ARL Citan 20140815 en 20140815

Body/Equipment Mounting Directives
for Vans
Citan
Issue date: 15.08.2014

Contents
3.9.3 Work before handing over the modified

1 Introduction............................................ 4
vehicle................................................... 42
1.1 The aim of these directives...................... 5
3.10 Special equipment................................. 44
1.2 Conventions............................................. 6
1.3 Vehicle safety.......................................... 7
1.4 Operational safety................................... 8 4 Technical threshold values for
1.5 Note on copyright.................................... 9 planning................................................ 45
4.1 Threshold values of the basic vehicle..... 45
4.1.1 Steerability and load distribution........... 45
2 General.................................................. 10
4.1.2 Maximum vehicle dimensions................ 45
! 2.1 Vehicle and model designation.............. 10
4.1.3 Do not perform welding work on........... 45
2.2 Model overview...................................... 13
4.1.4 Parts which must not be drilled............. 45
2.2.1 Seating possibilities............................... 14
4.2 Suspension threshold values................. 46
2.3 Advice for body manufacturers.............. 15
4.2.1 Permissible axle loads........................... 46
2.3.1 Certificate of non-objection................... 16
4.2.2 Approved tyre sizes................................ 46
! 2.3.2 Applying for a certificate of
4.2.3 Diameter of turning circle...................... 46
non-objection......................................... 16
4.2.4 Modifications to the axles ..................... 46
2.3.3 Legal claims........................................... 17
4.2.5 Modifications to the steering system..... 46
2.3.4 Product and vehicle information for body
4.2.6 Modifications to the brake system ........ 46
manufacturers....................................... 17
4.2.7 Modifications to springs, spring suspen-
2.3.5 Bodybuilder Portal................................. 17
sion/shock absorbers ........................... 47
2.3.6 Information for non-registered body manu-
4.2.8 Wheel alignment.................................... 47
facturers................................................ 18
4.3 Bodyshell threshold values.................... 48
2.3.7 Workshop Information System (WIS)...... 19
4.3.1 Modifications to the bodyshell............... 48
! 2.3.8 Xentry Kit............................................... 19
4.3.2 Vehicle roof/roof load........................... 48
2.3.9 CERON................................................... 20
4.4 Limits for engine peripherals/drivetrain.49
2.3.10 European type approval (ETA) and EC Certi-
4.4.1 Fuel system............................................ 49
ficate of Conformity (CoC)..................... 20
4.4.2 Modifications to engine/drivetrain compo-
2.3.11 Product Information Tool (PIT)............... 21
nents ..................................................... 49
2.4 Product safety and product liability....... 22
4.5 Interior threshold values........................ 50
2.4.1 Product safety........................................ 22
4.5.1 Modifications in the vicinity of the airbag.50
2.4.2 Product liability...................................... 22
4.5.2 Modifications to seats........................... 50
2.4.3 Safety-relevant features......................... 22
4.6 Limits for electrical/electronic system...51
2.5 Ensuring traceability.............................. 24
4.6.1 Electric wiring/fuses..............................51
2.6 Trademarks ........................................... 25
4.6.2 Earth points on the
2.7 Accident prevention .............................. 26
vehicle body........................................... 52
2.8 Reprocessing of components -
4.6.3 Earth points on transmission................. 57
Recycling............................................... 27
4.6.4 Location of electrical components......... 58
2.9 Quality system....................................... 28
4.6.5 Retrofitting electrical equipment
("e" mark).............................................. 59
3 Planning of bodies............................... 29 4.6.6 CAN bus................................................. 59
3.1 Selecting the basic vehicle..................... 30 4.6.7 Electronic Stability Program (ESP)......... 59
3.2 Vehicle modifications............................. 31
3.3 Dimensions and weights........................ 32
5 Damage prevention............................. 60
3.4 Vehicle type identification data.............. 33
5.1 Brake hoses/cables and lines................ 60
3.5 Vehicle stability...................................... 34
5.2 Position of cables in vehicle....................61
3.6 Tyres...................................................... 35
5.2.1 Position of cables - Overall vehicle......... 62
3.7 Threaded and welded connections........ 36
5.2.2 Cables and lines - ABS system............... 64
3.7.1 Threaded connections........................... 36
5.2.3 Firewall cable grommet.......................... 64
3.7.2 Welded connections............................... 37
5.3 Welding work......................................... 65
3.8 Soundproofing....................................... 40
5.4 Corrosion prevention measures............. 66
3.9 Maintenance and repairs........................41
5.5 Painting work/preservation work.......... 68
3.9.1 Preparation for storing the vehicle..........41
5.6 Storing and handing over the vehicle..... 69
3.9.2 Battery maintenance and storage.......... 42
Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

!Changes compared to version dated 25.03.2014. Only print out complete sections of the current version! 2
Contents
5.7 Information on electromagnetic compatibi- 8.3 Lighting................................................ 122

lity (EMC)............................................... 70 8.4 Battery................................................. 123
8.4.1 Main battery........................................ 123
6 Modifications to the basic vehicle..... 71 ! 8.4.2 Additional battery................................ 126
6.1 Suspension............................................ 71 8.5 Electrical lines/CAN bus...................... 132
6.1.1 General information on the chassis....... 71 ! 8.6 Alternators........................................... 133
6.1.2 Springs/shock absorbers...................... 71 8.7 Power tap interfaces............................ 134
6.1.3 Brake system......................................... 73 8.7.1 Exterior illumination power tap............ 134
6.1.4 Air suspension....................................... 76 8.7.2 Interior illumination power tap............. 136
! 6.1.5 Wheels/Tyres........................................ 76 8.8 Body manufacturer special module...... 140
6.1.6 Spare wheel .......................................... 76 8.9 Retrofitting electrical equipment ........ 142
6.2 Bodyshell/body..................................... 77 8.10 Mobile communications systems......... 146
6.2.1 General information on the bodyshell/ ! 8.11 Driving assistance systems.................. 147
body....................................................... 77 ! 8.11.1 Electronic Stability Program (ESP)....... 147
6.2.2 Fastening rings in cargo area................. 79 ! 8.11.2 Tyre pressure monitoring.................... 147
! 6.2.3 Modifying the partition wall................... 82
6.2.4 Sidewall, windows, doors and 9 Calculations........................................ 149
flaps....................................................... 86 9.1 Centre of gravity.................................. 149
6.2.5 Mudguards and wheel arches................ 90 9.1.1 Determination of the centre of gravity in the
6.2.6 Bodyshell............................................... 90 x-direction............................................ 149
6.2.7 Underfloor panelling.............................. 90 9.1.2 Determination of the centre of gravity in the
6.2.8 Panel van/passenger van roof............... 91 z-direction.............................................151
6.3 Engine peripherals/drivetrain................ 95
6.3.1 Fuel system............................................ 95 10 Technical details................................ 155
6.3.2 Exhaust system...................................... 96 10.1 Vehicle data......................................... 155
6.3.3 Engine air intake.................................... 97
6.4 Interior................................................... 98 Index .............................................................161
6.4.1 General ................................................. 98
6.4.2 Safety equipment................................... 99
6.4.3 Seats .................................................. 107
6.4.4 Reducing noise in the vehicle interior... 111
6.4.5 Ventilation ............................................112
6.4.6 Auxiliary heating ..................................112
6.5 Attachments.........................................113
6.5.1 Roof racks ............................................113
6.5.2 Fitted shelving .....................................114
! 6.5.3 Trailer coupling.....................................114
7 Design of bodies.................................115
7.1 Interior compartment of the body.........115
7.1.1 Modifications in the cockpit area..........115
7.1.2 Retrofitting additional seats .................115
7.2 Modifications to panel vans/passenger
vans......................................................117
7.3 Refrigerated vehicles/temperature-control-
led vehicles...........................................118
7.4 Vehicles for transportation of technical
gases....................................................119
8 Electrical system............................... 120

8.1 General information ............................ 120
8.2 Electromagnetic compatibility (EMC)....121

!Changes compared to version dated 25.03.2014. Only print out complete sections of the current version! 3
1 Introduction
These body/equipment mounting directives provide

body manufacturers with important technical infor-
mation which must be observed in the planning and
production of a safe and roadworthy body. The attach-
ments, bodies, equipment or modifications installed
and implemented by the body manufacturer are subse-
quently referred to as "body modifications".
These body/equipment mounting directives are based
on the vehicle developed primarily for the European
market.
Due to the large number of body manufacturers and
body types, Daimler AG cannot take into account all
the possible modifications to the vehicle, e.g. perfor-
mance, stability, load distribution, centre of gravity
and handling characteristics, that may result from
body mounting work. For this reason, Daimler AG can
accept no liability for accidents or injuries sustained
as a result of such modifications to your vehicles, in
particular if such modifications have a negative impact
on the entire vehicle. Accordingly, Daimler AG will only
assume liability as manufacturer within the scope of
the design and production work which it has performed
itself and as per the instructions it has issued itself.
The body manufacturer will undertake to ensure that
his body mounting work is not defective in itself, nor is
it capable of causing defects or hazards in the vehicle
as a whole. If this obligation is violated in any way, the
body manufacturer shall assume full product liability.
These body/equipment mounting directives are inten-
ded for the use of professional body manufacturers. As
a result, these body/equipment mounting directives
assume that the body manufacturer has suitable back-
ground knowledge. Moreover, the body manufacturer
must adhere to the operator's manual valid for the res-
pective vehicle. Please be aware that certain types of
work (e.g. welding work on load-bearing components)
may only be carried out by appropriately qualified per-
sonnel. This will avoid the risk of injury and will attain
the degree of quality required for the body mounting
work.
The current valid version of all laws, standards and
directives specified in these body/equipment mounting
directives always applies unless stated otherwise (in
the case of standards and directives).

!Please observe the modification notes! Only print out complete sections of the current version! 4
1 Introduction
1.1 The aim of these directives
1.1 The aim of these directives
These directives are divided into the following interlinked

sections to help you find the information you require
quickly:
1 „Introduction“ (e Page 4)
2 „General“ (e Page 10)
3 „Planning of bodies“ (e Page 29)
4 „Technical threshold values for planning“
(e Page 45)
5 „Damage prevention“ (e Page 60)
6 „Modifications to the basic vehicle“
(e Page 71)
7 „Design of bodies“ (e Page 115)
8 „Electrical system“ (e Page 120)
9 „Calculations“ (e Page 149)
10 „Technical details“ (e Page 155)
Appendix:
„Index“ (e Page 161)
For further information, see subsection 2.3.4 „Pro-
duct and vehicle information for body manufacturers“
(e Page 17)
The index in pdf format is linked to help you find the
information you require quickly.
Make absolutely sure that you observe the threshold
values specified in section 4 „Technical threshold
values for planning“ (e Page 45) as planning must
be based on these values.
The chapters entitled "Modifications to the basic
vehicle" and "Construction of bodies" are the main
source of technical information contained in these
body/equipment mounting directives.

1 Introduction
1.2 Conventions
1.2 Conventions
The following conventions are used in these directives:
aa WARNING
Warning notes draw attention to issues which could

endanger the health or life of yourself or others.
HH Environmental note
An environmental note gives you tips on the protec-

tion of the environment.
!! Note
This note draws your attention to possible damage to
your vehicle.
ii Additional information
This note points out any additional information.
e Page This symbol specifies the page that cont-

ains further information on this topic.

1 Introduction
1.3 Vehicle safety
1.3 Vehicle safety
aa WARNING
Before starting to install non-MB bodies or equip-

ment, please read the relevant sections of these
body/equipment mounting directives, the instruc-
tions and information from the equipment supplier
and the detailed operator's manual for the base
model vehicle. You could otherwise fail to recognise
dangers, which could result in injury to yourself or
others.
Notes on vehicle safety

We recommend that you use the parts, major assem-
blies, conversion parts and accessories that have been
tested and found suitable by Mercedes-Benz for the
vehicle model concerned.
If parts, assemblies, conversion parts or accessories
are used that have not been recommended, have the
safety of the vehicle verified without delay.
!! Note
Make absolutely sure that you comply with national
registration regulations as body mounting work on
the vehicle may change the vehicle type approved
and may invalidate the general operating permit.
This applies in particular to:
• modifications which change the vehicle type
approved in the general operating permit
• modifications which could endanger road users,
or
• modifications which adversely affect exhaust
emissions or noise levels

1 Introduction
1.4 Operational safety
1.4 Operational safety
aa WARNING
Work incorrectly carried out on equipment and its

software can prevent this equipment from working.
Since the electronic systems are networked, this can
also affect systems that have not been modified.
Malfunctions in the electronic systems can seriously
jeopardise the operational safety of the vehicle.
Have work on or modifications to electronic compo-
nents carried out at a qualified specialist workshop
which has the necessary expertise and tools to carry
out the work required.
Mercedes-Benz recommends that you use a Merce-
des-Benz Service Centre for this purpose.
In particular, work relevant to safety or on safety-re-
lated systems must be carried out at a qualified
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.

1 Introduction
1.5 Note on copyright
1.5 Note on copyright
All the text, illustrations and data contained in these

body/equipment mounting directives are protected by
copyright.
This also applies for the editions on CD-ROM, DVD or
other media.
If you have any questions, please contact the Merce-
des‑Benz Support Centre
Telephone: 00800-97-777-777

2 General
2.1 Vehicle and model designation
For information on the position of the identification

plates, see 3.4 „Vehicle type identification data“
(e Page 33).
These Body/Equipment Mounting Directives are valid for

the following vehicle model designation:
Vehicle model designations by permissible GVW
Max. GVW [kg] 1785 1885 - 1980 2100 2200
Code XK0 Code XK1, XK2, XK5, Code XK7 Code XK8
XK6
Wheelbase [mm] 2313 2697 2697 3081
Body length A1 Body length A2 Body length A2 Body length A3
Version
Panel van C415.6011 C415.6031 C415.6031 C415.6051
C415.6012 C415.6032 C415.6032 C415.6052
Mixto C415.6051
C415.6052
Passenger van C415.7031 C415.7031
C415.7032 C415.7032

2 General
Engine variants
Engine Max. out- Fuel Emissions Sales desi- Panel van Mixto Passenger
code put standard gnation van
[kW (hp)]
Diesel engines
MO1 55 (75) Diesel Euro 51
Euro 62
108 CDI
· ·
Euro 62
109 CDI
· · ·
Euro 62
111 CDI
· · ·
Gasoline engines
MO4 84 (114) Gasoline Euro 51
Euro 62
112
· ·
1
Code MOx + MB5
Code MOx + MB6
2
• Obtainable ex works

2 General
Body codes and body versions (selection)
Body code Body version Weight variants Permissible
gross weight
Panel van XK0 1785 kg
XK1 1885 kg
XK2 1920 kg
XK5 1950 kg
XK6 1980 kg
XK7 2100 kg
XK8 2200 kg
ZK4 Mixto XK8 2200 kg
Passenger van XK1 1885 kg
XK2 1920 kg
XK5 1950 kg
XK6 1980 kg
XK7 2100 kg
You can obtain information about a vehicle's availa-

bility and registration possibilities from your con-
tact partner under „Technical advice on the basic
vehicle“ (e Page 15).

2 General
2.2 Model overview
2.2 Model overview
Country-specific regulations must be complied with.

You can obtain information about a vehicle's availability and registration possibilities from your contact partner under
„Technical advice on the basic vehicle“ (e Page 15).
Max. GVW Wheel- Model
base
[kg] [mm] Panel van Mixto Passenger van
FKA/LCV FKA/Mixto FKB/Passenger van
1785 2313 _ _
1885-1980 2697 _
2100 2697 _
2200 3081 _

2 General
2.2 Model overview
2.2.1 Seating possibilities
Particular attention must be paid to whether the

combination of vehicle model designation, weight
code, engine code and seating variant is eligible for
registration.
You can obtain information about a vehicle's availa-
bility and registration possibilities from your con-
tact partner under „Technical advice on the basic
vehicle“ (e Page 15).
Wheelbase [mm]
Model 2313/ Code R1 2697/ Code R2 3081/ Code R3
Panel van
Mixto _ _
Passen- _ _
ger van

2 General
2.3 Advice for body manufacturers
Technical advice on body compatibility Technical advice on the basic vehicle

The team at the "VAN Body Manufacturer Centre" is avai- In case of questions regarding configuration and equip-
lable to provide technical advice to body manufacturers ment of basic vehicle, please contact the technical
on the compatibility of bodies with the basic vehicle and advice team at the MB Vans Order Centre at the Düssel-
also to issue certificates of non-objection, and can be dorf plant:
contacted using the following contact details:
Contact details
Contact details Name: Mr Marcel Baust
Name: Mr Miroslav Trivuncevic E-mail: marcel.baust@daimler.com
E-mail: miroslav.trivuncevic@daimler.com Telephone: +49 (0)211-953-2109
Telephone: +49 (0)711-17-22870 Name: Mr Sebastian Jankowski
Postal Daimler AG E-mail: sebastian.jankowski@daimler.com
address: VAN/VSA department
Telephone: +49 (0)211-953-3132
HPC (in-house post code) A446
Postal Daimler AG
D-70546 Stuttgart, Germany
address: VAN/PSO department
Name: Mr Jens Lobinski
HPC (internal post code) PS31
E-mail: jens.lobinski@daimler.com D-40467 Düsseldorf, Germany
Telephone: +49 (0)3378-83-2924
Technical advice outside Germany
Postal Mercedes-Benz Ludwigsfelde
address: GmbH Contact the body manufacturer co-ordinator at Daimler
VAN/VSA department AG in your country for technical advice on modifications.
In-house post code VS14 All contact persons with their job description can also be
D-14961 Ludwigsfelde, Germany found in the Bodybuilder Portal under
https://bb-portal.mercedes-benz.com/portal/apps/
ansprechpartner_db/

2 General
2.3.1 Certificate of non-objection
!! Note
Daimler AG does not issue any body/equipment appro-
vals for non-MB bodies. These directives only supply National laws, guidelines and registration regulations
important information and technical specifications to must be complied with.
body manufacturers explaining how to handle the pro-
duct. Daimler AG therefore recommends that all work on
the basic vehicle and body is performed in compliance 2.3.2 Applying for a certificate of non-objec-
with the permissible gross vehicle weight and permis- tion
sible axle load, as per the current Mercedes-Benz body/ Requests regarding the certificates of non-objection/cer-
equipment mounting directives applicable to the vehicle. tificates must be submitted online to the body manufac-
Daimler AG issues certificates of non-objection volunta- turer support (e Page 15) of „VAN Body Manufacturer
rily based on the following criteria: Centre“ via Bodybuilder Portal (e Page 17). Log on to
Daimler AG's assessment shall be based solely on the begin the process and navigate to the tool of the com-
documents submitted by the body manufacturer carrying mission via „Contact“ and „To Apply for Certificate“ or
out the modifications. The assessment and certification via „My Portal“ > „My Certificates“ > „To Apply for new
shall only cover the expressly defined scopes and their Certificate“.
basic compatibility with the designated chassis and/or
basic vehicle and its connection points or, in the case of ii Additional information
chassis modifications, the basic feasibility of the design
for the designated chassis. The certificate of non-objec- Further detailed explanations on certificates and their
tion shall not refer to the overall design of the body, its application can be found using the Bodybuilder Portal
functions or its intended application. The certificate of in body manufacturer information edition 12/2014.
non-objection shall only be valid if design, production In case of questions, please call the hotline on the
and assembly are performed by the body manufacturer body manufacturer portal:
carrying out the modifications in accordance with the https://bb-portal.mercedes-benz.com/
state of the art and in compliance with the valid body/
equipment mounting directives of Daimler AG - unless Assessment in connection with the granting of a certi-
deviations from these directives are endorsed. Nevert- ficate of non-objection requires the submission of the
heless, the certificate of non-objection shall not release following documents and drawings before work on the
the body manufacturer carrying out the modifications vehicle is begun:
from its product liability or its obligation to perform its • All deviations from these Mercedes-Benz Body/
own calculations, tests and trials on the entire vehicle Equipment Mounting Directives
in order to ensure that the overall vehicle produced
• Complete data on dimensions, weights and centres
by the company meets the required specifications for
of gravity (weight certificates)
operational and road safety and handling characteristics.
Accordingly, it shall be the sole duty and responsibility • How the body is attached to the vehicle
of the body manufacturer to ensure the compatibility
of its body mounting work with the basic vehicle and to
guarantee the operating and road safety of the vehicle.

2 General
• The vehicle's conditions of use, e.g. 2.3.5 Bodybuilder Portal
• on rough roads General
• in very dusty conditions The Bodybuilder Portal is the central communications
• at high altitude platform between Mercedes-Benz Commercial Vehicles
• at extremely high or low outside temperatures and you, our partners in the body manufacturing
industry. The Bodybuilder Portal provides information
• Certificates ("e" mark, seat tensile strength test)
and access to body-related topics for all model series
Submitting the required documentation in full will make of Mercedes-Benz trucks and vans. The portal can be
queries on our part unnecessary and will speed up the accessed at the following address:
procedure. https://bb-portal.mercedes-benz.com/
2.3.3 Legal claims MBAS-Web Technology

• No legal claim can be made as to the issue of a certi- In the MBAS-Web (Technology) section of the portal,
ficate of non-objection. you can find the relevant technical data sheets, tender
• Daimler AG reserves the right to refuse the issue of drawings, circuit diagrams, engine diagrams and body/
a certificate of non-objection due to ongoing techni- equipment mounting directives. As well as the current
cal development and the knowledge gained from it, model series, you will also find directives for vehicle
even if a similar certificate was issued in the past. models that are no longer produced (under Archive).
• The certificate of non-objection may be restricted Ensure that work is only ever carried out based on the
to individual vehicles. current body/equipment mounting directives.
• The retroactive issue of a certificate of non-objec- Under Current topics, you can find the latest product
tion for vehicles already completed or delivered can information in the form of body manufacturer informa-
be refused. tion bulletins (newsletters) or the "ABH-Aktuell" maga-
zine.
• The body manufacturer alone shall be responsible
for: You are also able to add your Company profile to the
• the functionality and compatibility with the portal so that you can present your company and pro-
basic vehicle of his body mounting work ducts to us, to our sales staff and, after a further step,
to customers.
• operating and road safety
You are thus optimally equipped to provide your custo-
• all body mounting work and fitted parts
mers with quick, cost-efficient and comprehensive
advice and feasibility studies, to plan and determine
2.3.4 Product and vehicle information for the final vehicle design, to compile quotations and to
body manufacturers prepare designs.
As a body manufacturer, you are also able to obtain
detailed information on our products and systems in
addition to the possibility of directly contacting the
body manufacturer support staff at Mercedes-Benz
(e Page 15).

2 General
Design data 2.3.6 Information for non-registered body

manufacturers
As a body manufacturer, you can obtain original 3D
data for Citan BM415. 3D data can be ordered using a Using the "Service&Parts net" portal at
form available to you in the Bodybuilder Portal in the http://service-parts.mercedes-benz.com
"Additional information" catalogue.
Mercedes-Benz body manufacturers not registered
CERON registration in the portal can find After-Sales information on the
It is possible to register for the CERON system using a following topics:
form which is available in the "Additional information" • Service/parts information
catalogue in the Bodybuilder Portal. • Diagnosis
Additional information on the CERON system can be • SCN coding
found in section 2.3.9 „CERON“ (e Page 20).
• Special tools
• Xentry TIPS

2 General
2.3.7 Workshop Information System (WIS) 2.3.8 Xentry Kit
The Workshop Information System (WIS) is available in The tool Xentry Kit is available for the system Xentry
the "Service/Parts Information" menu item in "Ser- in "Service&Parts net" under the heading "Diagnosis".
vice&Parts net". For example, the WIS contains: The Xentry Kit diagnostic tool was developed by Merce-
• Basic data (dimensions, tightening torques) des-Benz to facilitate vehicle diagnosis. The Xentry Kit
can be used to read out fault entries from the vehicle
• Function descriptions
and diagnose them. It can also be used to change para-
• Circuit diagrams meters in control units.
• Repair instructions Fault entries which occurred during the mounting of the
• Maintenance sheets body can also be erased.
Non-MB body manufacturers can purchase access to In addition, Xentry Kit can also be used to update con-
WIS from the following address: trol units using SCN coding. For example, online SCN
http://service-parts.mercedes-benz.com coding must be used to update the data (coding) for the
instrument cluster.
Further information can be obtained from your Merce-
des-Benz Service Partner or at the Customer Support It is possible to connect the Xentry Kit to the central
Centre (CSC): server of Daimler AG during SCN coding over a LAN or
WLAN connection. The relevant SCN coding is requested
Contact details online and is used to uniquely identify the control unit
Telephone: +49 (0)1805-010-7979 variants installed in the vehicle. The data for the hard-
ware, flashware and vehicle-specific coding is encrypted.
Fax: +49 (0)1805-010-7978
Additional information on SCN coding can also be
E-mail: customer.support@daimler.com found in Service&Parts net.
Xentry Kit can be purchased or leased by body manufac-
turers.
If you have any questions about Xentry Kit, contact
your Daimler sales and service outlet or the Customer
Assistance Centre (CAC):
Contact details
Telephone: +49 (0)1805-010-7979
Fax: +49 (0)1805-010-7978
E-mail: customer.support@daimler.com

2 General
2.3.9 CERON CoC stands for Certificate of Conformity. A document
The CERON (Certification Online) system is a platform that attests that certain goods - including vehicles and
for exchanging and providing documents on the sys- bodies - conform to recognised (international) stan-
tem approvals and overall operating permits of the EC dards. The meaning and purpose of this EC Certificate
(European Community) and ECE (Economic Commis- of Conformity is to simplify the approval process for
sion for Europe). Here you can find e.g. documents on introducing international brands to the markets. This
ETA (European Type Approval) and GOP (General Opera- document is therefore required for customs clearance
ting Permit) for trucks, vans, buses and Unimogs. in the context of import and export in particular. The
manufacturer, who is in possession of an EC type
Use of the CERON system is chargeable. approval certificate or EC small series type approval
It is possible to register for the CERON system using a certificate, is obliged to provide every vehicle which
form which is available in the "Additional information" corresponds to an approved model with a certificate of
catalogue in the Bodybuilder Portal. conformity.
The vehicle-specific data of the EC certificate of con-
2.3.10 European type approval (ETA) and EC formity (CoC) for the basic vehicle are available in the
Certificate of Conformity (CoC) Bodybuilder Portal for convenient and quick processing
The 2007/46/EC Directive of the European Parliament of the body scope.
forms the basis for approval of motor vehicles and If you are planning an ETG in a subsequent stage (mul-
motor vehicle trailers as well as of systems, com- ti-stage type approval), a contract is required as per
ponents and automatic technical devices for these 2007/46 EC Appendix XVII Paragraph 1.1. The use of
vehicles. In these guidelines, regulations have been CERON is also regulated as part of this contract. The
enacted concerning the approval of vehicles which are manufacturer agreement concerning the multi-stage
manufactured in several stages, i.e. the multi-stage procedure can be obtained at:
type approval procedure. According to this, every multistage-cv@daimler.com
manufacturer involved in the construction of a vehicle
is himself responsible for the approval of modified or
added scopes in his own manufacturing stage. The
manufacturer can select one of the following four pro- Supplemental explanations on accessing the data
cedures: of the EC certificate of conformity (CoC) can be
• EC type approval (ETG) found using the Bodybuilder Portal in body manufac-
• EC small series type approval turer information edition 16/2013 for vans, dated
• National small series type approval 24.09.2013.
• Individual approval You can find the data for the basic vehicle in the
Bodybuilder Portal under "My portal" > "My order
data" > "Order data system" > "Order list/order
number" > "Approval data". You can choose between
an overview and an Excel file, but not the original
document of the EC certificate of conformity.
In case of questions, please call the hotline on the
body manufacturer portal:
https://bb-portal.mercedes-benz.com/

2 General
2.3.11 Product Information Tool (PIT)
You can access the PIT system via the Bodybuilder
Portal. The PIT system contains information on vehicle
equipment possibilities (codes, suspension variants,
overview of products, towing capacities etc.).

2 General
2.4 Product safety and product liability
2.4.1 Product safety 2.4.3 Safety-relevant features

Both vehicle manufacturers and body manufacturers Components and systems are safety-relevant when their
must always ensure that the products they are respon- fault or failure could result in an immediate danger to the
sible for manufacturing are safe when they are brought life and limb of road users.
into circulation and do not present a hazard to the user Daimler AG recommends that an assessment of the saf-
or to third parties. Otherwise, there may be consequen- ety relevance of the components or functions be carried
ces under civil, criminal or public law. Every manufactu- out for the following work:
rer is always liable for the product that it has manufactu-
• Modifications on the chassis
red.
• Installations in the vehicle
The manufacturers of bodies, implements, installations
and modified equipment must guarantee compliance • The interface between the vehicle and the body
with the Directive 2001/95/EC on general product (mechanical components, electrics/electronics,
safety. power take-offs, hydraulics, pneumatics)
2.4.2 Product liability A component or function must be classified as safe-

The body manufacturer bears responsibility for ty-relevant if one of the following ten safety functions in
• the operating and road safety of the body particular is affected:
• the operating and road safety of parts and modifica- • Occupant protection in accidents
tions • Avoiding momentary loss of road view
• testing and maintaining the operating and driving • Avoiding steering failure
safety of the vehicle after the body/equipment is • Avoiding loss or partial failure of braking function
mounted (the body and/or equipment must not have • Avoiding failure of driving function
a negative effect on the driving, braking or steering
• Avoiding uncontrolled drive
characteristics of the vehicle)
• Avoiding sudden failure of driving power
• influences of parts or modifications on the chassis
• Avoiding leakage of operating fluids/risk of fire
• consequential damage resulting from the attach-
ment, equipment or modification • Avoiding loosening of cargo/trailers/parts/bodies/
semi-trailers
• consequential damage resulting from retrofitted
electrical and electronic systems • Avoiding injury while driving and during alternative
operation of the vehicle
• maintaining the functional reliability and unobstruc-
ted movement of all moving parts of the chassis (e.g.
axles, springs, propeller shafts, steering, gearshift
linkage, etc.) after the body/equipment is mounted,
even in the case of diagonal torsion of the vehicle
Work carried out or modifications on the chassis or body
must be entered in the maintenance booklet, section
"Confirmations of the body manufacturer".

2 General
In the assessment of safety relevance, the following
customer-induced influences must be taken into
account:
• Extreme operating conditions
• Misuse due to unfamiliarity
• Misuse due to improper reactions
• Wear and tear
• Ambient conditions in the vehicle
Documentation
If safety relevance is identified according to the ten
safety aspects, these aspects are to be appropriately
marked as safety-relevant in paper and data records and
the associated functions and features documented.

2 General
2.5 Ensuring traceability
2.5 Ensuring traceability
There is a possibility that body-related hazards may

only be detected after the vehicle is delivered, making
retroactive market measures necessary (customer infor-
mation bulletins, warnings, recalls). To ensure that these
measures can be implemented as efficiently as possible,
it must be possible to trace the product after delivery.
We strongly recommend that body manufacturers store
the serial number/identification number of their body
together with the chassis identification number of the
basic vehicle in their databases for this purpose and to
allow them to use the Central Vehicle Register (ZFZR)
of the Federal Office for Motor Vehicles in Germany or
a comparable database in other countries. On this note,
the storage of customer addresses is also recommended
as is giving subsequent owners the possibility to register
their details.

2 General
2.6 Trademarks
2.6 Trademarks
The Mercedes-Benz star and Mercedes-Benz badge are

trademarks of Daimler AG.
Mercedes-Benz trademarks may not be removed or
applied to another point without approval.
Mercedes-Benz trademarks supplied separately must be
attached at the points specified by Mercedes-Benz.
Information on the use of the Mercedes-Benz star

and Mercedes-Benz badge can be found in the
"Guideline for the attachment of Mercedes-Benz
trademarks on vans" in the Bodybuilder Portal under
"Marketing":
https://bb-portal.mercedes-benz.com/
Daimler AG reserves the right to demand the removal of

the Daimler AG trademarks if the vehicle fails to comply
with the appearance and quality standards required by
Mercedes-Benz.

2 General
2.7 Accident prevention
2.7 Accident prevention
The body and attached or installed equipment must

comply with all applicable laws and regulations, 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 con-
ditions that may be unsafe or liable to cause an accident.
In Germany, information for commercial carriers is avai-
lable from the Berufsgenossenschaft für Fahrzeughaltun-
gen (German Trade Association of Vehicle Owners):
Telephone: +49 (0)40-39-80-0
Fax: +49 (0)40-39-80-19-99
E-mail: info@bgf.de
Homepage: http://www.bgf.de
Postal address: Berufsgenossenschaft für Fahr-
zeughaltungen,
Fachausschuss "Verkehr"
Sachgebiet "Fahrzeuge"
Ottenser Hauptstrasse 54
D-22765 Hamburg, Germany
National laws, guidelines and registration regulations

must be complied with.
The body manufacturer shall be responsible for compli-
ance with these laws and regulations.

2 General
2.8 Reprocessing of components - Recycling
2.8 Reprocessing of components -
Recycling
• It must be ensured that service fluids can be remo-

ved simply and in an environmentally responsible
When planning bodies or equipment, the following manner by means of drain plugs, etc.
principles for environmentally compatible design • Wherever possible, components should not be pain-
and material selection shall be taken into account, in ted or coated; coloured plastic parts are to be used
particular with regard to the EU Directive on end-of- instead.
life vehicles 2000 / 53 / EC. • Components in areas at risk from accidents must be
designed in such a way that they are damage-tole-
Body manufacturers shall ensure that attachments and rant, repairable and easy to replace.
bodies (or conversions) comply with current environmen- • All plastic parts must be identified as per VDA mate-
tal legislation and applicable regulations, in particular EU rial sheet 260 ("Motor vehicle components; identifi-
Directive 2000/53/EC concerning end-of-life vehicles cation of materials") e.g. "PP - GF30R".
and EU Directive 2003/11/EC concerning restrictions
on the bringing into circulation and use of certain dan-
gerous substances and dangerous preparations ("low
flammability" and certain flame retardants) to specify the
Directive 76/769/EEC.
The installation documentation for the conversions shall
be kept by the vehicle owner and, if the vehicle is to be
scrapped, handed over to the dismantling company con-
cerned at the time of vehicle handover. This is intended
to ensure that even converted vehicles are processed in
an environmentally responsible manner.
Materials with risk potential, such as halogen additives,
heavy metals, asbestos, CFCs and CHCs, are to be
avoided.
• EU Directive 2000/53/EC must be complied with.
• It is preferable to use materials which permit recy-
cling and closed material cycles.
• Materials and production processes that generate
only low quantities of easily recyclable waste during
production must be selected.
• 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 with recycled ele-
ments.
• It must be ensured that components can be dismant-
led easily for recycling, e.g. by snap connections,
predetermined breaking points, easy accessibility, or
by using standard tools.

2 General
2.9 Quality system
2.9 Quality system
World-wide competition, increased quality standards For the reasons quoted above, Daimler AG urgently advises
demanded by the customer from the van as a whole, all body manufacturers to set up and maintain a quality
national and international product liability laws, new orga- management system with the following minimum require-
nisational forms and rising cost pressures make efficient ments:
quality assurance systems a necessity in all sectors of the • To define responsibilities and authorities including
automotive industry. organisational planning
The requirements for a quality management system of this • To describe processes and procedures
kind are described in DIN EN ISO 9001. • To appoint a manager responsible for quality
A working group of the VDA (Association of the German • To carry out contractual inspections and buildability
Automotive Industry) has produced the guideline "Qua- checks
lity management in the automotive industry - Minimum
• To carry out product checks on the basis of specified
requirements for a management system for trailer and
instructions
body manufacturers - System description and assess-
ment" for German body manufacturers, which is based on • To regulate the handling of faulty products
DIN EN ISO 9000 ff. Published as VDA Volume 8 [VDA 8] • To document and archive test results
(including CD-ROM), order no. A 13DA00080. • To ensure that all employees have currently valid proof
of the qualification required
• To systematically monitor the test equipment
• To systematically identify materials and parts
• To carry out quality assurance measures at the sup-
pliers
• To ensure that the instructions for processes, work and
inspections are up-to-date and available in all depart-
ments and at all workplaces

3 Planning of bodies
General
The relevant operating conditions of the subsequent
complete vehicle are crucial to the selection of a suita-
ble basic vehicle or chassis when planning work on the
vehicle body.
Observe the following points:
• Customised design of vehicle or chassis
• Body variant
• Standard and special equipment
The model plate, model designation and vehicle identi-
fication number (VIN) must also be used for guidance
when planning, see 3.4 „Vehicle type identification
data“ (e Page 33).
For more information on the body variants on offer,
see the section 2.2 „Model overview“ (e Page 13)
or contact the department responsible 2.3.4 „Pro-
duct and vehicle information for body manufacturers“
(e Page 17).

3.1 Selecting the basic vehicle
3.1 Selecting the basic vehicle
In order to ensure safe operation of the vehicle, it is

essential to choose the basic vehicle carefully in accor-
dance with the intended use.
Planning should therefore consider the following items
in particular and adapt them to the intended use:
• Wheelbase
• Engine/transmission
• Permissible gross vehicle weight
• Position of the centre of gravity
!! Note
When planning bodies, in addition to a user-friendly
and maintenance-friendly design, the careful choice
of materials and the associated corrosion protection
measures are of great importance (e Page 66).
!! Note
Before carrying out body modifications, the deli-
vered vehicle must be submitted to a check to verify
whether it fulfils the necessary requirements.

3.2 Vehicle modifications
3.2 Vehicle modifications
Before starting work on the body, the body manufacturer

must check whether:
• the vehicle is suitable for the planned body The "Body technical advice" team is available to
• the vehicle model and equipment are suitable for the answer your questions (e Page 15).
operating conditions intended for the body
You can plan bodies by requesting the department !! Note
responsible to send you tender drawings, product
information and technical data or you can retrieve this On no account should modifications be made to the
information from the communications system (e See soundproofing.
page 17).
Vehicle approval
Furthermore, you should note the special equipment that
is available from the factory (e Page 44). The body manufacturer must inform the officially reco-
gnised approval authority or inspector of any modifica-
As supplied ex works, all vehicles comply with EC direc- tions to the basic vehicle/chassis. The approval/testing
tives and national regulations (except for some vehicles organisations decide whether laws and regulations are
for non-European countries). complied with after any changes are made to the basic
The vehicles must still comply with EC Directives or nati- vehicle/chassis and thus decide whether the complete
onal regulations after modifications have been carried vehicle is eligible for registration.
out.
!! Note
!! Note
National laws, guidelines and registration regulations
Adequate clearances must be maintained in order must be complied with.
to ensure the function and operational safety of
assemblies.
aa WARNING
Do not carry out any modifications to the steering or

brake system. Any modifications to the steering and
the brake system may result in these systems mal-
functioning and ultimately failing. The driver could
lose control of the vehicle and cause an accident.

3.3 Dimensions and weights
3.3 Dimensions and weights
On no account should modifications be made to the

aa WARNING
vehicle width, vehicle height or vehicle length if they
exceed the threshold values specified in the current ver- Make sure that you do not exceed the permissible
sion of the body/equipment mounting directives. axle loads. If the permissible axle loads are excee-
Please refer to the tender drawings and technical data ded or the minimum axles loads are dropped below,
in the MBAS-Web Technology portal (e Page 17) and the driver could lose control of the vehicle and cause
to the Technical Threshold Values (e Page 45) for an accident.
all dimension and weight specifications. These refer to The minimum value for the front axle load during
vehicles equipped as standard - special equipment is not driving operation is:
taken into account.
40 % of the gross vehicle weight
Weight tolerances of up to +5% in production must be
taken into consideration (in accordance with DIN 70020 Information about changes in weight is available from
in Germany). your contact person (e Page 15).
The permissible axle loads and the highest permissible
gross vehicle weight specified in Section 4 „Technical !! Note
threshold values for planning“ (e Page 45) may not
be exceeded. All bodies must comply with the individual permis-
sible axle loads and the permissible gross vehicle
aa WARNING weight.
The vehicle tyre load capacity may not be exceeded The permitted number of vehicle occupants and a suf-
by overloading the vehicle beyond its specified gross ficient margin for the payload must also be taken into
vehicle weight. The tyres can otherwise overheat and account.
suffer damage. The driver could lose control of the
The payload may be composed of luggage, special equip-
vehicle and cause an accident.
ment, etc.
The braking distance may increase considerably
Take the weight of special equipment into consideration
when the vehicle is overloaded.
when making calculations.
Information on the permissible weights can be found
National regulations and guidelines must be observed.
on the model plate on the vehicle (e Page 13).

3.4 Vehicle type identification data
3.4 Vehicle type identification data
The model plate is on the right door frame.

The plate with information about the vehicle weight and
vehicle dimensions is located on the right front mudgu-
ard above the side turn signal lamp.
The vehicle identification number is on the right in the
engine compartment.
1 Identification plate
2 Vehicle identification number (VIN) for France and
countries which perform homologation/type appro-
val according to the French regulation system.
!! Note
The Vehicle Identification Number (VIN) and model
plate of the vehicle may neither be modified nor
moved to another location.

3.5 Vehicle stability
3.5 Vehicle stability
For approval of the vehicle with body/equipment moun-

aa WARNING
ted, a calculation of the height of the centre of gravity of
the laden vehicle must be submitted in accordance with Make sure that you do not exceed the permissible
EC Directive on brakes 71 / 320 /EEC. axle loads. If the permissible axle loads are excee-
For this purpose, the centre of gravity height of the ded or the minimum axles loads are dropped below,
load can be combined with the centre of gravity height the driver could lose control of the vehicle and cause
calculated in chapter 9 „Calculations“ (e Page 149) an accident.
under 9.1.2 „Determination of the centre of gravity in the The minimum value for the front axle load during
z-direction“ (e Page 151) of the fully completed and driving operation is:
equipped (but not laden) vehicle.
• 40 % of the gross vehicle weight
Daimler AG will make no statements concerning:
• driving characteristics
• braking characteristics
• steering characteristics
This applies to bodies intended for operation with loads
with unfavourable centres of gravity (e.g. loads at the
rear end, high loads and side loads), as these aspects
are primarily influenced by body mounting work and can
therefore be assessed exclusively by the body manufac-
turer.
aa WARNING
The driving style must be adapted as necessary

(reduced cornering speeds, avoiding sudden steering
movements) on vehicles with unfavourably located
centres of gravity and depending on the attach-
ments, bodies, equipment or modifications and their
intended uses (e.g. rear, high or side loads). The per-
missible axle loads, gross vehicle weights and centre
of gravity locations must be complied with. There is
otherwise a risk of accident.
Neither in the ready-to-drive condition nor with equip-

ment installed nor with modifications having been car-
ried out may the permissible wheel/axle loads, or gross
vehicle weights ever be exceeded.

3.6 Tyres
3.6 Tyres
The body manufacturer must ensure that:

• There is always sufficient space between the tyre
and the mudguard or wheel arch, even if snow or For more information (e See page 17) and
anti-skid chains are fitted and the suspension is fully (e See page 46).
compressed (also allowing for axle twist), see 6.2.5
„Mudguards and wheel arches“ (e Page 90), and
that the relevant data in the tender drawings are
observed.
• Only permissible tyre sizes are used, see motor
vehicle registration certificate and 4.2.2 „Approved
tyre sizes“ (e Page 46).
aa WARNING
Exceeding the specified tyre load-bearing capacity

or the permissible maximum tyre speed can lead to
tyre damage or tyre failure. This could cause you to
lose control of the vehicle and cause an accident
with possible injury to yourself and others.
For this reason, only fit tyres of a type and size
approved for your vehicle and observe the tyre
load-bearing capacity required for your vehicle and
the tyre speed rating.
In particular, comply with national regulations con-
cerning the approval of tyres. These regulations may
define a specific type of tyre for your vehicle or may
forbid the use of certain tyre types which are appro-
ved in other countries.
If you have other wheels fitted:
• the brakes or components of the suspension
system could be damaged
• wheel and tyre clearance can no longer be gua-
ranteed
• the wheel brakes or components of the suspen-
sion system may no longer function correctly.

3.7 Threaded and welded connections
3.7.1 Threaded connections • If screws/bolts are tightened to the required torque

If it is necessary to replace standard bolts/nuts, use only and tightening angle by Mercedes-Benz, a construc-
bolts/nuts: tive modification is not possible.
• of the same diameter • The Mercedes-Benz Workshop Information System
(WIS) must be used to determine whether screws/
• of the same strength grade bolts and nuts of suspension components must only
• of the same bolt standard/type be tightened when the vehicle is in ready-to-drive
• of the same surface coating (corrosion protection, condition.
friction factor) • Additional tensioned parts of the body must be of
• with the same thread pitch equal or greater strength than the preceding tensi-
We recommend the use of standard Mercedes-Benz oned assembly.
parts.
aa WARNING Information is available from any Mercedes-Benz
Do not modify any threaded connections that are Service Centre.
relevant to safety, e.g. that are required for wheel
control, steering or braking functions. They may aa WARNING
otherwise no longer function correctly. The driver
could lose control of the vehicle and cause an acci- Screws/bolts or nuts with locking splines, micro-en-
dent. capsulated screws/bolts and self-locking nuts must
always be replaced after a single use. Before new
Parts must be refitted in accordance with Merce- micro-encapsulated screws/bolts are screwed in,
des-Benz service instructions and using suitable the mating thread must be recut or the nuts repla-
standard parts. We recommend the use of genuine ced to remove all residual screw locking compound.
Mercedes-Benz parts. Finally, the recut through-tapped or blind-tapped
holes must be blown out with air because any
• VDI guideline 2862 must be applied to all installation
adhesive residue in the thread would prevent correct
work.
tightening of the screws/bolts.
• It is prohibited to shorten the free clamping length,
If these instructions are not observed, bending
change to a stretch shank or use bolts with a shorter
forces could act on the screw/bolt due to the lack of
free thread.
pretension and cause the screw/bolt to break. The
• The settling behaviour of threaded connections must driver could lose control of the vehicle and cause an
be taken into account. accident.
• The use of Mercedes-Benz tightening torque specifi-
cations requires an overall friction factor in the range
of µtot=0.08 to 0.14 for the respective mating piece.

aa WARNING
Choice of welding method
The mechanical properties of weld seams depend on
There is an increased risk of injury when microen- selection of the welding method and on the geometry
capsulated screws/bolts are loosened because of the elements to be joined.
of the sudden loosening of the screws/bolts. For
If overlapping sheets are to be welded, the choice of
this reason, ensure you have sufficient freedom
welding method will depend on whether only one or
of movement when loosening microencapsulated
both sides of the workpiece is/are accessible:
screws/bolts.
Accessible on one side Gas-shielded plug wel-
ding
Accessible on both Resistance spot welding
The Mercedes-Benz Workshop Information Sys- sides
tem (WIS) or the "Body technical advice" team can
provide information on special threaded connections Resistance spot welding
(e Page 15). Resistance spot welding is used for welding overlapping
parts which are accessible from both sides. Spot wel-
ding of more than two sheet layers must be avoided.
3.7.2 Welded connections
General Distance between spot welds
In order to maintain the high standard of welding To avoid arching (shunt effects), the specified distances
demanded by Mercedes-Benz, the work must only be between the spot welds must be maintained (d = 10e +
carried out by appropriately qualified welders. 10 mm).
For high-quality weld seams, we recommend that you:
• clean the area to be welded thoroughly
• make several short welding beads rather than one
long bead
• make symmetrical beads to limit shrinkage
• avoid more than 3 welds at any one point
• avoid welding in strain-hardened zones
!! Note
The battery must be disconnected before any
welding work is carried out and airbags, the airbag
control unit and seat belts must be protected from
d Distance between spot welds
welding splashes or removed if necessary.
e Sheet thickness

Distance from sheet edge Gas-shielded plug welding
To avoid melting core damage, the specified distances If overlapping sheets is only accessible from one side,
to the sheet edge must be maintained (L = 3e + 2 mm). use either inert gas plug welding or tack welding for the
weld joint.
If the joint is produced by stamping or drilling followed
by plug welding, the drilled area must be deburred
before welding.
e Sheet thickness
L Distance from sheet edge
D = Plug hole 4.5 5 5.5 6 6.5 7

diameter [mm]
e = Sheet 0.6 0.7 1 1.25 1.5 2
thickness
[mm]

Mechanical quality can be additionally improved by the Non-weldable parts
use of "elongated holes" (l = 2b).
No welding work may be performed on the following
components/major assemblies:
• A-, B-, C- and D-pillars
• Major assemblies such as the engine, transmission,
axles etc.
For further information, refer to Sections 4 „Techni-

cal threshold values for planning“ (e Page 45), 5
„Damage prevention“ (e Page 60), Sub-section
6.2 „Bodyshell/body“ (e Page 77) and the Merce-
des-Benz Workshop Information System (WIS).
b Width of slotted hole Anti-corrosion protection after welding

I Length of slotted hole On completion of all welding work on the vehicle, you
must comply with the specified corrosion protection
Tack welding
measures (e Page 66).
In case of sheet thicknesses > 2 mm, overlapping
sheets may also be joined by tack welding !! Note
(30 mm < L < 40e; d > 2L).
The instructions in section 5 „Damage prevention“
(e Page 60) and 6 „Modifications to the basic
vehicle“ (e Page 71) must also be observed for
welding.
Figure: Dimensions for tack welding

d Distance between tack weld centres
e Sheet thickness
L Length of tack weld

3.8 Soundproofing
3.8 Soundproofing
If modifications are carried out on any parts whose ope-

ration produces noise, e.g.:
• engine
• exhaust system
• air intake system
• tyres, etc.
sound level measurements must be made.
National regulations and guidelines must be observed.
In the Federal Republic of Germany, the following must
be observed:
• ECE-R51 and
• Section 49.3 of StVZO (German vehicle licensing
regulations) (low-noise)
Noise-insulating parts fitted as standard must not be
removed or modified.
The level of interior noise must not be adversely affec-
ted.
!! Note
All modifications to the vehicle must comply with the
external vehicle noise levels defined in EC Directive
ECE-R51.
!! Note
To prevent modifications from changing the vehicle's
sound levels, it must be ensured that interior sound
levels are minimised when planning bodies (e See
page 111).
Information on material properties and finishing cri-

teria which must be complied with for internal noise
insulation can be found under 6.4.4 „Reducing noise
in the vehicle interior“ (e Page 111).

3.9 Maintenance and repairs
Maintenance and repair of the vehicle should not be • Daimler AG recommends adapting the scopes of
made unnecessarily difficult by the body. maintenance work on the body to each individual
Maintenance points and major assemblies must be body using the relevant Mercedes-Benz maintenance
easily accessible. systems. This applies both to the scope and type of
service work, and for determining the service due
• Observe the operating instructions.
dates for servicing intervals based on time elapsed
• Stowage boxes must be fitted with maintenance and distance covered.
flaps or removable rear panels.
The body manufacturer must provide the vehicle with
operating instructions and maintenance instructions for
The battery compartment must be sufficiently ventilated, the body and any additional assemblies installed. These
with provision for air to enter and exit. A battery vent instructions must be in the language of the country in
must be installed if necessary. which the vehicle is to be used.
• Check the condition and capacity of batteries and
service them in accordance with the manufacturer's 3.9.1 Preparation for storing the vehicle
specifications (e Page 42). Storing the vehicle
!! Note • Clean the entire vehicle
• Check the oil and coolant levels
Leaving the vehicle parked up for long periods of • Inflate the tyres to 0.5 bar above the specified tyre
time can lead to battery damage. This can be avoi- pressures
ded by disconnecting the battery and storing it in an
appropriate manner (e Page 42). • Release parking brake and prevent vehicle from
rolling away with chocks
The cost of any additional work incurred by the body/ • Disconnect the battery and grease battery lugs and
equipment in terms of terminals
warranty, maintenance or repairs will not be borne by • All safety precautions described in the Workshop
Daimler AG. Information System (WIS) under "Safety precautions
for new vehicles to be stored temporarily" must be
The following must be observed by the body manufactu- implemented, see 2.3.7 „Workshop Information Sys-
rer before delivery of the vehicle: tem (WIS)“ (e Page 19). The corrosion protection
• Check the headlamp setting or have this checked at of the brake disks is one example of an important
a qualified specialist workshop. We recommend a component of these measures.
Mercedes-Benz Service Centre.
Storing the vehicle in the open (< 1 month)
• Retighten the wheel nuts/ bolts to the specified
torque. • Carry out the same procedure as for storing in an
enclosed space
• Close all air inlets and set the heating system to
"Off"

Storing the vehicle in the open (> 1 month) !! Note

• Carry out the same procedure as for storing in an
enclosed space If the battery voltage drops below 12.1 V, the battery
• Fold the windscreen wipers away from the wind- is damaged and it will have to be replaced.
screen
• Close all air inlets and set the heating system to 3.9.3 Work before handing over the modified
"Off"
vehicle
• Remove the battery and store it in accordance with
The manufacturer must confirm the work and modi-
the manufacturer's specifications (e Page 42)
fications carried out by making an entry in the Main-
Maintenance work on stored vehicles (in storage tenance Booklet.
for > 1 month):
Checking the overall vehicle
• Check the oil level once a month
Check that the vehicle is in perfect condition. Repair
• Check the coolant once a month any damage if necessary.
• Check the tyre pressures once a month
Checking the brake system
Removing the vehicle from storage
If it is not known how long the vehicle has been in sto-
• Check the fluid levels in the vehicle rage, the brake fluid must be renewed.
• Adjust the tyre pressures to the manufacturer's Check electrical and hydraulic lines for all types of
specifications damage and repair or replace if necessary.
• Check the battery charge and install the battery Check the pneumatic system for all types of damage
• Clean the entire vehicle and repair or replace if necessary.
The brake fluid must be renewed every two years.
3.9.2 Battery maintenance and storage
Checking the vehicle electrical system
To avoid damage to the battery, disconnect the battery
if the vehicle is to be parked up for a period longer than After all work on the electrical or electronic system, the
one week. Always disconnect both terminals. fault memory of the control units must be read out and,
if necessary, erased.
If the vehicle is parked up for periods of longer than
one month, remove the battery and store it in a dry Checking the battery
place at temperatures between 0 °C and 30 °C. Test the battery charge before handing over the vehicle
Store the battery in an upright position. (e Page 42). The battery must be recharged if
The battery voltage must be kept above 12.55 V at all necessary.
times.
If the battery voltage drops below 12.55 V but not
below 12.1 V, the battery must be recharged.

Checking the tyres

Before handing over the vehicle, check that the tyres
are inflated to the specified pressure and check the
tyres for damage. Damaged tyres must be replaced.
Checking wheel alignment
We recommend that the axle geometry be checked
if modifications have been made to the body. More
detailed information on this is contained in the Merce-
des-Benz Workshop Information System (WIS).

3.10 Special equipment
3.10 Special equipment
Special equipment or retrofitted equipment can increase

aa WARNING
the kerb weight of the vehicle. In addition, special
The use of parts, assemblies, conversion compo- equipment can cause changes to the centre of gravity,
nents or accessories which have not been approved installation space conditions and component clearances.
may jeopardise the safety of the vehicle. For this reason, attention must be paid to maintaining
the functionality of the overall vehicle and complying
Before starting work on the vehicle, please read the with limits (e Page 45) whenever work is performed.
relevant sections of the vehicle operator's manual
and the operating and assembly instructions from The actual vehicle weight and axle loads must be deter-
the manufacturers of the accessories and special mined by weighing before mounting.
equipment. You could otherwise fail to recognise Not all special equipment can be installed in any vehicle
dangers, which could result in injury to yourself or without problems. This applies in particular for retrofitted
others. equipment because the installation space may already
be occupied by other components or the special equip-
We recommend using special equipment available as ment may require other components.
option codes to adapt the body to the vehicle optimally.
The "Body technical advice" team is available to
More information on special equipment can be answer your questions (e Page 15).
obtained from:
• Mercedes-Benz Service Centre
• PIT (product information for vans) in the body
manufacturer portal
• „Technical advice on the basic vehicle“
(e Page 15)
On the Mercedes-Benz homepage, you can assemble
vehicles in the Configurator and view the available
items of special equipment:
http://www.mercedes-benz.com

4 Technical threshold values for planning
4.1 Threshold values of the basic vehicle
4.1 Threshold values of the basic vehicle
4.1.3 Do not perform welding work on

!! Note
• The A and B-pillars
This section contains the basic vehicle technical • Radii
threshold values which are important for planning • In the vicinity of the airbags
work. In addition, you will find more information in
Plug welding is only permissible in the vertical webs of
the other sections of the current version of the body/
the longitudinal frame member.
equipment mounting directives.
4.1.1 Steerability and load distribution Additional information can be found under 3.7
• The front axle load must always be at least 40 % of „Threaded and welded connections“ (e Page 36)
the gross vehicle weight in all load states. and 5.3 „Welding work“ (e Page 65).
• Make sure that you do not exceed the permissible
axle loads.
4.1.4 Parts which must not be drilled
• Information about the load distribution of the avai-
lable vehicle models can be found in the tables in • The A and B-pillars
10.1 „Vehicle data“ (e Page 155). • The vehicle frame
• In the vicinity of load application points (e.g. axle
4.1.2 Maximum vehicle dimensions connections)
• In the vicinity of front axle or rear axle supporting
points
Information about the maximum vehicle dimen- • In the vicinity of the airbags
sions can be found under 10.1 „Vehicle data“
(e Page 155). !! Note
Ground clearance Holes in the longitudinal frame member are the

result of the production process and are not suita-
The ground clearance varies depending on the model ble for all body mounting work. On no account may
designation and configuration. holes resulting from the production process be used,
A construction package (as a national package) provi- as this could damage the frame.
des increased ground clearance as special equipment.
Additional information can be found in section 3

„Planning of bodies“ (e Page 29).

4.2 Suspension threshold values
4.2.1 Permissible axle loads 4.2.3 Diameter of turning circle

Refer to:
• Section 32d StVZO (German Road Traffic Licensing
Information about permissible axle loads can be Regulations)
found under 10.1 „Vehicle data“ (e Page 155). • European Union: 97/27/EC
Additional information about permissible axles load • European Union: 96/53/EC
can be obtained:
• from your contact persons, see 2.3 „Advice for 4.2.4 Modifications to the axles
body manufacturers“ (e Page 15) No modifications whatsoever may be made to the
• from 2.3.11 „Product Information Tool (PIT)“ suspension or the axles (e Page 71).
(e Page 21)
• from the vehicle configurator at 4.2.5 Modifications to the steering system
http://www.mercedes-benz.com On no account may any modifications be made to the
steering system (e Page 71).
4.2.2 Approved tyre sizes 4.2.6 Modifications to the brake system

ii Additional information On no account may any modifications be made to the
brake system.
Information about approved tyre sizes can be found On no account may any modifications be made to disc
under 10.1 „Vehicle data“ (e Page 155). brake air inflow and air outflow (e Page 73).
Information about the tyres/rims assigned to the
vehicle model and any limitations can be obtained:
• from your contact persons, see 2.3 „Advice for
body manufacturers“ (e Page 15)
• from the vehicle configurator at

4.2.7 Modifications to springs, spring
suspension/shock absorbers
Modifications to springs and shock absorbers can only
be made if they are matched at the front and rear.
On no account should springs or shock absorbers be
used if they do not correspond to the characteristics
of standard parts or parts obtainable as special equip-
ment. We recommend the use of standard Merce-
des-Benz parts.
spring mountings (e Page 71).
4.2.8 Wheel alignment

No modifications whatsoever may be made to wheel
alignment settings (e Page 71).

4.3 Bodyshell threshold values
4.3 Bodyshell threshold values
4.3.1 Modifications to the bodyshell

See section 6 „Modifications to the basic vehicle“
(e Page 71). For additional information see 6.2.8 „Panel van/
• Lowering the wheel arches is not permissible. passenger van roof“ (e Page 91) and 6.5.1 „Roof
racks“ (e Page 113) and 2.3 „Advice for body
• In general, any interference with the structure of the
manufacturers“ (e Page 15).
crossmembers should be refrained from.
• On no account should modifications be made to the Roof bows or supporting parts may not be removed or
rear door opening including the roof area. damaged without being replaced.
• If any modifications are made to the load-bearing The connection between the roof bow and the sidewall
structure, the rigidity must be equal to that of the must be of sufficient bending resistance .
standard vehicle.
• The clearance of the fuel filler neck, fuel tank and !! Note
fuel lines must be maintained.
• No drilling or welding work may be carried out on the Contact the "Body Technical Advice Team" before
A-, B-, C- and D-pillars. making modifications (e Page 15).
• If modifications are made 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
Standard roof Roof with ladder flap
[kg]* [kg]**
100 kg 60 kg
* Maximum overall roof load comprising weight
of the total mounting and roof luggage carrier
system and the evenly distributed payload on
the left and right (e.g.: carrier system incl. roof
railing code D11 (D11 only available for passen-
ger van wheelbase 2) and 80 kg payload)
** Payload on crossmember; ladder flap (code DL2,
only for wheelbase 1 or 2) excludes roof railing
with integrated basic carrier (code D11).
Roof railing with integrated basic carrier (code
D11) excludes ladder flap (code DL2).

4.4 Limits for engine peripherals/drivetrain
4.4 Limits for engine peripherals/drivetrain
4.4.1 Fuel system

• Modifications to the fuel system may only be car-
ried out in compliance with the relevant stipulations
(e Page 95).
4.4.2 Modifications to engine/drivetrain

components
• On no account may any modifications be made to
the engine air intake.
• Subsequent solutions for engine rpm regulation are
not possible alongside those available as special
equipment ("Interface for body manufacturers
(code EK8)" (e Page 144)).

4.5 Interior threshold values
4.5 Interior threshold values
4.5.1 Modifications in the vicinity of the air- 4.5.2 Modifications to seats

bag
aa WARNING
aa WARNING
It is not permitted to modify the driver and front pas-
On no account may any modifications be made senger seats or to mount seats on the wheel arches.
to the airbag system or the emergency tensioning In the event of an accident, the seats could become
retractor system. detached from their mountings.
Modifications to or work incorrectly carried out on a
restraint system (seat belt and seat belt anchorages, ii Additional information
airbag) or its wiring could cause the restraint sys-
tems to stop functioning correctly. This means, for Additional information can be found under
example, that airbags may be activated inadvertently 6.4 „Interior“ (e Page 98).
or may fail in the event of an accident even though
the rate of deceleration exceeds the deployment
threshold.
• On no account should modifications be made to

airbag components or in the vicinity of airbag compo-
nents and sensors.
• Subsequent modification of the headliner is not per-
missible on versions with windowbag.
• The vehicle interior must be designed in such a way
that airbags can fully deploy without impediment.
• On no account should modifications be made around
the airbag control unit .
Additional information can be found under 6.4.2

„Safety equipment“ (e Page 99).

4.6 Limits for electrical/electronic system
See also 8 „Electrical system“ (e Page 120).
4.6.1 Electric wiring/fuses

Max. perma- Fuse rating [A] Line
nent current cross-section
[A] [mm2]
0 - 4.9 5 0.5
5 - 9.9 10 1
10 - 18 20 2.5
19 - 28 30 4
29 - 35 40 6
36 - 48 50 10
49 - 69 70 46
70 - 98 100 25
99 - 123 125 35
124 - 148 150 50

4.6.2 Earth points on the
vehicle body
!! Note
Before intervening in the vehicle electrical system,
read chapter 4.6 „Limits for electrical/electronic
system“ (e Page 51).
Use the earth points as illustrated for consumer

connections.
Only connect one consumer or one cable lug to each
earth point.
Observe the bolt type and torque specifications when
mounting cable lugs on the earth point.
Torques
Bolt type M6
Torque 8 Nm + 15 %
Modifications to earth points are not permissible.

Illustration: Earth points on vehicle body

Pos. Fig. no. Access
(see following pages)
Earth points used in original condition
1 2 Remove passenger-side trim and cover panel.
2 4 Remove trim of rear wheel arch.
3 3 Remove interior carpet of double floor, seats and base.
4 1 Remove front bumper.
Earth points available for body manufacturers
A 5 Remove trim of rear wheel arch.
B 3 Remove interior carpet of double floor, seats and base.
C 2 Remove trim of gearshift.
D 1 Remove front bumper.

Figure 1: View of engine compartment

Figure 2: View of passenger compartment
Figure 3: View of vehicle floor

Figure 4: View of cargo area
Figure 5: View of cargo area

4.6.3 Earth points on transmission
!! Note
Various earth points are available depending on the
transmission variant.
The cable lugs must be attached with a thread-cutting

M8 bolt of appropriate length or a self-locking M8 nut
with a torque of 21 Nm.
If the consumer being connected has several earth
lines, multiple cable lugs can connected to the earth
point.
Only connect one consumer to each earth point.
Illustration: Earth points on manual transmission

1 Earth point on housing of differential transmission

4.6.4 Location of electrical components
No. Designation No. Designation

1 ABS/ESP control unit 8 BIM (engine safety and switch module)
2 Airbag control unit 9 BVR processor (DCT transmission) - not
installed
3 Speed control unit
10 Battery
4 Parking assist control unit
11 Battery terminal
5 UVH (passenger compartment central
unit) 12 Engine control unit
6 BFRH (fuse and relay box) 13 Code EK9 (optional)
7 USM (Underbody Switch Module)

4.6.5 Retrofitting electrical equipment ("e" 4.6.6 CAN bus
mark) On no account should modifications be made to the
All subsequently installed electrical devices must comply CAN bus or the components connected to it.
with the currently valid version of the EC Directive ECE- As all consumers are networked and internally monito-
R10 at the time of installation. red, no modifications should be made to the CAN bus
EC type approval for electromagnetic compatibility (EMC) (e.g. breaking, extending or tapping).
in accordance with the currently valid version of the spe- The body manufacturer special module can be used to
cified EC Directive is required ("e" mark documented and access individual data via the CAN bus (e Page 140).
applied to device) if the retrofitted electrical equipment
has an effect on immunity to interference. In Germany, 4.6.7 Electronic Stability Program (ESP)
type approval must also be obtained for equipment with
the "e" mark as per the currently valid version of ECE aa WARNING
Regulation 10 (ECE-R 10).
In future, a certificate from the manufacturer or a CE The location, position and mounting of the ESP turn
mark will be sufficient for retrofitted electrical equipment rate sensor must not be modified. On no account
if the equipment has no effect on immunity to interfe- should modifications be made to wiring or ESP com-
rence. The body manufacturer should check or have an ponents. Otherwise there is a danger that the ESP
authorised technical inspection authority check whether system may no longer function correctly. This would
the equipment has any effect of this kind before installa- increase the risk of an accident, especially when
tion. driving near the system's limits.
Also note 5.7 „Information on electromagnetic com-

patibility (EMC)“ (e Page 70), and 8 „Electrical
system“ (e Page 120).
Further information can be obtained from the body
technical advice team (e Page 15).

5 Damage prevention
5.1 Brake hoses/cables and lines
5.1 Brake hoses/cables and lines
Test each of the systems for pressure loss and leaks

!! Note after installing compressed-air lines and hydraulic lines.
Any work carried out on the vehicle must comply No other lines may be attached to brake hoses.
with accident prevention regulations. Lines must be protected from heat by means of insula-
tion.
!! Note Line routing must be designed to prevent any increase in
pressure loss.
Comply with all national regulations and laws.
All pipes, hoses and electrical lines should be routed so
Cover plastic lines and brake hoses before carrying out that they are free of mechanical stress.
any welding, drilling and grinding work or before wor-
king with cutting discs. If necessary, the plastic lines aa WARNING
and brake hoses should be removed. Work carried out incorrectly on the brake hoses or
cables may impair their function. This may lead to
the failure of components or parts relevant to safety.

5 Damage prevention
5.2 Position of cables in vehicle
Before modifying the vehicle, the data sheet "Electrical

connections" must be consulted.
All cables must be routed free of mechanical loads.
Schematic illustrations of the wiring and connection
points are shown below.

5 Damage prevention
5.2.1 Position of cables - Overall vehicle
Illustration: Position of wiring - hinged rear doors

1 Front/rear bumper wiring 6 Roof wiring
2 Front end wiring 7 Hinged rear door wiring
3 Engine wiring 8 Underfloor wiring
4 Multimedia wiring 9 Monoblock wiring
5 Left/right front door / left/right side sliding 10 Wiring of dashboard, passenger cell side/
door wiring engine side

5 Damage prevention
Illustration: Position of wiring - liftgate

1 Front/rear bumper wiring 6 Roof wiring
2 Front end wiring 7 Liftgate wiring
3 Engine wiring 8 Underfloor wiring
4 Multimedia wiring 9 Monoblock wiring
5 Left/right front door / left/right side sliding 10 Wiring of dashboard, passenger cell side/
door wiring engine side

5 Damage prevention
5.2.2 Cables and lines - ABS system 5.2.3 Firewall cable grommet
!! Note !! Note
A minimum distance of 100 mm must be maintained Observe chapter 4.6 „Limits for electrical/electro-
from the ABS systems and components (control unit, nic system“ (e Page 51) with respect to routing
wiring and sensor system). cables through the firewall.
Making additional holes or openings in the firewall is

not permissible.
Use the ex-factory preinstallation for routing cables.
Cut off the plastic preinstallation flush and route the
cable through. The plastic preinstallation is suitable for
cables with a maximum cross-section of 10 mm².
Ensure that the hole is sealed watertight.
Figure: Routing of cables and lines in ABS systems

- rear
Illustration: Cable routing through firewall

1 Cable grommet
N54.18-2140
Figure: Routing of cables and lines in ABS systems

- front

5 Damage prevention
5.3 Welding work
5.3 Welding work
• Before welding, cover springs and air suspension

aa WARNING
bellows to protect them from welding spatter. Do
Welding in the vicinity of the restraint systems (air- not touch springs with welding electrodes or welding
bag or belts) can cause these systems to no longer tongs.
function correctly. Welding is therefore not permit- • Cover the fuel tank and fuel system (lines, etc.)
ted in the vicinity of the restraint systems. before carrying out welding work.
• Use only completely dry basic-coated electrodes
aa WARNING (diameter 2.5 mm).
• The maximum current may be 40 A per mm of elec-
Welding work that is not performed correctly could trode diameter.
lead to failure of components relevant to safety. It
• Weld only with electrodes connected to the positive
would then not be possible to rule out the risk of
terminal of a direct current source. Always weld from
an accident. For this reason, the following safety
bottom to top.
precautions must always be observed during any
work involving welding: • MIG welding is possible.
• Only use welding wires with a thickness of between
• Welding work on the chassis may only be carried out 1 and 1.2 mm.
by trained personnel. • The yield point and tensile strength of the welding
• Do not perform any welding work on the following material must be at least equal to that of the mate-
components: rial to be welded.
• A-, B-, C- and D-pillars • Plug welding is only permissible in the vertical webs
• Crossmember structure of the longitudinal frame member.
• Major assemblies such as the engine, transmis- • Welds must be ground down and reinforced with
sion, axles. angular profiles to prevent notching from welding
penetration.
• Disconnect the positive and negative terminals from
the battery and cover them. • Avoid welds in bends.
• Connect the welding-unit earth terminal directly to • There must be at least 15 mm between the weld and
the part to be welded. Do not connect the earth ter- the outer edges.
minal to assemblies such as the engine, transmission
or axles. !! Note
• Do not touch electronic component housings For further information on welding, see Sec-
(e.g. control units) and electrical lines with the wel- tion 3.7 „Threaded and welded connections“
ding electrode or the earth terminal of the welding (e Page 36), 6 „Modifications to the basic
unit. vehicle“ (e Page 71), 6.2 „Bodyshell/body“
• Before welding operations in the vicinity of the seat (e Page 77) and the M ercedes-Benz Workshop
belts, airbag sensors or the airbag control unit, these Information System (WIS).
components must be removed for the duration of
the work. You will find important information about
handling, transporting and storing airbag units under
6.4 „Interior“ (e Page 98).

5 Damage prevention
5.4 Corrosion prevention measures
Surface and anti-corrosion protection measures must be Preventing contact corrosion by means of electrical
carried out on the areas affected after modifications and insulation
installation work have been performed on the vehicle.
1
!! Note
Only protective agents tested and approved by Daim-
ler AG may be used for any anti-corrosion protection
measures performed. 3
2
HH Environmental note 2
As of 01. 07. 2007, surface protection (e.g. including

acc. to DBL 9440.40) is no longer allowed to contain
chromium 6.
Planning measures
3
Anti-corrosion protection measures should be included
in the planning and design stages by selecting suitable
materials and designing components accordingly.
ii Additional information Figure: Preventing contact corrosion

1 Insulating washer
A conductive connection occurs if two different
metals are brought into contact with each other 2 Insulating sleeve
through an electrolyte (e.g. air humidity). This causes 3 Insulating intermediate layer
electrochemical corrosion and the less noble of the Contact corrosion can be prevented by using electrical
two metals is damaged. The further apart the two insulation such as washers, sleeves or bushings.
metals are in the electrochemical potential series,
Avoid welding work on inaccessible cavities.
the more intense electrochemical corrosion beco-
mes.
For this reason, electrochemical corrosion must be
prevented by insulation or by treating the compo-
nents accordingly, or it can be minimised by selec-
ting suitable materials.

5 Damage prevention
Component design measures Coating measures

Corrosion can be prevented by design measures, in The vehicle can be protected against corrosion by
particular the design of joints between identical or applying protective coatings (e.g. galvanisation, pain-
different materials. ting, preservation or zinc coating applied by flame)
There is a risk of dirt or moisture accumulating in corn- (e Page 68).
ers, edges, beads and folds. After all work on the vehicle:
Anti-corrosion protection measures can be included in • Remove drilling chips.
the design by using inclined surfaces and drains, and • Deburr sharp edges.
by avoiding gaps in the joints between components.
• Remove any burned paintwork and thoroughly pre-
Gaps inherent in the design of welded connections pare surfaces for painting.
and how to avoid them • Prime and paint all unprotected parts.
• Preserve cavities with wax preservative.
• Carry out corrosion protection measures on the
underbody and frame parts.
Figure: Examples of types of welded connection
A = correct B = incorrect
(through-welded) (gap)

5 Damage prevention
5.5 Painting work/preservation work
5.5 Painting work/preservation work
Mask the following areas before painting:

!! Note
• Disc brakes
To dry the paint, an air circulation temperature of • Brake hoses
80°C and a component temperature of 60°C must • Brake fluid reservoir
not be exceeded. Control units or other components
• Gearing unit for parking brake
can be damaged at higher temperatures.
• Contact surfaces between disc wheels and wheel
Paintwork or preservation agent damaged by the body hubs/brake discs
manufacturer must be repaired by the body manufactu- • Contact surfaces of wheel nuts/wheel bolts
rer. • Airbags and seat belts
Observe the following points: • Sealing surfaces
• Daimler AG quality standards for initial painting and • Windows, mirror glass
paintwork repairs must be adhered to. • Illumination openings
• Only materials tested and approved by Daimler AG or • Breathers on transmissions, axles, etc.
equivalently suitable materials may be used for any
painting or preservation work performed. • Door locks
• The body manufacturer must observe the coat • Door catches in the hinges of the hinged rear door
thickness for each individual coat as specified by the • Contact surfaces on the guide rails for the sliding
factory. doors
• Paint compatibility must be guaranteed when repain- • Door retainers and opening limiters in the centre
ting. guide rails
• Moving parts of the sliding door carriage
• Piston rods e.g. on gas-operated springs of liftgate
You can obtain information on the paint materials • Components in the vacuum system
and coat thicknesses used at the factory and Merce- • Spring/spring mounting area
des-Benz paint numbers from any Mercedes-Benz • Sensors in the parking assist system
Service Centre.
Additional information on paintwork and preserva-

tion is available to you in the "Guidelines for pain-
ting":
https://aftersales.mercedes-benz.com

5 Damage prevention
5.6 Storing and handing over the vehicle
5.6 Storing and handing over the vehicle
Storage
To prevent any damage while vehicles are in storage,
we recommend that they be serviced and stored in
accordance with the manufacturer's specifications
(e Page 41).
Handover
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 (e Page 42).

5 Damage prevention
5.7 Information on electromagnetic compatibility (EMC)
5.7 Information on electromagnetic compatibility (EMC)
Electrical interference occurs in vehicle electrical circuits

because of the various consumers. At Mercedes-Benz,
electrical and electronic components installed at the fac-
tory are checked for their electromagnetic compatibility
in the vehicle. If subsequent modifications are made, this
may cause a reduction in comfort in some cases (e.g.
radio noise).
When retrofitting electric or electronic systems, they
must be tested for electromagnetic compatibility and
this must be documented.
The notes under 8.9 „Retrofitting electrical equipment“
(e Page 142) and 4.6 „Limits for electrical/electronic
system“ (e Page 51) must be observed.
Information about EMC can be obtained from the follo-
wing rules and standards:
• CISPR 12
• CISPR 25
• DIN EN 55012
• DIN EN 55025
• DIN 40839
• ISO 7637
• ISO 10605
• ISO 11451
• ISO 11452
• MBN 10284
• ECE-R10

6 Modifications to the basic vehicle
6.1 Suspension
6.1 Suspension
6.1.1 General information on the chassis 6.1.2 Springs/shock absorbers

Modifications to springs, shock absorbers and stabilizer
aa WARNING
bars can only be made in the combinations specified
Impermissible modifications to components of the by Daimler AG on the front and rear axle. In this case
chassis can result in impaired and unstable vehicle a certificate of non-objection is not required. For any
handling characteristics. For this reason, no modifi- further modifications, the front and the rear axles must
cations whatsoever may be made to components of be adapted to each other and a certificate of non-objec-
the suspension system. tion is required.
• We recommend genuine Mercedes-Benz springs.
This is especially valid for: • Do not damage the surface or corrosion protection
• Front transverse control arms: modifications to of the springs during installation work.
wheel alignment settings are not permitted. • Before welding, springs must be covered to protect
• Engine support: It is not permitted to modify the them against weld pearls and thermal stress.
engine support to mount additional equipment or • Do not touch springs with welding electrodes or
make other modifications. welding tongs.
• Anti-roll bars: Any modifications to anti-roll bars On no account should springs or shock absorbers be
(diameter, material) at the front and rear, and the used if they do not correspond to the characteristics of
retrofitting of same, require a certificate of non-ob- standard parts or parts obtainable as special equipment.
jection from the department responsible. We recommend the use of standard Mercedes-Benz
• Rear axle: On no account should modifications be parts.
made.
aa WARNING
• Brakes: On no account should modifications be
made. On no account should springs and shock absorbers
• Units, sensors, line routing for ESP/ABS: on no be used if they do not correspond to the characteri-
account should modifications be made. stics of standard parts or parts obtainable as special
equipment. Otherwise, if the vehicle is fitted with
ESP, this system may no longer work correctly and
could ultimately fail. The driver could lose control of
the vehicle and cause an accident.
!! Note
Refer also to the special equipment available as a
code (e Page 44).

6.1 Suspension
Front axle Rear axle

The front axle has a pseudo-MacPherson design with The rear axle is a compound-link axle.
torsion bar. Various springs are available for the rear axle depen-
The different vehicle models have different springs ding on the payload of the vehicle.
depending on the mass of the front axle.
!! Note
Modifications are not permitted either at the front
axle or rear axle.
Further information about the axle variants can be
obtained from your Mercedes-Benz sales and service
outlet or the technical advice team (e Page 15).
Illustration: Front axle with springs

6.1 Suspension
6.1.3 Brake system Installation of lines
aa WARNING
aa WARNING
Work carried out incorrectly on the brake hoses,
A sufficient distance must be maintained between
lines and cables may impair their function. This may
brake lines and heat sources, sharp-edged or moving
lead to the failure of components or parts relevant to
parts. Otherwise, the brake system function could
safety. Have work on brake hoses, lines and cables
be impaired or the brake system could suffer total
only carried out by an authorised specialist work-
failure as a result of bubbles forming in the brake
shop.
fluid or from chafing points in the brake lines.
After completion of the work, check that the brake
• We recommend the use of genuine Mercedes-Benz
system is working correctly. We recommend that the
brake line brackets for the attachment of the brake
brake system be inspected and approved by a technical
lines.
inspection centre.
• The maximum permissible distance between loops
If the routing has to be altered, avoid routing across is 500 mm.
sharp edges and through narrow cavities or near
moving components. • All pipes, hoses and electrical lines should be rou-
ted so that they are free of mechanical stress.
Hydraulic brake system
Routing lines along the brake hoses
• Hydraulic brake lines must be completely replaced
with approved wrapped tube of 4.75 mm x 0.7 mm No other lines may be attached to brake hoses.
or 6 mm x 0.7 mm in case of modifications to the
routing.
• 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 to the ends of lines (part no. A 000 428
04 72) and make 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 it is not known how long a vehicle equipped with
a hydraulic brake system has been in storage, the
brake fluid must be renewed.
• The brake fluid must be renewed every two years.

6.1 Suspension
Disc brakes
Cooling must not be impaired by attaching spoilers
below the bumper, additional hub caps or brake disc
covers, etc.
aa WARNING

air inflow and air outflow of the brake system. Any
modifications to the steering and the brake system
may result in these systems malfunctioning and
ultimately failing. The driver could lose control of the
Brake system overheating will not only impair bra-
king ability, it can also cause tyre damage.
For this reason, make sure that there is a sufficient
supply of cooling air at all times.
aa WARNING
On no account should modifications be made to

brake components (e.g. calipers, discs, etc.) or sen-
sors. Any modifications to brake components may
result in these systems not functioning correctly and
ultimately failing. The driver could lose control of the

6.1 Suspension
Brake circuit
The master brake cylinder is always on the left-hand
side of the vehicle.
The length of lines and cables depends on the vehicle
length.
Illustration: Brake circuit

1 Front axle
2 Axis of vehicle body
3 Master cylinder, brake fluid reservoir
4 ABS-ESP block

6.1 Suspension
6.1.4 Air suspension The body manufacturer must ensure that:
• The distance from the tyre to the mudguard or wheel
aa WARNING arch is sufficient, even if snow or anti-skid chains are
fitted and the suspension is fully compressed (allo-
On no account should springs and shock absorbers
wing for axle distortion as well). The relevant specifi-
be used if they do not correspond to the characteri-
cations in the tender drawings must be observed.
stics of standard parts or parts obtainable as special
equipment. This applies, in particular, to the retro- • Only approved tyre sizes are used, see "Motor
fitting of air suspension. Otherwise, the result may vehicle registration certificate", (e Page 17) and
be that the ESP, for example, no longer functions (e Page 46).
correctly or even fails. The driver could lose control • only permissible wheels are used (e Page 17).
of the vehicle and cause an accident.
!! Note
6.1.5 Wheels/Tyres You can obtain more information about tyres and
wheels from any Mercedes-Benz Service Centre or
aa WARNING under 3.10 „Special equipment“ (e Page 44).
Only fit tyres of a type and size approved for your

vehicle and observe the tyre load-bearing capacity 6.1.6 Spare wheel
required for your vehicle and the tyre speed index. When mounting a spare wheel, observe the following:
In particular, comply with national regulations con- • Legal requirements
cerning the approval of tyres. These regulations may
• Must be easily accessible and easy to handle
define a specific type of tyre for your vehicle or may
forbid the use of certain tyre types which are appro- • Must be double-secured against detachment
ved in other countries.
If you fit other wheels
• the brakes or components of the suspension
system could be damaged
• wheel and tyre clearance can no longer be gua-
ranteed
• the wheel brakes or components of the suspen-
sion system may no longer function correctly.

6.2 Bodyshell/body
6.2 Bodyshell/body
6.2.1 General information on the bodyshell/ Welding work on the bodyshell

body
Modifications must not have a negative effect on the aa WARNING
function or strength of vehicle equipment or controls or
on the strength of load-bearing parts. Impermissible welding work carried out in the area
of the airbags could cause them to function incorrec-
In the case of modified vehicles, it is not permissible to tly (e.g. they could trigger unexpectedly while driving
make modifications that affect the function or freedom or fail completely) (e Page 16). For this reason,
of movement of vehicle parts (e.g. during maintenance welding work must not be performed near airbags.
and inspection work) or accessibility of these parts.
In Germany, the handling, transportation and storage
Observe the following: of airbag units are subject to the law on explosive
• Changes to the wheelbase are not permitted. substances (Gesetz über explosionsgefährliche
• In general, any interference with the structure of the Stoffe).
crossmembers should be refrained from.
• On no account should modifications be made to the Drilling work on the frame
rear door opening or to the roof area.
• The clearance for the fuel filler neck, fuel tank and
!! Note
fuel lines must be maintained (e Page 95). Parts which must not be drilled:
• Avoid sharp-edged corners. • The lower flange of the frame
• No drilling or welding work may be carried out on the • Areas with a load-bearing function for the rear
A-, B-, C- and D-pillars. axle or parts fastened to the frame
• The maximum permissible axle loads must not be • Load application points
exceeded.
• Trailer connections must be checked for correct After drilling, deburr and countersink all holes, remove
operation. chips from the frame where possible and treat the holes
• Holes in the longitudinal frame member are the with body cavity sealant.
result of the production process and are not suitable
for all attachments, bodies, equipment and conver-
sions. On no account may holes resulting from the
production process be used, as this could damage
the frame.

6.2 Bodyshell/body
Drilling in floor of cargo area

The schematic illustration below shows the position
of the elements under the floor (fuel tank, muffler and
spare wheel etc.).
Before drilling, always pay attention to the various ele-
ments underneath the sheet metal being drilled such as
the tank, wiring, brake hoses, handbrake cable etc.
Anti-corrosion treatment must be applied to every hole
drilled through the sheet metal.
Illustration: Drilling areas, wheelbase 2

1 Exhaust system
2 Fuel tank
3 Spare wheel
A, B, C Recommended drilling areas
When drilling, observe the following distances:
• Distance in drilling area A, from floor to centre
channel, 284 mm
Illustration: Drilling areas, wheelbase 1 • Distance in drilling area B and C, from floor to spare
wheel, 60 mm
1 Exhaust system
2 Fuel tank
3 Spare wheel
A, B Recommended drilling areas
When drilling, observe the following distances:
• Distance in drilling area A and B, from floor to spare
wheel, 60 mm

6.2 Bodyshell/body
6.2.2 Fastening rings in cargo area Position of fastening rings
Eight, eleven or twelve fastening rings are installed in
the vehicle depending on the version. The fastening
rings are located symmetrically to body axis X. They are
attached to the body with mounting bolts M8 X 26.5.
All fastening rings correspond to standard DIN 75410.
Illustration: Fastening rings

1 Fastening ring on body
2 Fastening ring on floor Figure: R1 mounts with two seats
1 Fastening rings on body
Fastening rings
2 Fastening rings on floor
Body Floor
Bore Ø 6.2 x 12.2 Ø 9.2
Maximum load per 50 daN 500 daN
ring

6.2 Bodyshell/body
Illustration: Fastenings on R2 with two seats and Illustration: Fastenings on R2 with two seats and
one sliding door two sliding doors
1 Fastening rings on body 1 Fastening rings on body
2 Fastening rings on floor 2 Fastening rings on floor
3 Mounting holes with welded nuts M10 3 Mounting holes with welded nuts M10

6.2 Bodyshell/body
Illustration: Fastenings on R3 with two seats and Illustration: Fastenings on R3 with two seats and
one sliding door two sliding doors
1 Fastening rings on body 1 Fastening rings on body
2 Fastening rings on floor 2 Fastening rings on floor

6.2 Bodyshell/body
6.2.3 Modifying the partition wall Installing a new partition wall
If it is necessary to cut through the partition, it is • Enough space must be left so that side airbags and
possible to do this in connection with a continuous - if installed - curtain airbags can deploy.
surrounding frame. • It must be possible to move the driver and front
Partitions may be totally or partially removed. Also passenger seat sufficiently far to the rear.
observe 7.2 „Modifications to panel vans/passenger • It must be possible to adjust backrests adequately
vans“ (e Page 117). to the rear.
• Country-specific regulations must be observed.
aa WARNING
On no account should subsequent modifications be Installation of a sealed partition wall

made to the headliner or roof panel if the vehicle is • Forced ventilation from the cab must be put in
equipped with windowbags. Otherwise, the window- place so that the doors can be closed without
bag may no longer work correctly (e.g. windowbag problem and so that heating, ventilation and airbag
deployment is delayed or incomplete). deployment operate properly:
• Air vent area of at least 10000 mm2
Various partition wall types are available for the Citan: • No water or air entry from outside
• One-piece grille partition wall for left- and right- • No entry of dust or dirt
hand drive
• No increase in noise
• Grille partition wall with swivelling right-hand part,
• Secure (deflector which prevents access to the
only for left-hand drive.
controls for opening the doors)
• Continuous sheet metal partition wall for left- and
• Protected against impacts (e.g. from pebbles)
right-hand drive
• Continuous sheet metal partition wall with window,
only for left-hand drive.
• Two-piece bar-type partition wall behind second
seat row.
• The partition walls are attached with:
• M6 screws/bolts or nuts using a tightening torque
of 8 Nm.
• Self-locking M8 screws/bolts using a tightening
torque of 21 Nm.

6.2 Bodyshell/body
Continuous sheet metal partition wall Bar-type partition wall

The grille partition wall code DW5 behind the driver's
seat is a special equipment.
Figure: Continuous sheet metal partition wall

1 Frame of sliding door
2 Continuous sheet metal partition wall Illustration: Bar-type partition wall
1 Frame of sliding door
2 Grille partition wall

6.2 Bodyshell/body
Swivelling grille partition wall

The swivelling grille partition wall (load protection grille)
is available as an option in combination with a spring-
back front passenger seat and automatic locking.
Figure: Swivelling grille partition wall

1 Fixed part of partition wall
2 Swivelling part of partition wall
3 Fixed part of partition wall (as per DIN)
The fixed part (3) is required to comply with the DIN
standard on a country-specific basis. It is available
in two versions - depending on whether the vehicle is
equipped with a left or right side sliding door.

6.2 Bodyshell/body
Sheet metal partition wall

The closed sheet metal partition wall without window
code D50 is available for LHD and RHD variants. For the
commercial vehicle variants it is the series.
Illustration: Sheet metal partition wall with window

1 Driver seat indentation
2 Upper and lower part of sheet metal partition wall
3 Window (15 dm2)
Illustration: Sheet metal partition wall (LHD
vehicle)
1 Driver seat indentation
2 Upper and lower part of sheet metal partition wall

6.2 Bodyshell/body
Folding grille partition wall 6.2.4 Sidewall, windows, doors and

flaps
The folding grille partition wall separates the driver and
front passenger compartment from the cargo area. If Sidewall
the seats in the second seating row are tipped over, it If modifications are made to the sidewall of the panel
protects the driver and passenger compartment. It is van or the passenger van, the rigidity of the modified
only available for the Mixto (5-seater, wheelbase 3). body must be equal to that of the basic vehicle.
The roof frame must be retained and its function may
not impaired in any way.
A certificate of non-objection is required from the
department responsible (e Page 16).
!! Note
Upon completion of all work on the vehicle, you
must comply with the specified corrosion prevention
Doors and flaps

If modifications need to be carried out to the suppor-
ting structure of the basic vehicle (frame cross mem-
bers, pillars, reinforcements, attachment of roof bows)
in order to retrofit doors, the rigidity of the modified
body must be equal to that of the basic vehicle.
!! Note
Figure: Folding grille partition wall Any modifications to the rear door opening including
the roof area are only permitted in exceptional cases
1 Upper part of grille partition wall
and require a certificate of non-objection from the
2 Lower section of bar-type partition wall department responsible (e Page 15).
3 Nuts M6
4 Self-locking bolts M8

6.2 Bodyshell/body
Sliding door
The specified dimensions are the overall dimensions for
access through the sliding door, the entrance dimen-
sion and the position of the sliding door in relation to
the panel van.
The dimensions apply to both a left-hand and right-
hand sliding door.
N23.00-2031-00
1 Area of the rear portal
• Seats must be accessible directly from the outside

via 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.
Illustration: Opening dimensions - sides
• Fittings must allow sufficient clearance to the inte-
rior door handles regardless of the position of the The outward projection of the sliding door at the side
cargo area sliding door (anti-pinch protection). (closed state compared to open state) is approximately
• On no account should modifications be made to 115 mm.
the central locking system or to the immediate area 1 Axis of vehicle body
around the door or in the area of the pillars or cross 2 Minimum dimension of opening with full-length
members. partition wall - 479 mm
Minimum dimension of opening with tubular parti-
!! Note tion wall - 466 mm
Upon completion of all work on the vehicle, you
must comply with the specified corrosion prevention

6.2 Bodyshell/body
Rear-end doors and liftgates
Illustration: Opening dimensions - Rear end
Figure: Dimensions of the rear-end doors - Opening

180 °

90 °

6.2 Bodyshell/body
Vehicle heights (empty)

Vehicle Wheel- Vehicle height [mm]
model base
Panel van R1 1810
R2 1816
R3 1839
Passenger R2 1809
van (1868 with roof railing)
Mixto R3 1823

90 °
1 Maximum height at kerb weight
2 Minimum height at maximum GVW
Figure: Dimensions of the liftgate - Opening 91 °

Minimum height at maximum GVW/maximum height at
kerb weight

6.2 Bodyshell/body
6.2.5 Mudguards and wheel arches 6.2.7 Underfloor panelling
If parts of the standard underfloor panelling are remo-
aa WARNING
ved, additional corrosion protection is required in the
Lowering the wheel arches is not permissible. entire underfloor area.
Otherwise, the vehicle could be damaged (e.g. wheel If trim parts are removed, this can cause wind noises.
arches and tyres).
6.2.6 Bodyshell
Observe the following:
• Modifications to the wheelbase, the structure of
the longitudinal members, the windscreen and
windscreen frame or to the A or B-pillars are not
permissible.
• In general, any interference with the structure of
the crossmembers is not permissible.
• All modifications must be presented in advance in
the form of drawings and calculations and approved
by the vehicle manufacturer.
• The clearance for the fuel filler neck, fuel tank and
fuel lines must be maintained. Avoid sharp-edged
corners.
• The seat mounting consoles of the 1st and 2nd
rear seat row as well as the standard anchoring
lugs and their mounting points must be used with
priority when retrofitting attachments in the interior
compartment.
• Brackets (plug welds) must be used to attach
additional equipment to the longitudinal and cross
members. These 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.
• Trailer connections must be checked for correct
operation.

6.2 Bodyshell/body
6.2.8 Panel van/passenger van roof Superstructures
aa WARNING The permissible centre of gravity and axle loads must
be observed.
On no account should subsequent modifications be Roof height increase
made to the headliner or roof panel if the vehicle is
equipped with windowbags. Otherwise, the window- Increasing the height of the roof of the basic vehicle is
bag may no longer work correctly (e.g. windowbag not permissible.
deployment is delayed or incomplete).
aa WARNING
Vehicle heights (empty) The maximum permissible height for the centre of
Vehicle model Wheelbase Vehicle height gravity must not be exceeded.
[mm] Otherwise, if the vehicle is fitted with ESP, this sys-
Panel van R1 1810 tem may no longer work correctly and could ultima-
R2 1816 tely fail. The driver could lose control of the vehicle
and cause an accident.
R3 1839
Passenger van R2 1809 Retrofitting a pop-up roof
(1868 with roof
railing) aa WARNING
Mixto R3 1823
On no account should subsequent modifications be
Location of roof bows made to the headliner or roof panel if the vehicle is
equipped with windowbags. Otherwise, the window-
Removing the roof bows of the basic vehicle is not bag may no longer work correctly (e.g. windowbag
permissible. deployment is delayed or incomplete).
!! Note Maximum roof loads
The bows must be secured to the side panels in such The maximum permissible load on the carrier or on the
a way that a non-positive connection is guaranteed roof railing (code D11) is 80 kg. The roof load must be
(bend-resistant connection of bows and roof panel). evenly distributed on the left and the right.
Contact the "Body Technical Advice" team about this For versions R1 (wheelbase 1) and R2 (wheelbase 2) of
topic (e Page 15). the panel van, each with a ladder flap (code DL2), the
maximum load of the crossmembers is 60 kg.
For additional information see 4.3.2 „Vehicle roof/

roof load“ (e Page 48) and 3.9.2 „Battery
maintenance and storage“ (e Page 42) and 2.3
„Advice for body manufacturers“ (e Page 15).

6.2 Bodyshell/body
Roof modifications
aa WARNING
Modifications to the roof must not impair the

function of any components relevant to safety (e.g.
airbag units, sensors, pedals, gear lever, lines or
others). This may lead to the failure of components
or parts relevant to safety.
bag may no longer work correctly (e.g. windowbag
Illustration: Reference point for roof cutouts
Observe the permissible centre of gravity and the per-
missible axle loads must be maintained. !! Note
Roof cutouts • The definitions for cutouts A and B apply to
Roof cutouts must comply with the maximum values lis- panel vans R1 and R2.
ted below. If necessary, reinforcements with a suitable • The definition for cutout C only serves to deter-
structure must be added. mine the maximum values (emergency vehicle
warning light, triple flasher). However, the maxi-
Reference point for roof cutouts mum opening cannot be cut out on panel van R2.
The starting point of all cut dimensions refers to the
edge of the square hole for the aerial and the symmetri-
cal axis of the vehicle.

6.2 Bodyshell/body
Dimensions for roof cutouts
Illustration: Roof cutouts R1

6.2 Bodyshell/body
Illustration: Roof cutouts R2

6.3 Engine peripherals/drivetrain
6.3.1 Fuel system

Modifications to the fuel system may only be carried
out with the approval of the department responsible
(e Page 15).
The clearance of the fuel filler neck, fuel tank and fuel
lines must be maintained.
!! Note
Non-approved modifications to the fuel system (tank,
lines etc.) may lead to impaired driving performance
and trigger engine emergency running mode.
For connections supplying fuel for auxiliary heating, the

procedure for design approval must be followed.
that they are free of mechanical stress.
Modifications carried out incorrectly to the fuel sys-

tem may have a detrimental effect on the environ-
ment.

6.3.2 Exhaust system It is not permissible to relocate the fastening hooks of
On no account may any modifications be made to the the original exhaust line.
exhaust system.
The following minimum clearances from plastic lines,
electric cables and spare wheels must be maintained
with all modifications:
• 200 mm for exhaust systems without shielding
• 80 mm with sheet metal shielding
• 40 mm with sheet metal shielding and additional
insulation
Additional shielding is required
• Near control panels
• Near assemblies, attachments and equipment, Figure: Exhaust system of panel van, wheelbase
unless they are made of heat-resistant material. R1, petrol engine MO4
1 Catalytic converter
Exhaust line
2 Muffler
The position of the exhaust system depends on the
type of vehicle, the wheelbase and the engine.
Figure: Exhaust system, passenger van & panel

Figure: Exhaust system of panel van, wheelbase van, wheelbase R2, diesel engine MO3
R1, diesel engine MO3 1 Particulate filter
1 Particulate filter 2 Muffler
2 Muffler

Engine cooling system 6.3.3 Engine air intake
It is not permissible to modify the cooling system (radi- Modifications to the engine air intake are not permis-
ator, radiator grille, air ducts, coolant circuit, etc.). sible.
An adequate throughput of cooling air must be guaran- The filtered-air side of the engine air intake system
teed: must not be modified in any way.
• Do not obstruct the radiator air inlet. Warm air
• Do not affix warning signs, labels or decorative • The intake of warm air will lead to a loss of engine
objects in the area in front of the radiator. power. A bulkhead between the intake point and
Provision for additional cooling equipment for assem- the engine compartment is therefore essential.
blies shall be made for when the vehicle is stationary • The intake temperature should not exceed the outs-
and if a high continuous output is demanded. ide temperature by more than 10 °C.
Disc brakes Water

Cooling must not be impaired by attaching spoilers • Make sure that water cannot reach the intake
below the bumper, additional hub caps or brake disc points through any fresh-air inlets. The flow rate at
covers, etc. the intake points must not be increased by modifi-
cations to the opening of the intake points.
aa WARNING Dust/dirt
• The area of the intake must be shielded against
Modifications to the air flow of the brake system can
swirling dust from the wheel arch.
negatively affect the braking power.
• Increased dust intake will lead to shorter main-
In extreme cases, brake system overheating will not
tenance intervals for the air filter.
only impair stopping power, it can also cause tyre
damage.
For this reason, modifications which impair the flow
of cooling air to the brake system are only permis-
sible in consultation with Daimler AG (e Page 15).

6.4 Interior
6.4 Interior
6.4.1 General For the modification of vehicles in the Federal Repub-

Modifications in the cockpit area and above the waistrail lic of Germany, appropriate information sheets can be
are not permitted. requested from the relevant technical inspection autho-
rities for motor vehicles (e.g. TÜV (Technical Inspection
aa WARNING Association), DEKRA).
The interior fittings must be designed in such a way that
On no account may any modifications be made there are no sharp edges or corners (accident preven-
to the airbag system or the emergency tensioning tion).
retractor system.
Fittings must be made of flame-resistant materials and
Modifications to or work incorrectly carried out on a be fitted securely.
restraint system (seat belt and seat belt anchorages,
Unimpeded access to the seats must be ensured. There
airbag) or its wiring could cause the restraint sys-
must not be any protruding parts, edges or corners
tems to stop functioning correctly. This means, for
which could cause injury in the area of the seats.
example, that airbags may be activated inadvertently
or may fail in the event of an accident even though
the rate of deceleration exceeds the deployment
threshold.
This applies in particular to the deployment areas of the

airbags (wooden trim, additional fittings, mobile phone
holders, bottle holders, etc.).
See the illustrations of the airbag deployment areas for
more information (e Page 103).
The permissible centre of gravity and maximum permis-
sible axle loads must not be exceeded.

6.4 Interior
6.4.2 Safety equipment
Seat belts
aa WARNING
Vehicles designed to travel at a maximum speed of over
25 km/h must be equipped with seat belts (see mini- We advise against removing the seat belt system or
mum requirements for seat belts, ECE-R16). its components. If removal is unavoidable, the points
The anchoring of the seat belts must be tested according listed in the table must be observed.
to EC Directive ECE-R14.
The legal requirements detailed in this section relate
to current legislation in Germany. The relevant national
legislation must be observed in all other countries.
Anchoring Remarks
Bevel gear on vehicle body Pre-installed screw/bolt on bevel gear of the seat belt. During
reinstallation, the bolt cannot be replaced.
Emergency tensioning retractor on vehicle Once the bolt has been removed, it cannot be reused. It must be
body replaced with a new bolt.
Belt fitting anchor on seat
Belt fitting anchor on vehicle body
The following must also be observed: Check the following when installing emergency tensio-
• No other components may be added to the original ning retractors
equipment. • Correct indexing position of emergency tensioning
• The anchors must be tightened using a torque retractor before bolting.
wrench and a tightening torque of 21 Nm + 15 %. • The belt may not be twisted between the emergency
• No modifications may be made to seat belts. tensioning retractor and last anchor point.
• No foreign objects may come into contact with the
belt.
• The belt may not be changed due to the vehicle
modification.

6.4 Interior
Illustration: Anchoring of seat belts - two sliding

doors
1 Front axle
2 Anchor - left rear
3 Anchor - right rear

6.4 Interior
Figure: Anchoring of the seat belts - Without sliding

doors
1 Front axle
2 Anchor - front
Vehicle heights (empty)
Vehicle Wheelbase Vehicle height [mm]
model
Panel van R1 1810
R2 1816
R3 1839
Passenger R2 1809
van (1868 with roof
railing)
Mixto R3 1823

6.4 Interior
Airbags and emergency tensioning retractors aa WARNING

The driver and front passenger airbag units, the
windowbags and the emergency tensioning retractors If modifications are made to the vehicle structure by
are pyrotechnic components. the body manufacturer, such as:
Handling, transportation and storage are subject to • modifications to the seats and thus changes in
legislation concerning potentially explosive substances the kinematics of the occupants in the event of
(for example, the “Gesetz über explosionsgefährliche an impact
Stoffe” in Germany) and must therefore be reported to • modifications to the frame front end
the relevant trades inspectorate. • installation of parts in the vicinity of airbag infla-
The purchase, transportation, storage, fitting, removal tion points or in airbag deployment areas
and disposal of potentially explosive substances may • installation of non-MB seats
only be carried out by trained personnel and in accor- • modifications to the A-pillar and B-pillar, the roof
dance with the relevant safety regulations. frame and its lining
All airbag units are labelled with "Airbag" or "SRS": reliable operation of the front airbag, windowbag and
• The driver's airbag unit is identified by the "Airbag" emergency tensioning retractors is no longer guaran-
inscription on the steering wheel boss. teed. This could result in personal injury.
• The front passenger airbag unit is also identified by
the "Airbag" inscription.
• Windowbags are identified by the "Airbag" inscrip-
tion on the side of the headliner.
An additional identifying feature is the red indicator
lamp on the instrument cluster (6).
The following illustrations show the location and deplo-
yment areas of the thorax bag, driver and front passen-
ger airbags and windowbag.
!! Note
Modifications to the floor structure in the area of the
airbag control unit are not permitted.

6.4 Interior
Airbag deployment range
Illustration: Deployment range of dashboard

airbags
Airbag deployment range
Airbag Width Height Depth
[mm] [mm] [mm]
Driver airbag 500 550 260
Front passenger airbag 520 680 350

6.4 Interior
Airbags installed in vehicle

The installed airbag units in the Citan comprise the
driver airbag, front passenger airbag and windowbag
in addition to the thoraxbag (special equipment) in the
driver and front passenger seats.
Illustration: Position of airbags in vehicle

1 Driver airbag (standard equipment)
2 Front passenger airbag
3 Thorax sidebag, driver
4 Thorax sidebag, front passenger
5 Windowbag, driver
6 Windowbag, front passenger
7 Airbag control unit

6.4 Interior
Airbag control unit and side crash sensors Transport of airbag and emergency tensioning
It is not permitted to modify the standard installation retractor units
location, installation position and attachment of airbag Internal transport should always be carried out using
control units for occupant safety systems and side the spare parts packaging and utilising the vehicle
crash sensors on vehicles equipped with windowbags. trunk or cargo area.
It is not permitted to attach or position other vehicle
components on the airbag control unit, side crash sen- !! Note
sors or their attachment points.
Transporting airbag units in the passenger compart-
aa WARNING ment in any way is prohibited.
Vehicle parts that produce vibrations must not be Storage of airbag and emergency tensioning
attached in the vicinity of the airbag control unit or retractor units
sensor mounting points, otherwise the reliable fun- In Germany, airbag and emergency tensioning retractor
ctioning of the front airbag, windowbag and emer- units must be stored in accordance with the second
gency tensioning retractors is no longer guaranteed. ordinance of the German Explosives Law (Zweite Ver-
This could result in personal injury. ordnung zum Sprengstoffgesetz) dated 17.04.86.
This ordinance allows small amounts of substances and
The airbag control unit incl. triggering sensors and the
materials to be stored in secure areas as specified in
ESP turn rate sensor are located in the footwell/centre
the Explosives Law without requiring special storage
console behind the trim.
permission.
When removed, ESP turn rate sensors are susceptible
Class T1 pyrotechnic materials may only be stored in
to shock and must be stored in a shock-free environ-
limited quantities on premises used for commercial
ment.
purposes.
aa WARNING Annex 6 of the appendix to the second ordinance of
the German Explosives Law specifies that the following
For safety reasons, ESP turn rate sensors may maximum storage quantities are permissible without
no longer be installed if they are dropped on the obtaining special approval from the relevant authority,
floor. In this case, a genuine replacement part from where materials are stored on premises used for com-
Mercedes-Benz must be installed. mercial purposes and certain conditions are fulfilled
(e.g. steel cabinet):
• General storage space: 20 kg gross

6.4 Interior
Installing and removing airbag and emergency The vehicle battery must be disconnected, the negative
tensioning retractor units terminal covered and the test coupling/connection dis-
connected before the airbag and emergency tensioning
• Test and installation work may only be carried out
retractor units are removed.
and supervised by trained personnel.
• The airbag and emergency tensioning retractor Disposing of airbag and emergency tensioning
units must be fitted without delay and immedia- retractor units
tely on removal from storage. The vehicle battery In Germany, airbag and emergency tensioning retrac-
must have been disconnected, the negative pole or tor units must be electrically detonated as specified in
negative terminal covered and the test coupling/ accident prevention regulations and in accordance with
connection disconnected. the safety specifications to render them unusable prior
• If work is interrupted, the airbag and emergency to disposal.
tensioning retractor units must be locked away These safety measures are necessary because pyro-
again. technic materials could cause injury if activated incor-
Safety precautions for handling airbag and rectly.
emergency tensioning retractor units
!! Note
aa WARNING Airbag and emergency tensioning retractor units
must be disposed of by personnel who have under-
Removed airbag units must always be stored in such gone special training for this task. Accident preven-
a way that the upholstered side faces upwards. If the tion regulations must be observed.
upholstered side faces downwards, the airbag unit
will be catapulted through the air if it is triggered Hazards arise from disposal using cutting torches, by
accidentally. smelting, or if primed parts are disposed of on open
fires or smouldering fires on waste disposal sites.
• The airbag and belt tensioner units may not be tre-
ated with grease, cleaning agents or other similar In order to ensure that no additional work arises due
products. to these safety precautions, we recommend that you
entrust the disposal of pyrotechnical substances to an
• The airbag and emergency tensioning retractor
external waste disposal company, which will implement
units may not be exposed to temperatures above
the required safety precautions (incl. 10 m safe dis-
100 °C, even for a short period of time.
tance, special ignition equipment).
Airbag and emergency tensioning retractor units must
When the materials are handed over, the waste dispo-
be replaced if they are dropped from a height of more
sal company must sign a declaration containing the
than 0.5 m. Airbag and emergency tensioning retractor
obligation to dispose of the pyrotechnical materials
units may only be subjected to electrical tests using the
in accordance with accident prevention regulations.
specified testers when the airbag and emergency tensi-
Agreements of this kind must ensure that it is not pos-
oning retractor units have been fitted. We recommend
sible to extract pyrotechnical materials after disposal
that tests be carried out at a Mercedes-Benz Service
and to pass them on for repairs.
Centre.

6.4 Interior
Handling airbag and emergency tensioning 6.4.3 Seats

retractor units Proof of the strength of the seats delivered from the
Work involving removed airbag and emergency tensio- factory is only valid if the seats are secured in original
ning retractor units must only be carried out by skilled mountings. Any deviations from this requirement must
personnel. be agreed upon with the relevant department.
• In the event of a crash in which a certain decelera- If rear seats with two-point or three-point seat belts
tion threshold is exceeded, the airbag and emer- deviate from the standard seat design, they must com-
gency tensioning retractors are triggered by an ply with the requirements of ECE R14.
electrical signal sent by the control unit. This makes Seats without seat belts are not permissible. The ECE
a replacement necessary. R14 test certificate (tensile test including floor assem-
• If emergency tensioning retractors that have not bly) is required for approval by Daimler AG. Test certifi-
been triggered require detonation for disposal pur- cates for seats on a rigid plate will not be accepted.
poses, place them in the footwell of a vehicle which
has been sent for scrapping, and connect them aa WARNING
directly using a 2-pin plug.
For safety reasons, Mercedes-Benz recommends
• If the upholstery pads on the airbag units have not only using seat covers which have been tested for
been destroyed, the airbag units must be detonated Mercedes-Benz vehicles and which are equipped
using the 2-pin plug. with a cutout for thorax sidebags. Otherwise, thorax
sidebags may not be able to inflate correctly and
offer the intended protection in an accident. This
could result in personal injury.
You can obtain suitable covers at a Mercedes-Benz
Service Centre, for example.
Please also refer to the additional information in the
operator's manual of your vehicle.
!! Note
Information on retrofitting seats can be found in
chapter 7 „Design of bodies“ (e Page 115).

6.4 Interior
Removal and reinstallation of seats

If it is necessary to remove seats as part of a modifi-
cation, it is not permissible to use any parts other than
the original components for reinstallation.
All work should be carried out with the seat contacts
disconnected, the battery contacts disconnected and
airbag control unit locked (use diagnostic tool).
Due to static electricity, contact with conducting parts
of the pyrotechnical elements (belt pretensioner or
airbag) should be avoided.
Re-installation of the seats must be carried out with a
torque wrench and in compliance with the tightening
torques from the table below.
aa WARNING
Bolts may not be reused once removed. Removed

bolts must be replaced with new bolts.

6.4 Interior
Tightening torques - Seats
Torque Position
Front seat mounting
Fastening points 30 Nm + 15 % See „Illustration: Position of fastening points“
Body (e Page 110) item 1.
Rear bench mounting
Fastening points 21 Nm + 15 % See2.3.7 „Workshop Information System (WIS)“
Front cap (e Page 19) item 4.
Fastening points 44 Nm + 15 % See „Illustration: Position of fastening points“
Rear cap (e Page 110) item 2.
Attachment point 62 Nm + 15 % See „Illustration: Position of fastening points“
6th point (e Page 110) item 3.
Information about the mounting material and the

required parts can be obtained from your Merce-
des-Benz Service Centre.

6.4 Interior
Position of fastening points - Seats
Illustration: Position of fastening points

1 Front seat fastening points
2 Rear bench fastening points - rear cap
3 Rear bench fastening point - 6th point
Illustration: Position of fastening points - Rear

bench
1 Rear bench fastening points - front cap

6.4 Interior
6.4.4 Reducing noise in the vehicle interior Roof and side panels
Noise-insulating material can be installed in order to In addition to effective insulation, the insulating materi-
reduce the noise level in the vehicle interior. It must be als used should have the following properties:
barely inflammable.
• Not hygroscopic
Floor area • Not water-retaining
A structure as shown in the illustration is advisable for • Not water-absorbing
insulation and soundproofing. An additional covering • Not water-attracting
with heavy-duty insulating foil may be provided in the
area of the wheel arches. • Water-repellent
Arrangements are to be made for the rapid and unhin-
!! Note dered drainage of accumulated moisture or condensa-
tion in order to avoid conditions that promote corros-
Insulating foils, e.g. bituminous felt, have limited ion.
temperature resistance. They should therefore not
The standard drain holes must be preserved intact.
be installed in the immediate vicinity of the engine or
If necessary, additional drain holes must be crea-
exhaust system.
ted after consultation with the relevant department
(e Page 16).
The inside must be covered with a sound-transmitting
material (perforated card, plastic, fabric cover).
aa WARNING

Seals
Openings, gaps and slots between the engine compart-
ment or the vehicle underside or the bulkhead and the
vehicle interior must be carefully sealed with elastic
material. Vent openings must not be fitted in the imme-
diate vicinity of sources of noise.
1 Carpet (rubberised underside)
2 Wooden floor (12 mm plywood)
3 Heavy-duty insulating foil (weight per unit area 8-10
kg/m2)
4 Supporting construction

6.4 Interior
In addition, the information from the manufacturer of 6.4.6 Auxiliary heating
the soundproofing material used must be observed. The floor of the vehicle must be airtight if exhaust
Here you can also obtain information about optimal gases are routed out under the vehicle.
soundproofing.
Openings in the vehicle floor provided for control
panels must be sealed with rubber boots.
6.4.5 Ventilation
The interior compartment and driver area must have Retrofitting auxiliary heaters
adequate ventilation with provision for air to enter and When retrofitting an auxiliary heating system, the speci-
exit. fications for fire protection, impact performance and
Defrosting of the windscreen and side windows must accident protection must be observed. The danger of
remain effective. poisoning or suffocation due to gaseous substances
must be prevented through the selection of the installa-
tion location or through appropriate sealing measures.
The following components of the auxiliary heater may
not be mounted within the cab, the passenger compart-
ment or cargo area:
• Auxiliary heating
• Exhaust pipes of the auxiliary heater
• Ventilation equipment for the components in the
auxiliary heater system
• Fuel lines
• Fuel tank and tank filler neck
that they are free of mechanical stress.
Contact the "Body Technical Advice" team

before installing auxiliary/stationary heaters
(e Page 15).

6.5 Attachments
6.5 Attachments
The permissible axle loads must always be complied Fastening points

with, see section 4 „Technical threshold values for plan-
ning“ (e Page 45).
Attachments must not impair the function of vehicle
parts.
Comply with national legal requirements.
6.5.1 Roof racks

• Make sure that the load is distributed evenly across
the entire roof area.
Limits for roof load
Roof type Max. roof loads Illustration: Crossmember - Roof with ladder flap R2
Normal roof 100 kg* 1 Front axle
Roof with ladder flap 60 kg**
(code DL2)
* Gross weight from roof mounting system, roof
racks and simultaneously distributed payload on
the left and right (not for ladder flap code DL2).
** Payload for panel van with wheelbase 1 and
wheelbase 2 with code DL2 (ladder flap not
present for wheelbase 3).
For additional information see 4.3.2 „Vehicle roof/ Illustration: Roof railing/roof carrier - Normal roof R2
roof load“ (e Page 48) and 6.2.8 „Panel van/pas-
senger van roof“ (e Page 91) and 2.3 „Advice for 1 Front axle
body manufacturers“ (e Page 15).

6.5 Attachments
6.5.2 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
!! Note
On no account should attachments transfer forces
only to the vehicle sidewalls.
Illustration: Roof railing/roof carrier - Normal roof R1
1 Front axle 6.5.3 Trailer coupling
We recommend only using trailer couplings (AHK)
approved by Mercedes-Benz or of equal reliability. These
should only be attached at the intended 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).
• Attachment of the trailer coupling must comply with
the specifications of the countries in question: e.g.
as per ECE-R55 within the EU.
• If there are any deviations from the German accident
Illustration: Roof railing/roof carrier - Normal roof
prevention regulations (UVV), a technical certificate
R3 must be requested in Germany from the Berufsge-
1 Front axle nossenschaft für Fahrzeughaltung, 22757 Hamburg,
Germany (tel. +49 (0)40-381091):
http://www.bgf.de/

7 Design of bodies
7.1 Interior compartment of the body
This section contains information concerning the body to Passenger cabin/cargo area
be produced by the body manufacturer.
If a rear bench seat with 2- or 3-point seat belts deviates
from the standard seat design, it must comply with the
7.1.1 Modifications in the cockpit area requirements in EC Directives ECE-R14 and 74/408/
Modifications in the cockpit area and above the waist- EEC.
rail are not permitted. This applies in particular to the Retrofitting of seat belt anchors is possible. Retrofit solu-
deployment areas of the airbags (wooden trim, additio- tions have been developed and tested for this purpose.
nal fittings, mobile phone holders, bottle holders, etc.). You can request the relevant appraisals from the depart-
See the illustrations of the airbag deployment areas for ment responsible (e Page 15).
more information (e Page 102).
aa WARNING
7.1.2 Retrofitting additional seats
On no account may seats be mounted on the wheel
Daimler AG will issue a certificate of non-objection at arches. In the event of an accident, persons could
its discretion for modifications to the seat attachments be injured if the seats become detached from their
(including seat bases) and seat belt anchorages or for anchorages, and this could result in further damage
the installation of seats other than those available from to the vehicle.
the factory (e Page 15).
Proof of the strength of the seats delivered from the If rear seats with two-point or three-point seat belts
factory is only valid if the seats are secured in original deviate from the standard seat design, they must comply
mountings. with the requirements of ECE R14.
When re-installing seat belts, the specified bolts must Seats without seat belts are not permissible. The ECE
be tightened to the original torque. R14 test certificate (tensile test including floor assembly)
is required for approval by Daimler AG. Test certificates
aa WARNING for seats on a rigid plate will not be accepted.
It is not permitted to modify the driver and front pas-
senger seats or to mount seats on the wheel arches.
In the event of an accident, the seats could become
detached from their mountings.
New bolts must always be used for attaching seats
and seat belts. Bolts used previously should be ren-
dered unusable and disposed of.

7 Design of bodies
aa WARNING
For safety reasons, Mercedes-Benz recommends

only using seat covers which have been tested for
Mercedes-Benz vehicles and which are equipped
with a cutout for thorax sidebags. Otherwise, thorax
sidebags may not be able to inflate correctly and
offer the intended protection in an accident. This
could result in personal injury.
You can obtain suitable covers at a Mercedes-Benz
Service Centre, for example.
Also refer to the additional information in the
owner's manual of the vehicle.

7 Design of bodies
7.2 Modifications to panel vans/passenger vans
7.2 Modifications to panel vans/passenger vans
Floor assembly
On the Citan, the body forms a self-supporting unit. If
body parts are modified or fitted, they must only be
welded if a bonded connection is not possible. For this
reason, windows, roof hatches and vent openings must
be mounted in a sturdy frame. The frame must then
be joined by a non-positive attachment to other body
elements.
Partitions
If it is necessary to cut through the partition, it is
possible to do this in connection with a continuous
surrounding frame.
Partitions may be totally or partially removed. Observe
6.2.3 „Modifying the partition wall“ (e Page 82).
aa WARNING

You can obtain more information about special equip-

ment from your Mercedes-Benz Service Centre, in the
responsible department (e Page 15) or from Section
3.10 „Special equipment“ (e Page 44).
Vehicle roof
Information on roof modifications can be found under
6.2.8 „Panel van/passenger van roof“ (e Page 91).

7 Design of bodies
7.3 Refrigerated vehicles/temperature-controlled vehicles
7.3 Refrigerated vehicles/temperature-controlled vehicles
Refer also to the following sections:

• 6.2.8 „Panel van/passenger van roof“
(e Page 91)
• 6.4.4 „Reducing noise in the vehicle interior“
(e Page 111)
• 8.9 „Retrofitting electrical equipment“
(e Page 142)
These requirements and notes are also applicable for
vehicles used to transport loads under constant condi-
tions within the load compartment, for example with a
constant temperature higher than 0 °C.

7 Design of bodies
7.4 Vehicles for transportation of technical gases
7.4 Vehicles for transportation of technical gases
Containers and lines, e.g. for liquefied gases, must be

equipped with adequate thermal insulation from the rest
of the vehicle. The interior protection measures installed
as standard are not designed for this application and
must be appropriately modified by the body manufactu-
rer. Containers, lines, valves and additional components
in the gas forwarding system must be routed through the
vehicle body and vehicle bodyshell thermally insulated
and mechanically decoupled.
The body manufacturer is responsible for corrosion pro-
tection, painting, the body and bodyshell in connection
with the transport of liquefied gases.
To allow venting of liquefied gases, a minimum dis-
tance of at least three metres is required between the
vent opening and the vehicle. If venting is necessary,
make sure that the vent opening points away from the
vehicle.
The accumulation of vented gases beneath the vehicle
must be reliably prevented.
Any escaping condensation must be caught is a suita-
ble container.
The specifications and information on the data sheets
for the gases must be observed.

8 Electrical system
8.1 General information
8.1 General information
• Do not release or remove the battery terminals when

the engine is running.
• Only charge batteries with a quick charger if the
positive and negative terminals are disconnected
from the on-board electrical system.
• A positive total charge balance must be ensured
when additional electrical consumers are installed
(e Page 142).
!! Note
You can obtain more information from the depart-
ment responsible (e Page 15).
• Electrical and electronic components must fulfil the

test requirements of ISO 16750.
• Cables routed in the vicinity of exhaust systems
must be encased in fireproof sleeves, see „Installa-
tion of lines“ (e Page 73).
• Cables must be routed in such a way that there
are no chafing points, see „Installation of lines“
(e Page 73).
• Disconnect batteries before leaving the vehicle sta-
tionary for longer than one week. The battery must
have sufficient charge when the vehicle is put into
operation again (e Page 42).
• Observe the operating instructions.

8 Electrical system
8.2 Electromagnetic compatibility (EMC)
8.2 Electromagnetic compatibility (EMC)
Electromagnetic compatibility describes the ability of an

electrical system to act neutrally in the vicinity of other
systems when operating at full function. The system in
question does not interfere with any of the active sys-
tems in the vicinity, nor does it suffer any interference.
Electrical interference occurs in vehicle electrical circuits
because of the various consumers. At Mercedes-Benz,
electrical and electronic components installed at the fac-
tory are checked for their electromagnetic compatibility
in the vehicle. If subsequent modifications are made, this
may cause a reduction in comfort in some cases (e.g.
radio noise).
When retrofitting electric or electronic systems, they
must be tested for electromagnetic compatibility and
this must be documented.
The equipment must possess a type approval certificate
in accordance with EU Directive ECE-R10 (in the current
version) and must bear the „e“ mark.
Further important information can be found in section 5
„Damage prevention“ (e Page 60).

8 Electrical system
8.3 Lighting
8.3 Lighting
Adjusting the headlamps Installing lighting

National regulations shall apply. National regulations shall apply.
The headlamp basic setting must be observed (see If lighting equipment is covered by more than 50% when
vehicle identification plate). moving vehicle parts are in operation, the vehicle must
Only check the headlamp setting with the vehicle unla- be safeguarded accordingly.
den (ready to drive – full tank and with 1 driver or 75 kg An appropriate note must be attached at a point where it
load). can easily be seen by the driver of the vehicle.
• Park the vehicle on a level, horizontal surface. Detailed information about the installation of illumina-
• Align the headlamp beam adjuster and the vehicle at tion and signalling equipment and on the requirements
right angles to each other. with respect to coverage of illumination and signalling
• Correct the tyre pressures (refer to the tyre pressure equipment by moving vehicle parts can be found in ECE
table). directive No. 48.
• Move the headlamp range control to the basic set- Vehicle perimeter lamps/clearance lamps
ting 0. End-outline marker lamps increase passive safety and
• Switch on the headlamps. are required by law on vehicles with a width of over 2.10
• Every headlamp must be checked separately and the m. They may be attached on vehicles from a width of
second headlamp and other lamps must be blacked 1.80 m. (Section 51b, Paragraph 2 of German vehicle
out while doing so. licensing regulations (StVZO)).
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 ground) minus the
specified headlamp basic setting, also see 4.1.2 „Maxi-
mum vehicle dimensions“ (e Page 45).

8 Electrical system
8.4 Battery
8.4 Battery
8.4.1 Main battery

The main battery has its own approved attachment sys-
tem. It is forbidden to make any changes to the original
attachment. The main battery may not be relocated to
another position.
The main battery may not be used as a jacking point to
mount additional modules: it is not permissible to mount
any element (e.g. additional terminal strip, coupler) on
the main battery.
The main battery is installed in an acid collecting pan to
protect sensitive vehicle components. Accumulated acid
is drained away downwards through a hose.
!! Note
The hose for draining battery acid may not be plug-
ged or used as a sleeve for electrical lines.
The service life specification of the battery must remain

visible after conversion.
The ventilation system for the main battery may not be
restricted or blocked by modifications.

8 Electrical system
8.4 Battery
Cable lugs and battery terminal strip !! Note

The battery clamp for the positive terminal must be at
a minimum distance of 25 mm away from the vehicle The terminal stud (3) for the additional battery on
earth. the positive terminal of the main battery may, if
necessary, only be replaced by an M6 threaded stud.
The main battery must be connected via the original
terminal strip of the vehicle.
Always ensure that access to the mounting nut of the
An additional terminal strip may not impair installation or positive terminal is not impaired. Furthermore, this
removal of the battery. The attachment of an additional current tap must be protected by a cutoff relay which
terminal strip to the battery using clips or similar compo- is controlled by the starter relay. This is intended to
nents may not damage the battery housing in any way. prevent overload of the starter relay. This also applies to
Mounting Nut type Torque connection of the additional battery.
Terminal strip M6 8 Nm + 15 % !! Note
to battery ter-
minal When installing additional electrical consumers,
Nuts on cable M5 5 Nm + 15 % especially on vehicles with factory-installed special
lugs equipment which uses the additional battery, the
M6 8 Nm + 15 % body manufacturer must ensure a positive total
M8 12 Nm + 15 % charge balance.
Figure: Engine compartment - Main battery with

terminal strips
1 Battery cover
2 Positive terminal strip
3 Terminal stud for additional battery (on positive ter-
minal)
4 Positive terminal
5 Main battery
6 Negative terminal with negative terminal strip

8 Electrical system
8.4 Battery
Battery variants
Batteries with different capacities and designs may be used for the Citan. The batteries are housed in the battery box in
the engine compartment and are maintenance-free.
The following batteries are used depending on the vehicle and climate zone:
Engine Max. output Fuel Battery Capacity Climate zone Automatic
code type start/stop
system
MO1 55/66 kW Diesel Fluid-filled 60 Ah/ Temperate without
MO2 (75/90 hp) 510 A EN zone/
subtropics
70 Ah/ Cold zone without
720 A EN
VRLA-AGM 70 Ah/ All zones with
760 A EN
MO3 81 kW (110 hp) Diesel VRLA-AGM 70 Ah/ All zones with/without
760 A EN
MO4 84 kW (114 hp) Gasoline VRLA-AGM 70 Ah/ All zones with
760 A EN
AGM - Absorbent Glass Material Fuses

EN - European standard 60095-1 All cables retrofitted to the main battery must be pro-
VRLA - Valve Regulated Acid tected by fuses. These fuses must correspond to the
consumer, cable cross-section and cable length.
VRLA-AGM designates a sealed lead rechargeable bat-
tery whereby the electrolyte is bound to a mat made of The distance between the fuse box and the main battery
fibreglass. must be a maximum of 200 mm. If this specification
cannot be met, the fuse box must be located as close as
!! Note possible to the battery and the part of the cable which is
not electrically fused should be physically protected (e.g.
It is not permissible to use a different battery type with protective tubing).
other than the approved version.
The fuse box must be installed away from splash zones
Battery maintenance and storage and a water drainage facility must be put in place. A
minimum distance of 30 mm from fluid-bearing circuits
Even low-maintenance batteries require maintenance. must be maintained.
Low-maintenance only means that there is no need to
check the fluid level. Every battery is subject to self- A distance of at least 300 mm must be maintained bet-
discharge. This can even lead to battery damage from ween the fuse box and combustible fluids (gasoline filter,
deep discharging if the battery is not checked at all. tank etc.).
Information can be found under 3.9.2 „Battery main-

tenance and storage“ (e Page 42).

8 Electrical system
8.4 Battery
8.4.2 Additional battery If the vehicle is stored for an extended period of time, it
The use of a second battery is recommended if a large is recommended to check the charge level of the additio-
amount of electrical equipment is used and, in particular, nal battery regularly (at least every 2 months).
if this equipment is used with the engine switched off. If an additional battery is installed in the passenger cell,
The additional battery must be exclusively assigned to a sealed battery which does not use liquid acid must be
defined auxiliary consumers such as stationary heaters, installed. If the battery is installed outside of the pas-
charging aids or electrical devices. senger cell, an acid collecting pan is required in order to
divert acid away from sensitive areas of the vehicle.
Only use batteries which are a maximum of 5 months old
at the time of installation and carefully check the battery In order to avoid corrosion of vehicle parts, the battery
data. used must always be equipped with a ventilation outlet
with ventilation hose. The battery gases must be diver-
The power tap from the additional battery should be
ted outwards to an area which is not sensitive to acid
limited so that it is not fully discharged. The additional
through the ventilation hose.
battery should be suitable for the power usage situation
of the vehicle in order to extend its service life. If an additional battery is installed in the passenger cell,
it is recommended to mount the battery from above.
There are two possible usage profiles for an additional
battery: The manufacturer specifications about battery mounting
and electrical connection must be observed.
• Occasional use (without significant discharge of the
battery) and where the battery is outside the passen- The installation must be carried out in such a way that
ger compartment: standard lead battery of the same the service life specification of the additional battery is
design as the starter battery of the vehicle (sealed visible and the battery clamp of the positive terminal is
cover, lead-calcium, pressure-resistant body). The at least 25 mm away from the vehicle earth.
use of batteries with a "magic eye" (visual indicator
of charge level on top of battery) is recommended. !! Note
• Intensive use (potentially with significant discharge An additional battery may only be installed in con-
of the battery) or for use when the engine is swit- junction with a battery cutoff relay.
ched off or battery is in the passenger cell: battery
model VRLA-AGM (gel, spiral-type or other).

8 Electrical system
8.4 Battery
Figure: Battery with connection for the additional Figure: Fuse housing on the air filter (recommended
battery at the positive terminal strip position and mounting type)
1 M6 threaded stud, high-voltage output in area of 1 Air filter
battery positive terminal 2 Cable tie with support clip for mounting
2 Fuse for power consumer/additional battery in sepa- 3 Fuse housing
rate fuse housing
The fuse housing is seated on the air filter and is atta-
!! Note ched to it with 2 cable ties with support clips.
When installing additional electrical consumers,

especially on vehicles with factory-installed special 1
equipment which uses the additional battery, the
body manufacturer must ensure a positive total
charge balance. 2
N54.10-2378
Figure: Negative terminal strip

Figure: Fuse housing (detailed view) 1 M6 stud (tightening torque 8 Nm)
2 Earth contact at 90 ° bent cable lug

8 Electrical system
8.4 Battery
Battery cutoff relay formed as schematically displayed in the following figure.

The cutoff relay must be installed so that the electric
The use of a second battery is recommended if a large
circuit of the electrical consumer is separated from the
amount of electrical equipment is used and, in particular,
basic vehicle during the vehicle starting procedure and
if this equipment is used with the engine switched off.
so that safe power supply to the vehicle is ensured. A
When installing electrical consumers with high power positive charge balance must be guaranteed in all opera-
consumption, it is also necessary to install an additional ting modes (driving and stationary operation).
battery and a cutoff relay. The connection must be per-
Figure: Schematic illustration of battery coupling

1 Earth 4 Battery coupling with
2 Alternator a) Status indicator
3 Main battery b) Intelligent monitor
5 Additional battery
6 Additional consumers

8 Electrical system
8.4 Battery
The battery cutoff relay must meet the following requi-
rements for operation of the main battery and additional
!! Note
battery: The attachment may not damage any vehicle compo-
• Ensure that current can be transferred from the main nents.
battery to the additional battery. The coupling system must not be attached to the
• Coupling may only be enabled if the charge level housing of the main battery.
of the battery is above 90 %. This is the case when
the voltage of the main battery is 13.6 V < coupling
threshold < 13.7 V.
• Ensure that the batteries are decoupled when the
charge level of the main battery declines. This is the
case when the voltage of the main battery is 12.6 V
< decoupling threshold < 12.8 V.
• The transfer current from the main battery to the
additional battery should be limited to 40 A.
• The current coupling status must be identifiable.
• The battery cutoff relay must be compatible with all
possible usage conditions of the vehicle (operating
temperature, resistance to vehicle fluids, vibrations,
materials used etc.).
• The coupling system must comply with the EU
standard on electromagnetic compatibility (EMC) (CE
mark) and "e" mark.

8 Electrical system
8.4 Battery
Retrofitting an additional battery Contact (overlaps) between positive and negative battery
cables must be avoided (risk of insulation wearing out
To ensure that the vehicle can be started at any time,
resulting in short circuit).
both batteries must be separated from each other. The
auxiliary equipment must only be supplied via the additi- Protection with motor-vehicle fuses which are approp-
onal battery. riate for the consumers and wiring and which starts at
the additional battery is recommended. The fuse box
In order to avoid damaging the basic system, a battery
should be mounted as close as possible to the additio-
cutoff relay which is able to limit the current of the addi-
nal battery.
tional battery must be used.
The additional battery should have a fixed connection
It is not permissible to change or replace the original
to the vehicle and the mounting type should match that
wiring of the main battery or the terminal strips on the
of the original battery as a minimum.
battery clamps.
In order to ensure safe removal and rule out the risk of
Contact (overlaps…) between positive and negative bat-
a short circuit, the positive terminal may not be located
tery cables must be avoided (risk of insulation wearing
near metallic elements which are connected to earth.
out resulting in short circuit). In order to ensure safe
removal, the positive clamp must be at a sufficient dis- If the battery is installed in the passenger compart-
tance from unprotected metal parts connected to earth. ment or a critical area (e.g. loading area), it is strongly
recommended to use a battery cover to protect the
This reduces the risk of a short circuit.
battery, the coupling system and the additional wiring
If electrical systems are added near the main battery, from external influences. This protection also prevents
these may not hinder removal of the original terminal vehicle occupants from accessing this area.
strip.
The connections for the auxiliary battery, coupling
We recommend following the specifications in the Sec- system and additional cables must meet the connection
tion "Wiring" for the wiring from the battery (terminal "+" requirements (cable lugs and cables, tightening torque,
cable colour red; terminal "-" cable colour black). socket, insulation, leak-tightness).
We recommend using battery cables and cable lugs During installation of the additional battery ensure that
which are protected against reverse connection and the same battery type of starter battery is used. An AGM
which prevent a short circuit if an attempt is made to battery must always be used on vehicles with a start/
install the battery with the polarity reversed. stop automatic system.

8 Electrical system
8.4 Battery
Other additional batteries
!! Note
If the vehicle is already equipped with an additio-
nal battery, no further additional batteries may be
connected in parallel without a charging current
limiter. This can be realized through supplementary
electronics. A maximum charging current for both
additional batteries of 40 A must be ensured by the
body manufacturer. If this is not the case, the basic
vehicle may be damaged.
A positive total charge balance is to be assured
through selection of a suitable alternator.
Retrofitting further auxiliary brakes requires certificate
of non-objection (e Page 16) from the department
responsible (e Page 15).

8 Electrical system
8.5 Electrical lines/CAN bus
8.5 Electrical lines/CAN bus
If the routing has to be altered, avoid routing across

sharp edges and through narrow cavities or near moving
components.
Additional power circuits
If additional power circuits are installed, they must be
protected against the main power circuit by fuses of
adequate rating.
The wiring used must be adequate for the load and must
be protected against the effects of impact and heat.

8 Electrical system
8.6 Alternators
8.6 Alternators
The Citan is equipped with different alternators and star-

ters depending on the engine variant (e Page 11).
The following non-eligible alternators and starters are
used on vehicles with Euro 5 (engine code + code MB5)
and Euro 6 (engine code + code MB6):
Diesel engines (MO1 + MO2)
Alternator 14 V/150 A
Starter 1,2 kW1
1,4 kW2
Diesel engines (MO3)
Alternator 14 V/150 A
Starter 1,4 kW
Gasoline engine (MO4)
Alternator 14 V/120 A3
14 V/150 A4
Starter 1,0 kW2
1
without ECO start/stop function (code I4C)
2
with ECO start/stop function (code MJ7)
3
without PTC element (code I2B)
4
with electric heater (code HZ0)

8 Electrical system
8.7 Power tap interfaces
8.7.1 Exterior illumination power tap

Please observe the following if electrical accessories
are retrofitted:
• No additional consumers may be connected to
assigned fuses.
• No additional lines may be connected to existing
lines (e.g. with cut-and-clamp connections).
• Provide consumers with adequate protection by
means of additional fuses.
Additional electrical accessories must be connected via
the positive terminal of the battery and vehicle earth. Figure: Connector in the engine compartment
An adequate line cross-section must be used according
to the intended power consumption. The additional
lines may be attached to the 6 mm screw connection.
An additional fuse corresponding to the intended power
consumption is required.
!! Note
Tampering/improper installations in the vehicle
electrical system/vehicle electronics can impair Figure: Connector - Pin assignment
operational safety and cause the warranty/operating
Pin Assignment
permit to expire.
1 Left main-beam headlamp
The "Interface for body manufacturers" can be orde- 4 Left front foglamp
red via code EK8 and the "Body manufacturer special
5 Right front foglamp
module" via code EK9.
8 Left dipped-beam headlamp
Engine compartment power tap
11 Right main-beam headlamp
The power tap in the engine compartment for additional
exterior lights is available in the connector in the cover 14 Left turn signal lamp
of the BIM (engine safety and switch module). 15 Right turn signal lamp
16 Right standing lamp
17 Left standing lamp
18 Right dipped-beam headlamp
Each of these connections controls just one vehicle

relay (no power is available).

8 Electrical system
Right rear lamp power tap Pin Assignment

This power tap is available in the connector of the right 1 Left turn signal lamp
rear lamp.
2 Left standing lamp
4 Hand brake (earth) S. EK8
5 Relief accessories (-12 V)
6 Right turn signal lamp
7 Rear lamp
8 Right standing lamp
9 Brake lights
10 Earth
Available current:
Figure: Connector of right rear lamp • Vehicles with trailer coupling:
1 Housing of right rear lamp Each of these connections controls just one vehicle relay
(no power is available).
2 Connection on right rear lamp
• Vehicles without trailer coupling:
One consumer can be connected to each of these
connections where its power matches that of the trailer
bulbs i.e.:
• Connection for left standing light:
One 5 W consumer
• Connection for right standing light:
One 5 W consumer
• Connection for brake light:
Two consumers of 21 W each
Figure: Connector - Pin assignment (or one consumer of 42 W)
This power tap point is suitable for consumers without • Connection for rear lamp:
timer control. One 21 W consumer
• Connection for left turn signal:
One 21 W consumer
• Connection for right turn signal:
One 21 W consumer
• Front fog lamp:
One 21 W consumer

8 Electrical system
8.7.2 Interior illumination power tap
Conditions for power tap
• The progressive earth signal features analogue time
control. Power may not be tapped at this signal.
• Each of the cables can be extended by 3 m (maxi-
mum) and an additional supply of max. 500 mA
(6 W) can be taken from each of them.
• In the case of consumption of over 500 mA (6 W):
• The time-controlled supply must control a relay
which controls another supply.
• A specific earth must be used (the progressive
earth can no longer be used).
• If the "open door" information is required, a
door contact switch must be added.
An option code L66 is available for version R3 with 2
seats to add an additional dome lamp in the rear area.
In this case, no additional electrical equipment may be
connected to the line for the dome lamps.

8 Electrical system
Front illumination power tap (driver-side) !! Note

This information is available at the connector of the
dashboard/at the dome illumination in the front inside The information must always be taken from the
carrier on the left behind the trim of the windscreen wiring at the dashboard side (because the roof
carrier (area of left rearview mirror). A corresponding wiring is specific and must not be tampered with).
mating connector can be obtained from your Merce- The cable cross-section is 0.35 mm², which makes it
des-Benz sales and service outlet. very difficult to fold the sleeves onto this cable (see
general technical guidelines). It is strongly recom-
mended to take this information from the cargo area
lamp.
2nd row
illumination power tap (passenger cell)
Modification of the illumination is not permissible.
Figure: Connector for interior illumination
Figure: Connector - Pin assignment

This connector contains several connections for activa-
ting the done lamp:
Pin Assignment
1 13E: Progressive earth, active when
door is opened and degressive when
door is closed or +APC.
2 MYH: Permanent earth
3 BPT3: +12 V, time-controlled

8 Electrical system
Cargo area illumination power tap

The location of the cargo area illumination depends on
the type of vehicle body in the left rear section of the
vehicle.
Pin Assignment
2 13E: Progressive earth, active when
door is opened and degressive when
door is closed or +APC.
3 MYH: Permanent earth
4 BPT3: +12 V, time-controlled
Figure: Position of the cargo area illumination in
panel van/Mixto
Figure: Position of the cargo area illumination in

passenger van

8 Electrical system
Specific cargo area illumination for A2, 2 seats,

special equipment code L67
A dome lamp is added at the rear above the right-hand
sliding door (see illustration).
The connector is identical to that of the standard cargo
area illumination.
Figure: Position of the cargo area illumination A2

with code L67

8 Electrical system
8.8 Body manufacturer special module
The body manufacturer special module (code EK9) Information Information types
utilizes the electrical information of the vehicle. With the
additional module, modifications can be carried out on Bus Binary Analo-
the vehicle without needing to change the CAN network CAN 2 gue
or electrical network. Engine speed ² ²
The additional module transmits the following informa- Driver request ²
tion types: Braking status ² ²
• 13 encoded information types in CAN format (BUS Water temperature ²
CAN2). Copy of 12 vehicle CAN information types
Engine status ² ²
• 8 binary information types
• 2 analogue information types Clutch status ² ²
The equipment is available as special equipment ex Vehicle speed ² ²

factory. The control unit is located in the cockpit, above Left/right turn ² ²
the glove compartment. If your vehicle is equipped with signal
ECO-Stop, code EK9 cannot be installed ex factory. Hazard warning ² ²
flasher
Ignition key status ² ²
Door status ² ²
(opening status)
Central locking ² ²
Fuel consumption ²

8 Electrical system
Pin assignment - Body manufacturer special Pin Output type Designation

module
1 Binary 2 Braking status
2 Binary 1 Air conditioning status
3 Analogue Vehicle speed
4 Analogue Engine speed
5 Binary 11 Not used
7 Binary 8 Ignition lock position
8 Binary 7 Door status
9 Binary 6 Hazard warning flasher
10 Binary 5 Left/right turn signal
Figure: Pin assignment - Body manufacturer special 11 Binary 12 Not used
module 12 CAN L CAN L2
13 Binary 3 Engine running status
14 Binary 4 Clutch status
15 Binary 9 Central locking status
17 - Not used
18 - Not used
19 - Not used
20 - Not used
21 - Not used
22 - Not used
23 - Not used
24 CAN H CAN H2

8 Electrical system
8.9 Retrofitting electrical equipment
Please observe the following if electrical accessories are Interface for body manufacturers (code EK8)
retrofitted:
The interface for body manufacturers can be ordered
• Do not connect additional consumers to fuses using code EK8 and permits easy access to the vehicle's
already assigned electronic systems.
• Do not connect additional lines (e.g. with cut-and- With this option, the following features are pre-installed:
clamp connections) to existing lines
• One free connector in the area of the dashboard
• Provide consumers with adequate protection by (e See page 143).
means of additional fuses
• Two pins on the connector of the right taillight
The following must also be observed as a result of the (e See page 144).
alternator management system installed as standard:
The power supply for both interfaces is activated as of
• An advanced power supply system continuously stage 1 of the ignition key.
checks the charge level of the battery
• In order to maintain the battery charge level, the aa WARNING
+12 V power distributor connection may be tempora-
rily unavailable The interface for body manufacturers, code EK8, can
influence the power consumption of the vehicle and
All electrical equipment fitted must be tested in accor-
thus the battery discharge rate. Taking excessive
dance with EU Directive ECE-R10 and must bear the "e"
power from the battery can result in failure of (safe-
mark (e Page 59), (e Page 70).
ty-relevant) components and disable the vehicle.
The connection of additional electrical accessories must
It must therefore be ensured that the maximum
be carried out with special equipment (code EK8) and is
power consumption at both interfaces does not
described below.
exceed a total of 8 A.
aa WARNING
!! Note
Tampering with and unauthorised installations in the
vehicle electrical/electronic systems can impair the Code J47 (trip computer) is a pre-requisite for use of
functioning of these systems. This can lead to failure the interface for body manufacturers, EK8.
of components or of parts relevant to safety, and
may result in accidents or damage to the vehicle.
!! Note
Furthermore, tampering with the vehicle electrical/
electronic systems can invalidate the warranty or the
general operating permit.

8 Electrical system
Interface for body manufacturers under dashboard
The connector for the interface for body manufacturers,
EK8, is located on the left side of the vehicle on the
inside near the firewall grommet, the BFRH ( vehicle
interior fuse and relay box) and the lever for opening the
engine hood.
The connector is held on the dashboard wiring by a slide
connector.
Excess wire length is provided for the connection.
Figure: Permissible cable hole (1) through the engine

Figure: Interface for body manufacturers- bulkhead
Dashboard
1 Connector EK8
The mating piece for this connector can be obtained

from your Mercedes-Benz sales and service outlet.
Pin Assignment
1 (3ADA) Idle speed increase
2 (BMT1) Engine status Shared fuse 10 A
(cable cross-sec-
3 (SBP4) +terminal 12 V tion 1 mm2)
4 (MAN) Earth (cable cross-section 1.5 mm2)
Figure: Mating piece for connector EK8 - 5 Spare
Dashboard
6 Spare

8 Electrical system
Interface for body manufacturers in rear area
The interface for body manufacturers, EK8, in the rear
area provides the following information:
• Pin 1: + 12 V power distributor plate (red cable,
cross-section 1.5 mm²)
• Pin 2: Information about the status of the hand
brake
The wiring branch is available from your Mercedes-Benz
sales and service outlet.
Figure: Sketch of interface for body manufacturers

- Rear area
1 Right rear lamp
2 Wiring branch EK8
3 Additional information from EK8
Figure: Connection for wiring branch - Rear lamp
4 Original wiring of rear lamp
1 Housing of right rear lamp
2 Connection on right rear lamp
Figure: Wiring branch EK8 -

Rear area

8 Electrical system
Figure: Sketch of interface for body manufacturers

- Rear area with trailer coupling
1 Right rear lamp
2 Wiring branch EK8
3 Additional information from EK8
4 Original wiring of rear lamp
5 Trailer coupling harness branch
6 Trailer coupling output
On vehicles with a trailer coupling, the wiring branch EK8
(2) must always be installed on the branch for the trailer
coupling (5); exchanging or swapping is not permissible.

8 Electrical system
8.10 Mobile communications systems
8.10 Mobile communications systems
If mobile communication systems (e.g. telephone, CB Connecting and routing the wiring for the aerial
radio) are retrofitted (e Page 59), the following requi- (radio)
rements must be fulfilled in order to avoid malfunctions • Comply with manufacturer's notes and installation
developing on the vehicle at a later stage. instructions.
All electrical equipment fitted requires a type-approval • An aerial can be installed anywhere on the vehicle
certificate in accordance with EU Directive ECE-R10 and roof. The maximum transmission output must not be
must bear the "e" mark (e Page 59), (e Page 70). exceeded.
Equipment • The wiring routes must be kept as short as possible.
• The maximum transmission output must not be The wires must be twisted and screened (coaxial
exceeded: cable). Chafing points must be avoided.
• Ensure that the system has a good earth connection
Waveband Maximum trans-
to the body (aerial and equipment).
mission output
[W] • The aerial and connecting cables between the trans-
mitter, receiver and operating panel must be routed
Short wave (f < 54 MHz) 100 separately from the vehicle wiring harness in the
4 m band 30 vicinity of the body earth.
2 m band 50 • Route the aerial cable in such a way that it is not
Trunked radio/Tetra 35 kinked or pinched.
• Comply with regulations on the transport of hazar-
70 cm band 35
dous goods (GGVSE: German Law on the Road
GSM 900/AMPS 10 and Rail Transport of Hazardous Goods), and ADR
GSM 1800 10 (European Agreement concerning the International
Carriage of Dangerous Goods by Road).
UMTS 10
The information in section 5.4 „Corrosion prevention
• The mobile communications systems and brackets measures“ (e Page 66) and 5.5 „Painting work/pre-
must not be positioned in the deployment area of the servation work“ (e Page 68) must be observed.
airbags (e Page 103).
• Equipment must be permanently installed. Portable
or mobile devices may only be operated inside the
cab if they are connected to an exterior aerial which
has been installed in such a manner that it is reflec-
tion-free.
• The transmitter unit must be installed as far away
from the vehicle's electronic system as possible.
• The unit must be protected against moisture and
heavy physical shocks; the permissible operating
temperature must be observed.

8 Electrical system
8.11 Driving assistance systems
8.11.1 Electronic Stability Program (ESP)

aa WARNING
aa WARNING
If you fail to adapt your driving style or if you are
inattentive, the driving safety systems and driving The location, position and mounting of the ESP turn
assistance systems can neither reduce the risk of rate sensor must not be modified. On no account
an accident nor override the laws of physics. Driving should modifications be made to wiring or ESP com-
safety and assistance systems are merely aids. The ponents. Otherwise there is a danger that the ESP
driver is responsible for maintaining a safe distance, system may no longer function correctly. This would
the speed and braking in good time. The driving style increase the risk of an accident, especially when dri-
must always be adapted to suit the prevailing road ving near the system's limits.
and weather conditions, a safe distance must be
maintained and a careful driving style adopted.
The driving safety systems described only work as 8.11.2 Tyre pressure monitoring
effectively as possible when there is adequate contact In accordance with the European Union regulations ((EU)
between the tyres and the road surface. Please pay 661/2009 (last changed by „(EU) 523/2012“) and UN/
special attention to the notes on tyres, recommended ECE regulation no. 64, series of amendments 02, cor-
minimum tyre tread depths, etc. under 3.6 „Tyres“ rection 1), all M1 Class vehicles (vehicles for passenger
(e Page 35), „Checking the tyres“ (e Page 43), transport with a maximum of eight seats, excluding the
4.2 „Suspension threshold values“ (e Page 46), driver‘s seat) which are registered for the first time after
6.1.5 „Wheels/Tyres“ (e Page 76), 6.2.5 „Mudgu- 01.11.2014 must be equipped with a precise monitoring
ards and wheel arches“ (e Page 90) and „Summer system for the internal tyre pressure. This also applies
and winter tyres“ (e Page 159). in the event of conversion to winter tyres or accessory
In wintry driving conditions, always use winter tyres tyres and for vehicles which have been retyped as Class
(M+S tyres) and, if necessary, snow chains. Only in M1 from other classes. The affected vehicles must
this way will the driving safety systems described in permanently be operated with tyre pressure sensors.
this section work as effectively as possible. Otherwise, this represents a deviation from the EU regu-
lations and can make the vehicle‘s operating permit void.
For this reason, vehicles without tyre pressure monitors
that are currently being constructed must be registered
by the end of October 2014. After this date, a national
exemption is required for registration. If other vehicles
(not M1) are equipped with a tyre pressure monitor, this
must comply with the regulations specified above.

8 Electrical system
The wireless tyre pressure monitoring system on the
front and rear axle (Code RY2) complies with the regula-
tions specified above. It is required for the initial regist-
ration of new M1 Class vehicles as of 1 November 2014
in the EU and EFTA Member States. For this reason,
modifying the components of this system or influencing
them by modifying or adding electromagnetic fields or
repositioning the system components is not permitted.
This also applies to other states that use EU Directives
and ECE regulations. National regulations must be com-
plied with.
The system‘s reception module/control unit is affixed
to the inside, on the roof between the driver and front
passenger seats. The pressure sensors are integrated
into the tyre valves.
If, despite this, body work is planned for the vehicle
underbody, in the engine compartment and the inte-
rior of the passenger cell, the technical advice team
(e Page 15) at the body manufacturer centre must be
consulted. After body work in this area, another inspec-
tion of the tyre pressure monitor by an officially recogni-
sed testing organisation may be required in accordance
with ECE Directive no. 64 at the body manufacturer‘s
expense. This serves to prove that the vehicle registra-
tion capability as per this regulation still exists as the
tyre pressure monitoring system has not been affected.
aa WARNING
Do not make any modifications in the area under the

floor of the vehicle, in the engine compartment and
the interior of the passenger cell, including the vehicle
axles and the system components of the tyre pressure
monitor. Otherwise, the function of the tyre pres-
sure monitoring system may be compromised by the
effects of reflections. This might result in the driver
being unaware of any tyre pressure loss, and he/she
could cause an accident. Furthermore, the vehicle
may no longer meet licensing requirements.

9 Calculations
9.1 Centre of gravity
The overall height of the centre of gravity (vehicle with 9.1.1 Determination of the centre of gravity in
equipment/complete body but without load) must be the x-direction
kept as low as possible.
CoG coordinate in x-direction
The position of the centre of gravity in the longitudinal (front/rear axle load distribution)
direction of the vehicle is specified with reference to a
vehicle axle. Procedure:
The centre of gravity height is specified with reference • The vehicle should be weighed with its complete
to the centre of the wheel hub or the road surface. equipment/body but without load.
Mercedes-Benz recommends that you have the position • Inflate the tyres to the tyre pressure specified for the
of the centre of gravity checked by a recognised and maximum permissible axle load on each axle.
experienced testing institution (e.g. DEKRA, Technical • Completely fill all fluid reservoirs (fuel tank, washer
Inspection Association (TÜV) etc.). Assistance in this fluid reservoir and, if installed, hydraulic tank, water
can be obtained from the relevant department, see 2.3 tank etc.).
„Advice for body manufacturers“ (e Page 15).
• Shut off the engine on the scales, shift the transmis-
If the centre of gravity is determined by the body sion to neutral and release the brakes.
manufacturer, the procedures described under 9.1.1
• The vehicle must be parked horizontally on level
„Determination of the centre of gravity in the x-direc-
ground for weighing.
tion“ (e Page 149) and 9.1.2 „Determination of the
centre of gravity in the z-direction“ (e Page 151) must • First weigh the individual axle loads (front and rear
be followed and services of qualified persons must be axle loads) and then the gross vehicle weight.
used so as to achieve realistic and useful results. • Using these measurements, the position of the
centre of gravity in the longitudinal direction of the
vehicle can be calculated using equations (3) and (4).
• Use (2) to check the results from (3) and (4).

9 Calculations
Figure: Axle load calculation

Weights:
(1) GG Gross weight of vehicle
GG = GHA + GVA
GVA Front axle load of the empty vehicle
(2) (Specification or weighing of the respective
l = lV + lH chassis)
GHA Rear axle load of the empty vehicle
(Specification or weighing of the respective
Calculation of the centre of gravity in the
chassis)
x-direction
(3) Dimensions
GHA × l
lV = lV Distance from the gross weight centre of gravity
GG of the empty vehicle to the front axle
lH Distance from the gross weight centre of gravity
GV A × l (4)
of the empty vehicle to the rear axle
lH =
GG l Wheelbase
SG Overall vehicle centre of gravity

9 Calculations
In order to reduce measurement errors, at least six
!! Note individual measurements must be performed for each
vehicle axle when measuring the axle load: three per
Practical determination of the centre of gravity
axle when the vehicle is in a level state and three when
height may only be carried out by appropriately qua-
an axle is raised. Based on the three measurements
lified staff using suitable and calibrated scales.
in each condition, an average should be calculated for
In order to reduce measurement errors, each measu- each axle. The mean of these three values is to be used
rement value should be determined at least three in the calculation according to the equations (5) to (9).
times and the average should be calculated from In order to improve the accuracy of the final result, the
these three values. This value is then used to per- axle load change should be determined both with a
form the calculation as per equations (3) and (4). raised rear axle and with a raised front axle.
ii Additional information !! Note

The wheelbase "I" is defined by the vehicle model In order to avoid erroneous measurements, please
designation (see Ordering) or must be determined note:
by means of a length measurement according to DIN • When weighing with the vehicle level, the vehicle
70020, Part 1. must be exactly horizontal. Any height diffe-
rences between the axles caused by the scales
must be compensated for accordingly.
9.1.2 Determination of the centre of gravity • The axle to be weighed must be blocked to
in the z-direction prevent suspension jounce and rebound when
Centre coordinates in z-direction (height of raising to the required lift height.
centre of gravity hS for the overall vehicle) • No part of the vehicle may bottom out when
For calculation of the height of the vehicle's overall raising to the required lift height.
centre of gravity hS by the body manufacturer, Merce- • All vehicle wheels must be able to roll: shift
des-Benz recommends that the procedure explained mechanism in neutral position, all brakes inclu-
below be followed after completion of the vehicle: ding parking brake released, chocks placed at a
After conversion, the vehicle should be weighed on sufficient distance from the wheels, if necessary.
a plate-type scale or suitable wheel load scale in two • For turning (in order to weigh the other axle),
different chassis positions in succession. Here, the axle move the vehicle under its own power so that
loads measured when the vehicle stands horizontal any stresses in the vehicle are relaxed.
and level (GVA and GHA, see 9.1.1 „Determination of the • Make sure that no objects inside the vehicle can
centre of gravity in the x-direction“ (e Page 149)) and move during the measurements.
the axle loads for an axle raised by h’ (QHA or QVA) must
be determined. The lift height h’ should be as large as
possible in accordance with the front and rear over-
hang angle of the vehicle (also known as the angle of
approach/departure). The target value is h’ > 600 mm.

9 Calculations
If the vehicle suspension cannot be blocked owing to its 9. Perform steps 4 to 7 three times in total (with blo-
design or space restrictions, further axle load measure- cked suspension).
ments must be taken at different raised positions (e.g. 10. The values obtained can be used to calculate the
600 mm, 700 mm and 800 mm). Here, errors can again CoG height according to the equations (5) to (9).
be limited by averaging. The centre of gravity height is
equal to the arithmetic mean of the individual centre of 11. When calculating using the equations (3) to (9), all
gravity heights for each raised position. length measurements must be used in millimetres
(mm) and all weights must be used in deca newton
Example of procedure (1 daN = 10 N).
G = 1 daN = 10 N is the weight force corresponding
1. The vehicle must be weighed with complete attach- to the mass m = 1 kg.
ments and body, and without load.
12. Lift the raised axle further (by 100 mm, for
2. Inflate tyres up to the interior tyre pressure that example) and measure the height of centre of gra-
is specified for the relevant maximum permissible vity again so as to confirm the measurement result.
axle load.
3. Fill all fluid reservoirs (fuel tank, window washing !! Note
fluid reservoir, or if necessary, hydraulic reservoir,
water tank etc.) completely. Practical determination of the centre of gravity
height may only be carried out by appropriately qua-
4. On the scales, switch off the engine, shift the trans- lified staff using suitable and calibrated measuring
mission to neutral and release the brakes. equipment and measurement tools.
5. Position the vehicle with the rear axle at a horizon-
tal and level position on the scales and determine
the axle load.
6. Raise the front axle (VA) by the value h’, at least
600 mm. Increasing the height h’ while taking
the other boundary conditions of the vehicle into
account improves the final result. The value h’ must
be determined for all individual measurements
with raised axle and should be identical wherever
possible. As an alternative to measuring the raised
height h’, the angle a between the wheel hubs can
be determined.
7. Determine the resulting axle load shift QHA at the
rear axle on the scales.
8. Lower the vehicle, turn it around and perform the
corresponding measurements on the front axle
(initially GVA with the vehicle level and then QVA with
the rear axle raised by h’).

9 Calculations
Figure: Determining the height of the centre of gravity
hS = ha + rstat (5) ii Additional information

rstat Static tyre diameter The wheelbase "I" is defined by the vehicle model
QVA Front axle load with rear end of vehicle raised designation (see Ordering) or must be determined
QHA Rear axle load with front end of vehicle raised by means of a length measurement according to DIN
70020, Part 1.
hS Height of centre of gravity above road surface
ha Height of centre of gravity above mid-tyre level
h’ Height by which the vehicle was raised
SG Overall vehicle centre of gravity
1 Weighing device

9 Calculations
Formulae for raised front axle:

QHA − GHA 1
hS = ×l× + rstat (6)
GG tan α
where
h
sin α = (6a)
l

h
α = arcsin (6b)
l

l QHA − GHA √ 2
hS = × × l − h2 ) + rstat (7)
h GG
Formulae for raised rear axle:

Q V A − GV A 1
hS = ×l× + rstat (8)
GG tan α
where
h
sin α = (8a)
l

l Q V A − GV A √ 2
hS = × × l − h2 ) + rstat (9)
h GG

10 Technical details
10.1 Vehicle data
10.1 Vehicle data
Vehicle model Wheelbase Dimensions [mm]

Vehicle width Vehicle height Vehicle length
Panel van R1 1810 3937
R2 1816 4321
1829 between door
R3 1839 4705
handles
Passenger van R2 2138 with external 1809 4321
mirror (1868 with roof rai-
ling)
Mixto R3 1823 4705
Vehicle model Wheelbase Load condition Ground clearance [mm]

Front Rear
min max min max
Panel van R1 Unloaded 178 186 220 247
Loaded 164 170 160 164
R2* Unloaded 191 200 233 256
Loaded 177 178 175 176
R2** Unloaded 198 207 251 274
Loaded 176 179 184 184
R3 Unloaded
Loaded
Passenger van R2 Unloaded 190 196 233 249
Loaded 172 177 175 181
Mixto R3 Unloaded
Loaded
* Optional 198-222 mm unloaded/168-192 mm loaded in combination with special equipment for raised ground
clearance
** Increased payload
The ground clearance varies depending on the model designation and configuration.
A construction package (as a national package) provides increased ground clearance as special equipment.

10.1 Vehicle data
Weight code Permissible Permissible axle loads [kg]

gross weight [kg] Front Rear
XK0 1785 882 980
XK1 1885 960 950
XK2 1920 1080 1070
XK5 1950 1080 1070
XK6 1950 1080 1070
XK7 2100 1095 1210
XK8 2200 1095 1210
Load distribution (empty vehicle)

Engine Model Weight Vehicle kerb Front axle Rear axle Front axle Rear axle
code weight* kerb weight* kerb weight* [%] [%]
[kg] [kg] [kg]
55/66 kW Panel van XK0 1295 767.5 527.5 59.3 40.7
(75/90 hp)
XK1 1285 798 487 62.1 37.9
XK5 1305 810 495 62.1 37.9
XK7 1314 812 502 61.8 38.2
XK8 1395 861 534 61.7 38.3
Mixto XK8 1450 879 571 60.6 39.4
Passenger XK1 1364 816 548 59.8 40.2
van
XK6 1383 827 556 59.8 40.2
XK7 1389 829 560 59.7 40.3
81 kW Panel van XK5 1321 827 494 62.6 37.4
(110 hp)
XK7 1330 829 501 62.3 37.7
XK8 1411 878 533 62.2 37.8
Mixto XK8 1466 896 570 61.1 38.9
Passenger XK6 1396 843 553 60.4 39.6
van
XK7 1402 845 557 60.3 39.7
84 kW Panel van XK2 1290 791 499 61.3 38.7
(114 hp)
Passenger XK2 1362 808 533 59.3 40.6
van
* All weight specifications in this overview apply to the respective basic vehicle variant without special equipment.

10.1 Vehicle data
Maximum CoG towards front

Engine Model Weight Maximum Minimum Total Front axle Rear axle
code front axle rear axle load [kg] [%] [%]
load [kg] [kg]
55/66 kW Panel van XK0 882 527.5 1409.5 62.6 37.4
(75/90 hp)
XK1 960 487 1447 66.3 33.7
XK5 1080 495 1575 68.6 31.4
XK7 1095 502 1597 68.6 31.4
XK8 1095 534 1629 67.2 32.8
Mixto XK8 1095 571 1666 65.7 34.3
Passenger XK1 960 548 1508 63.7 36.3
van
XK6 1080 556 1636 66.0 34.0
XK7 1095 560 1655 66.2 33.8
81 kW Panel van XK5 1080 494 1574 68.6 31.4
(110 hp)
XK7 1095 501 1596 68.6 31.4
XK8 1095 533 1628 67.3 32.7
Mixto XK8 1095 570 1665 65.8 34.2
Passenger XK6 1080 553 1633 66.1 33.9
van
XK7 1095 557 1652 66.3 33.7
84 kW Panel van XK2 1080 499 1579 68.4 31.6
(114 hp)
Passenger XK2 1080 553 1633 66.1 33.9
van

10.1 Vehicle data
Maximum CoG towards rear

Engine Model Weight Minimum Maximum Total Front axle Rear axle
code front axle rear axle load [kg] [%] [%]
load [kg] [kg]
55/66 kW Panel van XK0 767.5 980 1747.5 43.9 56.1
(75/90 hp)
XK1 798 950 1748 45.7 54.3
XK5 810 1070 1880 43.1 56.9
XK7 812 1210 2022 40.2 59.8
XK8 861 1210 2071 41.6 58.4
Mixto XK8 879 1210 2089 42.1 57.9
Passenger XK1 816 950 1766 46.2 53.8
van
XK6 827 1070 1897 43.6 56.4
XK7 829 1210 2039 40.7 59.3
81 kW Panel van XK5 827 1070 1897 43.6 56.4
(110 hp)
XK7 829 1210 2039 40.7 59.3
XK8 878 1210 2088 42.0 58.0
Mixto XK8 896 1210 2106 42.5 57.5
Passenger XK6 843 1070 1913 44.1 55.9
van
XK7 845 1210 2055 41.1 58.9
84 kW Panel van XK2 791 1070 1861 42.5 57.5
(114 hp)
Passenger XK2 808 1070 1878 43.0 57.0
van

10.1 Vehicle data
Summer and winter tyres

Manufacturer and Tyre size Purpose Wheel- Use Rim Air pressure [bar]
model base Front Rear
Michelin 195/65 R15 91T Summer R2 Standard Steel/alu- 2.5 2.7
Energy Saver payload minium
Continental 195/65 R15 91T Summer R2 Standard Steel/alu- 2.5 2.7
CEC3 payload minium
Continental 195/65 R15 95T Summer R2/R3 High Steel/alu- 2.3 2.7
Vanco Contact 2 payload minium
and rough
roads
Continental 195/65 R15 91T Summer R2 Standard Steel/alu- 2.3 2.7
CPC2e payload, minium
red. rolling
resistance.
Goodyear 195/65 R15 91T Summer/ R2 All-sea- Steel 2.5 2.7
Vector 4 Season Winter son tyres,
normal
payload
Continental 195/65 R15 91T Winter R2 Standard Steel/alu- 2.5 2.7
TS 830 Winter payload minium
Contact
Continental 195/65 R15 95T Winter R2/R3 High Steel/alu- 2.3 2.7
TS 850 Winter payload minium
Contact and rough
roads
Michelin 205/55 R16 92H Summer R2 Standard Aluminium 2.5 2.5
Energy Saver payload
Continental 205/60 R16 92H Winter R2 Standard Aluminium 2.5 2.5
TS 810 Winter payload
Contact
Dunlop 185/70 R14 88T Summer R1/R2 14" wheels Steel 2.4 2.6
SP30
Continental 185/70 R14 88T Winter R1/R2 14" wheels Steel 2.4 2.6
TS 810 Winter
Contact

10.1 Vehicle data
You can obtain further technical data about the

vehicle:
• from your contact persons, see 2.3 „Advice for
body manufacturers“ (e Page 15)
• from 2.3.11 „Product Information Tool (PIT)“
(e Page 21)
• from the vehicle configurator at

Index
A Flaps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Additional battery. . . . . . . . . . . . . . . . . . . . . . . . . . 126
Aerial. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 H
Airbag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50, 102
Handover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Airbag control unit . . . . . . . . . . . . . . . . . . . . . . . . . 105
Air suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 I
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Axle loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Identification data. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Interface for body manufacturers. . . . . . . . . . . . . 143
B Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Interior threshold values. . . . . . . . . . . . . . . . . . . . . 50
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 L
Bodies, refrigerated vehicles. . . . . . . . . . . . . . . . . 118
Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Body manufacturer special module. . . . . . . . . . . 140 Limits for electrical system. . . . . . . . . . . . . . . . . . . 51
Bodyshell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Limits for tyre sizes . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bodyshell threshold values. . . . . . . . . . . . . . . . . . . 48 M
Brake hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Mobile communications systems. . . . . . . . . . . . . 146
C Modifications in the area of the airbag/emergency
Cables and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 tensioning retractor. . . . . . . . . . . . . . . . . . . . . . . . . 50
Calculating the centre of gravity. . . . . . . . . . . . . . 149 Modifications to closed panel vans . . . . . . . . . . . 117
Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Modifications to seats. . . . . . . . . . . . . . . . . . . . . . . 50
CAN bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Modifications to the basic vehicle . . . . . . . . . . . . . 71
certificate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 114 Mudguards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Certificate of non-objection. . . . . . . . . . . . . . . . . . . 16 N
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Copyright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Noise in the vehicle interior. . . . . . . . . . . . . . . . . . 111
Corrosion protection. . . . . . . . . . . . . . . . . . . . . . 39, 66 O
D Operational safety. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Damage prevention. . . . . . . . . . . . . . . . . . . . . . . . . . 60 P
Design of bodies. . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 45 Painting work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Drivetrain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Panel van/passenger van roof . . . . . . . . . . . . . . . . 91
Driving assistance systems. . . . . . . . . . . . . . . . . . 147 Partition wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Power tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
E Preservation work. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . 120 R
Electromagnetic compatibility (EMC). . . . . . . 70, 121
Electronic Stability Program (ESP). . . . . . . . . 59, 147 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Emergency tensioning retractor. . . . . . . . . . . . . . 102 Roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Engine air intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Roof racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Engine cooling system. . . . . . . . . . . . . . . . . . . . . . . 97 S
Engine peripherals . . . . . . . . . . . . . . . . . . . . . . . 49, 95
Exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
F Selecting the basic vehicle . . . . . . . . . . . . . . . . . . . 30
Fitted shelving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Soundproofing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Index
Spare wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Springs/shock absorbers . . . . . . . . . . . . . . . . . . . . 71
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Storing and handing over. . . . . . . . . . . . . . . . . . . . . 69
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Suspension threshold values. . . . . . . . . . . . . . . . . 46
T
Tack welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Technical threshold values for planning . . . . . . . . 45
Threaded connections . . . . . . . . . . . . . . . . . . . . . . . 36
Threshold values of the basic vehicle . . . . . . . . . . 45
Trailer coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Tyre pressure monitoring. . . . . . . . . . . . . . . . . . . . 147
Tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
V
Vehicle approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Vehicle modifications. . . . . . . . . . . . . . . . . . . . . . . . 31
Vehicle safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vehicle stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Vehicle type identification data . . . . . . . . . . . . . . . 33
Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
W
Weight specifications. . . . . . . . . . . . . . . . . . . . . . . . 32
Welded connections. . . . . . . . . . . . . . . . . . . . . . . . . 37
Welding work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Wheel alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Wheel arches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wheels/Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76


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Body/Equipment Mounting Directives

Issue date: 15.08.2014

3.9.3 Work before handing over the modified

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

5.7 Information on electromagnetic compatibi- 8.3 Lighting................................................ 122

8 Electrical system............................... 120

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

These body/equipment mounting directives provide

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

These directives are divided into the following interlinked

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

The following conventions are used in these directives:

Warning notes draw attention to issues which could

An environmental note gives you tips on the protec-

This note points out any additional information.

e Page This symbol specifies the page that cont-

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Before starting to install non-MB bodies or equip-

Notes on vehicle safety

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Work incorrectly carried out on equipment and its

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

All the text, illustrations and data contained in these

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

For information on the position of the identification

These Body/Equipment Mounting Directives are valid for

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

You can obtain information about a vehicle's availa-

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Country-specific regulations must be complied with.

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Particular attention must be paid to whether the

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Technical advice on body compatibility Technical advice on the basic vehicle

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

2.3.3 Legal claims MBAS-Web Technology

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Design data 2.3.6 Information for non-registered body

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

2.4.1 Product safety 2.4.3 Safety-relevant features

2.4.2 Product liability A component or function must be classified as safe-

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

There is a possibility that body-related hazards may

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

The Mercedes-Benz star and Mercedes-Benz badge are

Information on the use of the Mercedes-Benz star

Daimler AG reserves the right to demand the removal of

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

The body and attached or installed equipment must

National laws, guidelines and registration regulations

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

• It must be ensured that service fluids can be remo-

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014

In order to ensure safe operation of the vehicle, it is

Mercedes-Benz Body/Equipment Mounting Directives for Citan, version 15.08.2014