1,000 900 M0C7 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 M112E 3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75 1,070
[ccm] [kW] [bhp] [rpm] [Nm] [rpm]
3,199.0 160 217 5,600 305 2,800 4,750 EU4Gr.1 9.50 10.00 75
Engine
Minimum engine oil [l] quantity Maximum engine oil [l] quantity Tank capacity [l]
103

6396113
Panel van
Normal Transmission NAGW5A [l] 9.00 W5A380 (3.59-0.83) A0C6 3.727 Coil springs Coil springs 195/ 65 R 16 6Jx 205/ 65 R 16 6.5 J Transmission oil quantity Transmission designation Rear-axle code Rear-axle ratio Front suspension Rear suspension Tyres Rims* High
63960313
Traveliner
63960513
Traveliner
Panel van
High NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727
Panel van
High
Traveliner
Normal NAGW5A 9.00 W5A380 (3.59-0.83) A0C6 3.727 Coil springs Coil springs 205/65 R 16 Drop centre rims, 6.5 J
Drive train
W5A380 W5A380 (3.59-0.83) (3.59-0.83) A0C6 3.727 A0C6 3.727
W5A380 W5A380 (3.59-0.83) (3.59-0.83) A0C6 3.727 A0C6 3.727
Chassis
*Well-base rim
104
8 Technical data 8.6 Viano CDI 2.0/CDI 2.2

8.6 Viano CDI 2.0/CDI 2.2
63981113
Wheelbase [mm] [m] [mm] [mm] [mm] 3,200 11.8 4,748 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,180 890 2,070 870 MOC2 OM646LA [ccm] [kW] [bhp] [rpm] [Nm] [rpm] [rpm] [l] [l] [l] 2,148.0 80 109 3,800 270 1,600 2,500 EUGr.3 8.00 8.50 75
2.0 CDI 63981313

3,200 11.8 4,993 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,170 925 2,095 845 MOC2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EUGr.3 8.00 8.50 75
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC2 OM646LA 2,148.0 80 109 3,800 270 1,600 2,500 EUGr.3 8.00 8.50 75
63981113
3,200 11.8 4,748 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,180 890 2,070 870 MOC3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EUGr.3 8.00 8.50 75
2.2 CDI 63981313

3,200 11.8 4,993 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,170 925 2,095 845 MOC3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EUGr.3 8.00 8.50 75
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC3 OM646LA 2,148.0 110 150 3,800 330 1,800 2,400 EUGr.3 8.00 8.50 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code
Permissible front axle [kg] load Permissible rear axle [kg] load
Weights
Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle
[kg] [kg] [kg] [kg]
Unladen vehicle [kg] (including driver, tank 90% full) Payload [kg] Engine code Engine designation Displacement Output Output At rated engine speed Torque From engine speed To engine speed Emissions level Minimum engine oil quantity Maximum engine oil quantity Tank capacity
Engine
105
8 Technical data 8.6 Viano CDI 2.0/CDI 2.2

63981113
Transmission NSG370 [l] 1.80
2.0 CDI 63981313

NSG370 1.80
63981513
NSG370 1.80
63981113
NSG370 1.80
2.2 CDI 63981313

NSG370 1.80
63981513
NSG370 1.80
Drive train
Transmission oil quantity Transmission designation Rear-axle code Rear-axle ratio Front suspension
G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) G370-6 (5.01-0.80) A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J A0C7 3.273 Coil springs Coil springs 205/65 R 16 6.5 J
Chassis
Rear suspension Tyres Rims*
*Well-base rim
106
8 Technical data 8.7 Viano 3.0/3.2

8.7 Viano 3.0/3.2
63981113
Wheelbase [mm] [m] [mm] [mm] [mm] 3,200 11.8 4,748 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,180 890 2,070 870 MOC8 M112Ered [ccm] [kW] [bhp] [rpm] [Nm] [rpm] [rpm] [l] [l] [l] 3,199.0 110 190 3,800 270 2,750 4,750 EUGr.4Gr.1 9.50 10.00 75
3.0 63981313
3,200 11.8 4,993 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,170 925 2,095 845 MOC8 M112Ered 3,199.0 110 190 3,800 270 2,750 4,750 EUGr.4Gr.1 9.50 10.00 75
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC8 M112Ered 3,199.0 110 190 3,800 270 2,750 4,750 EUGr.4Gr.1 9.50 10.00 75
63981113
3,200 11.8 4,748 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,180 890 2,070 870 MOC7 M112E 3,199.0 140 217 3,800 305 2,800 4,750 EUGr.4Gr.1 9.50 10.00 75
3.2 63981313
3,200 11.8 4,993 1,875 1,350 XA2 1,550 1,550 2,940 4,940 1,170 925 2,095 845 MOC7 M112E 3,199.0 140 217 3,800 305 2,800 4,750 EUGr.4Gr.1 9.50 10.00 75
63981513
3,430 12.5 5,223 1,872 1,350 XA2 1,550 1,550 2,940 4,940 1,240 880 2,120 820 MOC7 M112E 3,199.0 140 217 3,800 305 2,800 4,750 EUGr.4Gr.1 9.50 10.00 75
Dimensions
Turning circle Vehicle length Vehicle height Interior height Weight code
Permissible front axle [kg] load Permissible rear axle [kg] load
Weights
Permissible gross vehicle weight Permissible tractortrailer gross weight Front-axle load, unladen vehicle Rear-axle load, unladen vehicle
[kg] [kg] [kg] [kg]
Unladen vehicle [kg] (including driver, tank 90% full) Payload [kg] Engine code Engine designation Displacement Output Output At rated engine speed Torque From engine speed To engine speed Emissions level Minimum engine oil quantity Maximum engine oil quantity Tank capacity
Engine
107
Index
A Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Additional battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Additional equipment. . . . . . . . . . . . . . . . . . . . . . . . . . 85 Additional equipment threshold values . . . . . . . . . 43 Aerial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 Airbag control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Anti-corrosion protection for welding . . . . . . . . . . . 31 Attachment above cab . . . . . . . . . . . . . . . . . . . . . . . . . 86 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Battery isolating switch . . . . . . . . . . . . . . . . . . . . . . . 70 Belt tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 Bodies for motor caravans . . . . . . . . . . . . . . . . . . . . . 92 Bodies for refrigerated vehicles . . . . . . . . . . . . . . . . 91 Body/equipment approval . . . . . . . . . . . . . . . . . . . . . 12 Bodyshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56, 58 Bodyshell threshold values . . . . . . . . . . . . . . . . . . . . 39 Bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 53 C Cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Cable duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77, 78 Cables and lines . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 53 CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 78, 79 Centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Certificate of endorsement . . . . . . . . . . . . . . . . 12, 13 Chassis end cross-member . . . . . . . . . . . . . . . . . . . . 58 Checking the entire vehicle . . . . . . . . . . . . . . . . . . . . 34 Clearance dimensions, trailer coupling . . . . . . . . . 87 Closed panel van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Conversion work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . 31, 46
D Damage prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Damage prevention by painting . . . . . . . . . . . . . . . . 48 Damage prevention when storing and delivering the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 36 Disc brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Drilling holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Drilling work on the chassis. . . . . . . . . . . . . . . . . . . . 57 Drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 61 Drive train threshold values. . . . . . . . . . . . . . . . . . . . 40 Dust/dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 E Electrical interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electromagnetic compatibility . . . . . . . . . . . . . . . . . 83 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Engine air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Engine periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Engine periphery threshold values . . . . . . . . . . . . . 40 ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 82 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 F Faxback system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Floor assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 61 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 77 G General operating permit . . . . . . . . . . . . . . . . . . . . . . . 6 I Increasing the roof height . . . . . . . . . . . . . . . . . . . . . 94 Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 L Legal claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Line cross-sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
108
! Always print out the complete section from the current version.
Index
M Maintenance and repairs . . . . . . . . . . . . . . . . . . . . . . 33 Mercedes star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mercedes-Benz body/equipment manufacturer system (MB-AS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MIG plug welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mobile communications systems . . . . . . . . . . . 42, 76 Model designation. . . . . . . . . . . . . . . . . . . . . . . . 8, 9, 11 Model overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 11 Modifications to closed panel vans . . . . . . . . . . . . . 89 Modifications to mobile communications systems . 76 Modifications to the basic vehicle . . . . . . . . . . . . . . 52 Modifications to the bodyshell . . . . . . . . . . . . . . . . . 39 Motor caravans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 N Noise in the vehicle interior . . . . . . . . . . . . . . . . . . . . 69 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Noise level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 O Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Overview of Vito models . . . . . . . . . . . . . . . . . . . . . . . . 9 P Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Panel van/Traveliner roof . . . . . . . . . . . . . . . . . . . . . . 59 Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57, 89 PC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Permissible tyre sizes . . . . . . . . . . . . . . . . . . . . . . . . . 37 Pneumatic suspension . . . . . . . . . . . . . . . . . . . . . . . . 54 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Power take-offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Product liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 15 Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 PSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 72, 73 Q Quality assurance system . . . . . . . . . . . . . . . . . . . . . 20
R Raised roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 92, 93 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Reducing noise in the vehicle interior . . . . . . . . . . . 69 Refrigerated vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Reprocessing components . . . . . . . . . . . . . . . . . . . . . 19 Retrofitting electrical equipment . . . . . . . . . . . . . . . 76 Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 S Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 63 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 88 Securing points on the frame . . . . . . . . . . . . . . . . . . 39 Shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 52 Side-impact sensors . . . . . . . . . . . . . . . . . . . . . . . 65, 66 Sidewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 52 Steerability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Storing and delivering the vehicle . . . . . . . . . . . . . . 50 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T Tack welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Technical advice for body/equipment manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Tender drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Third-party trademarks . . . . . . . . . . . . . . . . . . . . . . . . 17 Towing and tow-starting . . . . . . . . . . . . . . . . . . . . . . . 49 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Tyre load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27, 55 U Underbody panelling . . . . . . . . . . . . . . . . . . . . . . . . . . 59
109
Index
V Vehicle approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Vehicle dimension threshold values . . . . . . . . . . . . 36 Vehicle dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Vehicle frame threshold values . . . . . . . . . . . . . . . . 39 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . 25 Vehicle identification plate . . . . . . . . . . . . . . . . . . . . 25 Vehicle modifications . . . . . . . . . . . . . . . . . . . . . . . . . 22 Vehicle outline lamps. . . . . . . . . . . . . . . . . . . . . . . . . . 42 Vehicle overhang. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Vehicle overhang threshold values . . . . . . . . . . . . . 39 Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Vehicle selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Vehicle width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 W Warranty claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Weight distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Welded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 36 Welding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Welding work on the bodyshell . . . . . . . . . . . . . . . . . 56 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Wheel arch lowering threshold values . . . . . . . . . . 39 Wheel arches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 81 Workshop Information System (WIS) . . . . . . . . . . . 14
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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.

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

! Always print out complete sections from the current version.

The aim of these Directives

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

! Always print out complete sections from the current version.

1 Introduction 1.2 Symbols

An environmental note gives you tips on the protection of the environment.

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

! Always print out complete section from the current version.

1 Introduction 1.3 Vehicle safety

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

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1 Introduction 1.4 Operational safety

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

! Always print out complete section from the current version.

2 General 2.1 Vehicle and model designations

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

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Compact Short wheelbase, short overhang, length 4,748 mm Panel van

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

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Double seat next to the driver option Easy entry option

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

! Always print out complete sections from the current version.

Compact Short wheelbase, short overhang, length 4,748 mm Trend, Ambiente

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

! Always print out complete sections from the current version.

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

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Issuing a certificate of endorsement

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

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Workshop Information System (WIS)

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

! Always print out complete sections from the current version.

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

! Always print out complete sections from the current version.

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

! Always print out complete sections from the current version.

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

! Always print out complete sections from the current version.

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

! Always print out complete sections from the current version.

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

! Always print out complete sections from the current version.

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

! Always print out complete sections from the current version.

3 Planning conversions 3.1 Vehicle selection

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

! Always print out complete sections from the current version.

3 Planning conversions 3.2 Vehicle modifications

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

! Always print out complete sections from the current version.

3 Planning conversions 3.3 Dimensions and weights

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

! Always print out complete sections from the current version.

3 Planning conversions 3.3 Dimensions and weights

1,790 1,900 2,070 2,770/2,940 1,470/1,550 1,470/1,550

1,845 1,925 2,095 2,770/2,940 1,470/1,550 1,470/1,550

1,870 1,950 2,120 2,940 1,470/1,550 1,470/1,550

Permissible front axle load Permissible rear axle