Body/Equipment Mounting Directives for Vans …...Mercedes-Benz body/equipment mounting directives for Vito/V-Class - BM 447, version 25.07.2014!Changes compared to version dated 24.01.2014

Body/Equipment Mounting Directives for VansVito/V-Class - BM 447

Issue date: 25.07.2014

Mercedes-Benz body/equipment mounting directives for Vito/V-Class - BM 447, version 25.07.2014!Changes compared to version dated 24.01.2014. Only print out complete sections of the current version! 2

Contents

1 Introduction ........................................... 4 1.1 The aim of these directives ..................... 5 1.2 Conventions ............................................ 6 1.3 Vehicle safety.......................................... 7 1.4 Operational safety................................... 8 1.5 Note on copyright ................................... 9

2 General ................................................. 10! 2.1 Advice for body manufacturers ............. 10 2.1.1 Certificate of non-objection ...................11 2.1.2 Applying for a certificate of

non-objection ........................................ 12 2.1.3 Legal claims .......................................... 12 2.2 Product and vehicle information for body

manufacturers ...................................... 13 2.2.1 Bodybuilder Portal ................................ 13 2.2.2 Information for non-registered body manu-

facturers ............................................... 13 2.2.3 Workshop Information System (WIS) ..... 14! 2.2.4 Xentry Kit .............................................. 14 2.2.5 CERON .................................................. 15! 2.2.6 European type approval (ETA) and EC Cer-

tificate of Conformity (CoC) .................. 15 2.2.7 Product Information Tool (PIT) .............. 16 2.3 Product safety and product liability ...... 17 2.3.1 Product safety ....................................... 17 2.3.2 Product liability ..................................... 17 2.3.3 Safety-relevant features ........................ 17 2.4 Ensuring traceability ............................. 19 2.5 Trademarks .......................................... 20 2.6 Accident prevention ............................. 21 2.7 Reprocessing of components -

recycling ............................................... 22 2.8 Quality system ...................................... 23

3 Planning of bodies .............................. 24 3.1 Selecting the basic vehicle .................... 25 3.1.1 Vehicle and model designation ............. 25 3.1.2 Vito engine variants .............................. 30 3.1.3 V-Class engine variants ......................... 31 3.1.4 Exhaust variants.................................... 32 3.1.5 Drive configurations .............................. 32 3.2 Vehicle modifications ............................ 33! 3.3 Dimensions and weights ....................... 34 3.4 Vehicle type identification data ............. 35 3.5 Vehicle stability ..................................... 36 3.6 Tyres ..................................................... 37 3.7 Threaded and welded connections ....... 38 3.7.1 Bolted connections ............................... 38 3.7.2 Welded connections .............................. 39 3.8 Soundproofing ...................................... 42 3.9 Maintenance and repairs ...................... 43

3.9.1 Storing the vehicle ................................ 43 3.9.2 Battery maintenance and storage ......... 44 3.9.3 Work before handing over the modified

vehicle .................................................. 44 3.10 Special equipment ................................ 45

4 Technical threshold values for planning ............................................... 46

4.1 Threshold values of the basic vehicle .... 46! 4.1.1 Steerability ............................................ 46 4.1.2 Maximum permissible positions of centre

of gravity ............................................... 46 4.1.3 Maximum vehicle dimensions ............... 46 4.2 Suspension threshold values ................ 47 4.2.1 Permissible axle loads .......................... 47 4.2.2 Approved tyre sizes ............................... 48! 4.2.3 Diameter of turning circle ......................51 4.3 Bodyshell threshold values ................... 52 4.3.1 Modifications to the bodyshell .............. 52 4.3.2 Vehicle roof/roof load .......................... 52 4.3.3 Threshold values for fastening points ... 52 4.4 Limits for electrical/electronic system . 53 4.4.1 Electric wiring/fuses............................. 53 4.4.2 Vehicle position and side marker lamps 53 4.5 Additional assembly threshold values ... 54

5 Damage prevention ............................ 55 5.1 Brake hoses/cables and lines ............... 55 5.2 Welding work ........................................ 56 5.3 Corrosion protection measures ............ 57 5.4 Painting work/preservation work ......... 59

6 Modifications to the basic vehicle .... 60 6.1 Chassis ................................................. 60 6.1.1 General information on the chassis ...... 60 6.1.2 Springs/shock absorbers ..................... 60 6.1.3 Brake system .........................................61 6.1.4 Air suspension ...................................... 62 6.1.5 Wheels and tyres .................................. 62 6.1.6 Spare wheel ......................................... 63 6.2 Bodyshell/body .................................... 64 6.2.1 General information on the bodyshell/

body ...................................................... 64 6.2.2 Modifying the partition wall .................. 65 6.2.3 Sidewall, windows, doors and flaps ...... 67 6.2.4 Mudguards and wheel wells .................. 68 6.2.5 Underfloor panelling ............................. 68 6.2.6 Modifications to the roof structure ....... 69 6.3 Engine peripherals / drivetrain ............. 71 6.3.1 Fuel system ........................................... 71 6.3.2 SCR system .......................................... 71 6.3.3 Exhaust system ..................................... 73

Mercedes-Benz body/equipment mounting directives for Vito/V-Class - BM 447, version 25.07.2014!Changes compared to version dated 24.01.2014. Only print out complete sections of the current version! 3

Contents

6.3.4 Engine cooling system .......................... 73 6.3.5 Engine air intake ................................... 74 6.3.6 Propeller shafts ..................................... 74 6.4 Interior .................................................. 75 6.4.1 General information .............................. 75 6.4.2 Safety equipment .................................. 76 6.4.3 Seats..................................................... 81 6.4.4 Reducing noise in the vehicle interior ... 82 6.4.5 Ventilation ............................................. 83 6.5 Additional assemblies ........................... 84 6.5.1 Auxiliary heating .................................. 84 6.6 Attachments ......................................... 85 6.6.1 Attachment above cab ......................... 85 6.6.2 Roof racks ............................................ 85 6.6.3 Fitted shelving ..................................... 85 6.6.4 Trailer coupling ..................................... 86

7 Design of bodies ................................. 87 7.1 Modifications to the interior .................. 87 7.1.1 Modifications in the cockpit area .......... 87 7.1.2 Retrofitting additional seats ................. 87 7.2 Refrigerated vehicles/temperature-cont-

rolled vehicles ....................................... 89 7.3 Vehicles for transportation of technical

gases .................................................... 90 7.4 Motor caravans ..................................... 91 7.5 Retrofitting a pop-up roof...................... 92 7.6 Roof height increase ............................. 93 7.7 Government vehicles ............................ 94

8 Electrical system ................................ 95 8.1 General information .............................. 95! 8.2 Electromagnetic compatibility (EMC) .... 96 8.3 Battery .................................................. 97 8.3.1 Main battery ......................................... 97 8.3.2 Retrofitting a battery main switch ......... 97 8.3.3 Additional battery ................................ 97 8.3.4 Backup battery (code E34).................... 99 8.3.5 Emergency battery ................................ 99 8.3.6 Battery maintenance and storage ........ 99 8.4 Interfaces / electrical lines ................. 100 8.4.1 Electric wiring/fuses........................... 100 8.4.2 Cable extension .................................. 100 8.4.3 CAN bus and networking .....................101 8.4.4 Connecting additional electrical consu-

mers ....................................................101! 8.4.5 Current consumption via terminal strip 102 8.4.6 Retrofitting an alternator .................... 103 8.4.7 Speed signal (Vito only) ...................... 104 8.5 Lighting ............................................... 105 8.5.1 Adjusting the headlamps .................... 105 8.5.2 Covering of lighting equipment ........... 105

8.5.3 Vehicle perimeter lamps/clearance lamps .................................................. 105

8.5.4 Exterior lamps ..................................... 106 8.5.5 Interior lamps...................................... 106 8.6 Mobile communications systems ........ 107 8.6.1 Equipment........................................... 107 8.6.2 Connecting and routing the wiring for the

aerial (radio)........................................ 107! 8.7 Driving assistance systems ................. 108! 8.7.1 Electronic Stability Program (ESP) ...... 108 8.7.2 Crosswind Assist .................................110 8.7.3 Collision Prevention Assist ...................110 8.7.4 Blind Spot Assist ..................................112 8.7.5 Highbeam Assist and Lane Keeping

Assist ...................................................113 8.7.6 Rain sensor/Headlamp Assist .............114! 8.7.7 Tyre pressure monitoring .....................115 8.7.8 Parking assistance systems .................116 8.8 Parametrizable special module (PSM) ..118 8.8.1 PSM functions ......................................119 8.8.2 PSM interfaces ................................... 120 8.8.3 ABH-CAN ............................................ 120 8.9 Continuous engine operation feature (Vito

only) .....................................................121 8.10 Automatic start/stop system .............. 122 8.11 Wiring diagrams ................................. 123

9 Calculations ....................................... 124 9.1 Centre of gravity ................................. 124 9.1.1 Determination of the centre of gravity in

the x-direction ..................................... 124 9.1.2 Determination of the centre of gravity in

the z-direction ..................................... 126

10 Technical details ............................... 130 10.1 Vehicle data ........................................ 130

Index ............................................................ 131

Mercedes-Benz body/equipment mounting directives for Vito/V-Class - BM 447, version 25.07.2014!Please observe the modification notes! Only print out complete sections of the current version! 4

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".

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 capa-ble 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 intended for the use of professional body manufac-turers. As a result, these body/equipment mounting directives assume that the body manufacturer has suitable background knowledge. Moreover, the body manufacturer must adhere to the operator's manual valid for the respective vehicle. Please be aware that certain types of work (e.g. welding work on load-bear-ing components) may only be carried out by appro-priately qualified personnel. 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).


1.1 The aim of these directives

1 Introduction

1.1 The aim of these directives

These directives are divided into the following inter-linked 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 24)

4 “Technical threshold values for planning” (e Page 46)

5 “Damage prevention” (e Page 55)

6 “Modifications to the basic vehicle” (e Page 60)

7 “Design of bodies” (e Page 87)

8 “Electrical system” (e Page 95)

9 “Calculations” (e Page 124)

10 “Technical details” (e Page 130)

Appendix:

“Index” (e Page 131)

For additional information, see subsection 2.2 “Prod-uct and vehicle information for body manufacturers” (e Page 13).

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 val-ues for planning” (e Page 46) as planning must be based on these values.

The chapters entitled "Modifications to the basic vehi-cle" and "Construction of bodies" are the main source of technical information contained in these body/equipment mounting directives.


1.2 Conventions

1 Introduction

1.2 Conventions

The following conventions are used in these directives:

a WARNING

Warning notes draw attention to issues which could endanger the health or life of yourself or others.

H 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.

i Additional information

This note points out any additional information.

e Page This symbol specifies the page that con-tains further information on this subject.


1.3 Vehicle safety

1 Introduction

1.3 Vehicle safety

a 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 genuine Mercedes-Benz parts, major assemblies, modification or accessory parts which are suitable for the respective vehicle model.

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


1.4 Operational safety

1 Introduction

1.4 Operational safety

a 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 Mercedes-Benz Service Centre for this purpose.

In particular, work relevant to safety or on safety-re-lated systems must be carried out at a qualified 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.


1.5 Note on copyright

1 Introduction

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 Mercedes-Benz Support Centre

Telephone: 00800-97-777-777


2.1 Advice for body manufacturers

2 General


Technical advice on body compatibility

The team at the "VAN Body Manufacturer Centre" is available to provide technical advice to body manu-facturers on the compatibility of bodies with the basic vehicle and also to issue certificates of non-objection, and can be contacted using the following contact details:

Contact details

Name: Dirk Karolczak

E-mail: [email protected]

Telephone: +49 (0)3378-83-2113

Postal address:

Mercedes-Benz Ludwigsfelde GmbHVAN/VSA departmentHPC (in-house post code) VS14Zum Industriepark 10D-14974 Ludwigsfelde, Germany

Name: Jens Lobinski


Telephone: +49 (0)3378-83-2924

Postal address:


Name: Mathias Götze


Telephone: +49 (0)3378-83-3154

Postal address:


Technical advice on the parameterizable special module (PSM)

In addition to the information on the parameterizable special module under 8.8 “Parametrizable special mod-ule (PSM)” (e Page 118), the PSM Support depart-ment at the Ludwigsfelde plant is available to answer any questions concerning PSM programming.

Contact details

Name: Dirk Karolczak


Telephone: +49 (0)3378-83-2113

Postal address:




2 General

Technical advice on the basic vehicle

Contact the staff at the order processing office of the Düsseldorf factory if you have any questions relating to the configuration and equipment of the basic vehicle.

Name: Patrick Rudolph


Telephone: +49 (0)211-953-3567

Name: Bernd Howahl


Telephone: +49 (0)211-953-2281

Name: Stefan Bock


Telephone: +49 (0)211-953-3558

Name: Markus Philippen


Telephone: +49 (0)211-953-2408

Postal address:

Daimler AGWerk DüsseldorfVAN/PSO departmentD-40467 Düsseldorf, Germany

Technical advice outside Germany

Contact the body manufacturer co-ordinator at Daim-ler AG in your country for technical advice on modifica-tions.

All contact persons with their job description can also be found in the Bodybuilder Portal under

https://bb-portal.mercedes-benz.com/portal/apps/ansprechpartner_db/

2.1.1 Certificate of non-objectionDaimler AG does not issue any body/equipment approvals for non-MB bodies. These directives only supply important information and technical specifica-tions to body manufacturers explaining how to handle the product. Daimler AG therefore recommends that all work on the basic vehicle and body is performed in compliance with the permissible gross vehicle weight and permissible axle load, as per the current Mercedes-Benz body/equipment mounting directives applicable to the vehicle.

Daimler AG issues certificates of non-objection volun-tarily based on the following criteria:

Daimler AG's assessment shall be based solely on the documents submitted by the body manufacturer carrying out the modifications. The assessment and certification shall only cover the expressly defined scopes and their basic compatibility with the des-ignated chassis and its connection points or, in the case of chassis modifications, the basic feasibility of the design for the designated chassis. The certificate of non-objection shall not refer to the overall design of the body, its functions or its intended application. The certificate of non-objection shall only be valid if design, production and assembly are performed by the body manufacturer carrying out the modifications in accordance with the state of the art and in compliance with the valid body/equipment mounting directives of Daimler AG - unless deviations from these direc-tives are endorsed. Nevertheless, the certificate of non-objection shall not release the body manufacturer carrying out the modifications from its product liability or its obligation to perform its own calculations, tests and trials on the overall vehicle in order to ensure that the overall vehicle produced by the company meets the required specifications for operational and road safety and handling characteristics.





2 General

Accordingly, it shall be the sole duty and responsibility 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.

! Note

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

2.1.2 Applying for a certificate of non-objec-tion

Assessment in connection with the granting of a certificate of non-objection requires the submission of the following documents and drawings to the relevant department “Technical advice on body compatibility” (e Page 10) before work on the vehicle is begun:

• All deviations from these Mercedes-Benz Body/Equipment Mounting Directives

• Complete data on dimensions, weights and centres of gravity (weight certificates)

• How the body is attached to the vehicle

• Operating conditions of the vehicle (e.g. on poor road surfaces, in dusty conditions, at high altitudes or in extreme outside temperatures)

• Certificates ("e" mark, seat tensile strength test)

Submitting the required documentation in full will make queries on our part unnecessary and will speed up the procedure.

2.1.3 Legal claims• No legal claim can be made as to the issue of a

certificate of non-objection.

• Daimler AG reserves the right to refuse the issue of a certificate of non-objection due to ongoing techni-cal development and the knowledge gained from it, even if a similar certificate was issued in the past.

• The certificate of non-objection may be restricted to individual vehicles.

• The retroactive issue of a certificate of non-objec-tion for vehicles already completed or delivered can be refused.

• The body manufacturer is solely responsible for adherence to the following requirements:

• Functionality and compatibility of body work performed by the manufacturer with the basic vehicle

• Road safety and operational safety

• All work performed on the body and installed parts


2.2 Product and vehicle information for body manufacturers

2 General


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 11).

2.2.1 Bodybuilder Portal

General

The Bodybuilder Portal is the central communications platform between Mercedes-Benz Commercial Vehi-cles and you, our partners in the body manufacturing industry. The Bodybuilder Portal provides information and access to body-related topics for all model series of Mercedes-Benz trucks and vans. The portal can be accessed at the following address:

https://bb-portal.mercedes-benz.com/

MBAS-Web Technology

In the MBAS-Web (Technology) section of the portal, you can find the relevant technical data sheets, tender drawings, circuit diagrams, engine diagrams and body/equipment mounting directives. As well as the current model series, you will also find directives for vehicle models that are no longer produced (under Archive). Ensure that work is only ever carried out based on the current body/equipment mounting directives.

Under Current topics, you can find the latest product information in the form of body manufacturer informa-tion bulletins (newsletters) or the "ABH-Aktuell" maga-zine.

You are also able to add your Company Profile to the portal so that you can present your company and prod-ucts to us, to our sales staff and, after a further step, to customers.

You are thus optimally equipped to provide your cus-tomers with quick, cost-efficient and comprehensive advice and feasibility studies, to plan and determine the final vehicle design, to compile quotations and to prepare designs.

Design data and drawings

As a body manufacturer, you can obtain original 3D data for the Vito/V-Class - BM 447. 3D data can be ordered using a form which is available in the "Sup-plemental Information" catalogue in the Bodybuilder Portal.

CERON registration

It is possible to register for the CERON system using a form which is available in the "Supplemental Informa-tion" catalogue in the Bodybuilder Portal.

Further information on the CERON system can be found under 2.2.5 “CERON” (e Page 15).

2.2.2 Information for non-registered body manufacturers

Body manufacturers not registered in the Mercedes-Benz Bodybuilder Portal can find After-Sales information using the portal "Service&Parts net":

http://service-parts.mercedes-benz.com

There, you can find information on the following topics:

• Service/parts information

• Diagnosis

• SCN coding

• Special tools

• Tips

https://bb-portal.mercedes-benz.com




2 General

2.2.3 Workshop Information System (WIS)The Workshop Information System (WIS) is available in the "Service&Parts net" under the heading "Service/parts information". For example, the WIS contains:

• basic data (dimensions, tightening torques)

• function descriptions

• circuit diagrams

• repair instructions

• maintenance sheets

Non-MB body manufacturers can purchase access to WIS from the following address:


Further information can be obtained from your Mercedes-Benz Service Partner or the Customer Sup-port Centre (CSC) under:

Contact details

Telephone: +49 (0)1805-010-7979

Fax: +49 (0)1805-010-7978


2.2.4 Xentry KitThe diagnostic tool Xentry Kit is available for the Xentry system as a tool in "Service&Parts net" under the heading "Diagnosis". The Xentry Kit diagnostic tool was developed by Mercedes-Benz to facilitate vehicle diagnosis. The Xentry Kit can be used to read out fault entries from the vehicle and diagnose them. It can also be used to change control unit parameters e.g. on the parameterizable special module (PSM).

Fault entries which occurred during the mounting of the body can also be erased.

In addition, Xentry Kit can also be used to update control units using SCN coding. The use of online SCN coding is required for the Vito/V-Class - BM 447 in order to perform a data update (coding) for the instru-ment cluster, amongst other things.

It is possible to connect the Xentry Kit to the central server of Daimler AG during SCN coding using a LAN or WLAN connection. The relevant SCN coding is requested online and is used to uniquely identify the control unit variants installed in the vehicle. The data for the hardware, flashware and vehicle-specific coding is encrypted.

Additional information on SCN coding can also be found in Service&Parts net.

Xentry Kit can be purchased or leased by body manu-facturers.

If you have any questions about Xentry Kit, contact your Daimler sales and service outlet or the Customer Support Centre (CSC):

Contact details

Telephone: +49 (0)1805-010-7979

Fax: +49 (0)1805-010-7978


mailto:[email protected]



2 General

2.2.5 CERONThe CERON (Certification Online) system is a platform for exchanging and providing documents on the sys-tem approvals and overall operating permits of the EU (European Union) and ECE (Economic Commission for Europe). Here you can find e.g. documents on ETA (European Type Approval) and GOP (General Operating Permit) for trucks, vans, buses and Unimogs.

Use of the CERON system is chargeable.

It is possible to register for the CERON system using a form which is available in the Supplemental Information catalogue in the Bodybuilder Portal.

2.2.6 European type approval (ETA) and EC Certificate of Conformity (CoC)

The 2007/46/EC Directive of the European Parliament forms the basis for approval of motor vehicles and motor vehicle trailers as well as of systems, com-ponents and automatic technical devices for these vehicles. In these guidelines, regulations have been enacted concerning the approval of vehicles which are manufactured in several stages, i.e. the multi-stage type approval procedure. According to this, every 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-cedures:

• EC type approval (ETG)

• EC small series type approval

• National small series type approval

• Individual approval

CoC stands for Certificate of Conformity. A document that attests that certain goods - including vehicles and bodies - conform to recognised (international) stan-dards. The meaning and purpose of this EC Certificate of Conformity is to simplify the approval process for introducing international brands to the markets. This document is therefore required for customs clearance in the context of import and export in particular. The manufacturer, who is in possession of an EC type approval certificate or EC small series type approval certificate, is obliged to provide every vehicle which corresponds to an approved model with a certificate of conformity.

The vehicle-specific data on the EC certificate of con-formity (CoC) for the basic vehicle are available in the Bodybuilder Portal for convenient and quick processing of the body scope.

If you are planning an ETG in a subsequent stage (multi-stage type approval), a contract is required as per 2007/46 EC Appendix XVII Paragraph 1.1. The use of CERON is also regulated as part of this contract. The manufacturer agreement concerning the multi-stage procedure can be obtained at:

[email protected]


Supplemental explanations on accessing the data of the EC certificate of conformity (CoC) can be found using the Bodybuilder Portal in body manufac-turer information edition 16/2013 for vans, dated 24.09.2013.

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.

If you have any questions about navigating within the Bodybuilder Portal, please use the specified hotline:


mailto:[email protected]




2 General

2.2.7 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.).


2.3 Product safety and product liability

2 General


2.3.1 Product safetyBoth vehicle manufacturers and body manufactur-ers must always ensure that the products they are responsible for manufacturing are safe when they are brought into circulation and do not present a hazard to the user or to third parties. Otherwise, there may be consequences under civil, criminal or public law. Every manufacturer is always liable for the product that it has manufactured.

The manufacturer of attachments, bodies, equipment or conversions must guarantee compliance with Direc-tive 2001/95/EC on general product safety.

2.3.2 Product liabilityThe body manufacturer bears responsibility for the following factors:

• The operational and road safety of the body

• The operational and road safety of parts and modi-fied equipment

• Testing and maintaining the operating and driving safety of the vehicle after the body/equipment is mounted (the body and/or equipment must not have a negative effect on the driving, braking or steering characteristics of the vehicle)

• Influences of parts or modifications on the chassis

• Consequential damage resulting from the attach-ment, equipment or modification

• Consequential damage resulting from retrofitted electrical and electronic systems

• Maintenance of functional reliability and unob-structed movement of all moving parts of the chas-sis (e.g. axles, springs, propeller shafts, steering, gearshift linkages etc.) after mounting the body; also in cases of diagonal torsion on the vehicle

Work carried out or modifications on the chassis or body must be entered in the maintenance booklet, sec-tion "Confirmations of the body manufacturer".

2.3.3 Safety-relevant featuresComponents and systems are safety-relevant when their fault or failure could result in an immediate danger to the life and limb of road users.

Daimler AG recommends that an assessment of the safety relevance of the components or functions be carried out for the following work:

• Modifications on the chassis

• Installations in the vehicle

• Interface between vehicle and body (mechanical components, electrical/electronic components, power take-offs, hydraulic components, pneumat-ics)

A component or function is to be classified as safe-ty-relevant when at least one of the following ten safety aspects could reasonably be expected to occur:

• Momentary loss of sight of the road

• Loss of ability to steer

• Loss or partial failure of the braking functions

• Failure of driving functions

• Uncontrolled propulsion

• Sudden failure of driving power

• Leakage of fuel/fire hazard

• Detachment of cargo/trailer/parts

• Injury from operation and other functions of the vehicle

• Occupant protection in accidents



2 General

In the assessment of safety relevance, the follow-ing 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.


2.4 Ensuring traceability

2 General

2.4 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 information 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 recom-mended as is giving subsequent owners the possibility to register their details.


2.5 Trademarks

2 General

2.5 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":


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.



2.6 Accident prevention

2 General

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

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

In Germany, information for commercial carriers is available from the Berufsgenossenschaft für Fahrze-ughaltungen (German Trade Association of Vehicle Owners):

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

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


Postal address: Berufsgenossenschaft für Fahrzeughaltungen, Fachausschuss "Verkehr", Sachgebiet "Fahrzeuge"Ottenser Hauptstrasse 54D-22765 Hamburg, Germany

Homepage: www.bgf.de


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


2.7 Reprocessing of components - recycling

2 General

2.7 Reprocessing of components - recycling


When planning bodies or equipment, the following principles for environmentally compatible design and material selection shall be taken into account, in particular with regard to the EU Directive on end-of-life vehicles 2000/53/EC.

Body manufacturers shall ensure that attachments and bodies (or conversions) comply with current environ-mental legislation and applicable regulations, in partic-ular EU Directive 2000/53/EC concerning end-of-life vehicles and EU Directive 2003/11/EC concerning restrictions on the bringing into circulation and use of certain dangerous substances and dangerous prepara-tions ("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 com-pany concerned 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 elements.

• It must be ensured that components can be dis-mantled easily for recycling, e.g. by snap connec-tions, predetermined breaking points, easy accessi-bility, or by using standard tools.

• It must be ensured that service fluids can be removed simply and in an environmentally responsi-ble manner by means of drain plugs, etc.

• Wherever possible, painting and coating compo-nents should be avoided and dyed plastic parts should be used instead.

• Components in areas at risk from accidents must be designed in such a way that they are damage-tol-erant, repairable and easy to replace.

• All plastic parts are to be marked in accordance with the VDA Materials Leaflet 260 ("Components of motor vehicles; identification of materials"), e.g. "PP – GF30R".


2.8 Quality system

2 General

2.8 Quality system

World-wide competition, increased quality standards demanded by the customer from the van as a whole, national and international product liability laws, new organisational forms and rising cost pressures make efficient quality assurance systems a necessity in all sectors of the automotive industry.

The requirements for a quality management system of this kind are described in DIN EN ISO 9001.

A working group of the VDA (Association of the German Automotive Industry) has produced the guideline "Qual-ity management in the automotive industry - Minimum requirements for a management system for trailer and body manufacturers - System description and assess-ment" for German body manufacturers, which is based on DIN EN ISO 9000 ff. Published as VDA Volume 8 [VDA 8] (including CD-ROM), order no. A 13DA00080.

For the reasons quoted above, Daimler AG urgently advises all body manufacturers to set up and maintain a quality management system with the following mini-mum requirements:

• To define responsibilities and authorities including organisational planning

• To describe processes and procedures

• To appoint a manager responsible for quality

• To carry out contractual inspections and buildability checks

• To carry out product tests in accordance with the specified procedure stated in the test instructions

• To regulate the handling of faulty products

• To document and archive test results

• 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 suppliers

• To ensure that the instructions for processes, work and inspections are up-to-date and available in all departments 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 suit-able 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 35).


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.

Here, it is imperative that the following points are taken into account in the planning phase and adapted to the respective field of application:

• Wheelbase

• Engine/transmission

• Final drive ratio

• Permissible gross vehicle weight and axle loads

• Position of the centre of gravity

• Standard and special equipment

• Compatibility of the assistance systems

! Note

When planning bodies, in addition to a user-friendly and maintenance-friendly design, the careful choice of materials and the associated corrosion protec-tion measures are of great importance (e See page 57).

! Note

Before carrying out body modifications, the deliv-ered vehicle must be submitted to a check to verify whether it fulfils the necessary requirements.


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

You can obtain further information on the available vehicle and body variants from the responsible depart-ment (e Page 13).

3.1.1 Vehicle and model designationFor information on the position of the identification plates, see 3.4 “Vehicle type identification data” (e Page 35).

Information about the availability and approval require-ments for the vehicle can be obtained through your contact person under “Technical advice on the basic vehicle” (e Page 11)

Additional information on dimensions can be found in the "Tender drawings" in the Bodybuilder Portal (e Page 13). Country-specific regulations must be complied with.





Vito panel van

Weight variant Code

A1 (compact), BM 447.601

A2 (long), BM 447.603

A3 (extra long), BM 447.605

2.5 t Code X29

MX1/MX2/MG7/MG3/

895 800

1866-1915

32004895

MX1/MX2/MG7/MG3/

895 1045

1858-1911

32005140

MX1/MX2/MG7/MG3/

895 1045

1861-1913

34305370

2.8 t Code XG6

MX1/MX2/MG7/MG3/MG4 (ZG2)

895 8001866-1915

32004895


895 1045

1858-1911

32005140


895 1045

1861-1913

34305370

3.05 t Code XA6


895 800

1866-1915

32004895


895 1045

1858-1911

32005140


895 1045

1861-1913

34305370

3.2 t Code XA5

MG7/MG3/MG4

895 800

1866-1915

32004895

MG7/MG3/MG4

895 1045

1858-1911

32005140

MG7/MG3/MG4

895 1045

1861-1913

34305370

The vehicle height shown is based on the respective basic suspension. In the case of dynamic suspensions, the vehicle height may vary by 30 mm.

The weight variant is not determined by the model designation but by the code.

Extract from body code options

QA4 Towing capacity 2.5 t

ZG2 All-wheel drive (only for MG4)

CF0 Basic suspension




Vito Mixto, code ZK4

Weight variant Code


A2 (long), BM 447.703


2.8 t Code XG6


895 800

1866-1915

32004895


895 1045

1858-1911

32005140


895 1045

1861-1913

34305370

3.05 t Code XA6


895 800

1866-1915

32004895


895 1045

1858-1911

32005140


895 1045

1861-1913

34305370

3.2 t Code XA5

MG7/MG3/MG4

895 800

1866-1915

32004895

MG7/MG3/MG4

895 1045

1858-1911

32005140

MG7/MG3/MG4

895 1045

1861-1913

34305370




ZK4 Mixto



CF7 Comfort suspension

CF9 Basic suspension plus




Vito Tourer

Weight variant Code


A2 (long), BM 447.703


2.8 t Code XG6

MX1/MX2

895 800

1866-1915

32004895

MX1/MX2

895 1045

1858-1911

32005140

MX1/MX2

895 1045

1861-1913

34305370

3.05 t Code XA6


895 8001866-1915

32004895


895 1045

1858-1911

32005140


895 1045

1861-1913

34305370

3.2 t Code XA5

MG7/MG3/MG4

895 800

1866-1915

32004895

MG7/MG3/MG4

895 1045

1858-1911

32005140

MG7/MG3/MG4

895 1045

1861-1913

34305370




ZK5 Tourer Base

ZQ8 Tourer Pro

ZQ9 Tourer Select







V-Class

Weight variant Code


A2 (long), BM 447.813


2.8 t Code XG6

MG7/MG3/MG4 (ZG2)

895 800

1866-1915

32004895

MG7/MG3/MG4 (ZG2)

895 1045

1858-1911

32005140

MG7/MG3/MG4 (ZG2)

895 1045

1861-1913

34305370

3.05 t Code XA6

MG7/MG3/MG4 (ZG2)

895 800

1866-1915

32004895

MG7/MG3/MG4 (ZG2)

895 1045

1858-1911

32005140

MG7/MG3/MG4 (ZG2)

895 1045

1861-1913

34305370




VQ1 Avantgarde



ZK7 Marco Polo (only for A2 + 3.05 t)


CF8 Sports suspension

CA1 FSD (frequency-selective dampening) suspen-sion

Z43 Approval as a special vehicle, camper van




3.1.2 Vito engine variantsPanel van

Engine code Engine Max. output [kW (hp)]

Sales designation by category and engine power

Emissions level

MX1 OM622 DE16LA 65 (88) 109 CDI

109 BLUETECMA4 MA6

MX2 OM622 DE16LA 84 (114) 111 CDI

111 BLUETECMA4 MA6

MG7 OM651 DE22LA 100 (136) 114 CDI

114 BLUETECMA4* MA6

MG3 OM651 DE22LA 120 (163) 116 CDI

116 BLUETECMF4/MA4*

MA6

MG4 OM651 DE22LA 140 (190) 119 BLUETEC MA6**

Mixto/Tourer

MX1 OM622 DE16LA 65 (88) 109 CDI

109 BLUETECMA4

MA6/MB6

MX2 OM622 DE16LA 84 (114) 111 CDI

111 BLUETECMA4

MA6/MB6

MG7 OM651 DE22LA 100 (136) 114 CDI

114 BLUETECMA4*

MA6/MB6

MG3 OM651 DE22LA 120 (163) 116 CDI

116 BLUETECMF4/MA4* MA6/MB6

MG4 OM651 DE22LA 140 (190) 119 BLUETEC MA6/MB6

* Only left-hand drive vehicles

** For all-wheel drive, code ZG2 119 BLUETEC all-wheel drive




3.1.3 V-Class engine variantsLuxury passenger van

Engine code Engine Max. output [kW (hp)]

Sales designation by cate-gory and engine power

Emissions level

MG7 OM651 DE22LA 100 (136) V 200 CDI

V 200 BLUETECMA4*

MA6/MB6

MG3 OM651 DE22LA 120 (163) V 220 CDI

V 220 BLUETECMF4/MA4* MA6/MB6

MG4 OM651 DE22LA 140 (190) V 250 BLUETEC MA6**/MB6**

* Only left-hand drive vehicles

** For all-wheel drive, code ZG2 V 250 BLUETEC all-wheel drive




3.1.4 Exhaust variantsCode Emissions level

MF4* Standard Euro 4 Gr. III

MA4 Standard Euro 5b+ Gr. III

MB6 Standard Euro 6 Gr. I

MA6 Standard Euro 6 Gr. III

* Only available in countries with a corresponding emissions standard

3.1.5 Drive configurationsDepending on the engine, varying drive configurations may be installed.

Engine code Front-wheel drive Rear-wheel drive All-wheel drive

MX1 X - -

MX2 X - -

MG7 - X -

MG3 - X -

MG4 - X X

X Available

- Not available


Information about the availability and approval requirements for the vehicle can be obtained through your contact person under “Technical advice on the basic vehicle” (e Page 11).


3.2 Vehicle modifications


3.2 Vehicle modifications

Before starting work on the body, the body manufac-turer must check whether:

• the vehicle is suitable for the planned body

• the vehicle model and equipment are suitable for the operating conditions intended for the body

You can plan bodies by requesting the department responsible to send you tender drawings, product information and technical data or you can retrieve this information from the communications system (e See page 13).

Furthermore, you should note the special equipment that is available from the factory (e Page 45).

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

The vehicles must still comply with EC Directives and national regulations after modifications have been carried out.

! Note

Adequate clearances must be maintained in order to ensure the function and operational safety of assemblies.

a 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.


The "Body technical advice" team is available to answer your questions (e Page 10).

! Note

On no account should modifications be made to the soundproofing.

Vehicle approval

The body manufacturer must inform the officially recognised approval authority or inspector of any modifications to the basic vehicle. The approval/testing organisations decide whether laws and regulations are complied with after any modifications are made to the basic vehicle and thus decide whether the complete vehicle is eligible for registration.

! Note



3.3 Dimensions and weights


3.3 Dimensions and weights

On no account should modifications be made to the vehicle width, vehicle height or vehicle length if they exceed the threshold values specified in the current version of the body/equipment mounting directives.

Dimensions and weights may be found in the tender drawings and technical data in the Mercedes-Benz Bodybuilder Portal (e Page 13) and in the technical threshold values section (e Page 46). These refer to vehicles equipped as standard - special equipment is not taken into account.

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

The permissible axle loads and the highest permissible gross vehicle weight specified in Section 4 “Technical threshold values for planning” (e Page 46) may not be exceeded.

a WARNING

The vehicle tyre load capacity may not be exceeded by overloading the vehicle beyond its specified gross vehicle weight. The tyres can otherwise overheat and suffer damage. The driver could lose control of the vehicle and cause an accident.

The braking distance may increase considerably when the vehicle is overloaded.

Information on the permissible weights can be found on the model plate on the vehicle (e Page 35).

a WARNING

Make sure that you do not exceed the permissi-ble axle loads. If the permissible axle loads are exceeded or dropped below, the driver could lose control of the vehicle and cause an accident.

The minimum values for front axle load during driv-ing operation are:

• 35 % of the respective current gross vehicle weight

Information about changes in weight is available from your contact person (e Page 10).

! Note

All bodies must comply with the individual permis-sible axle loads and the permissible gross vehicle weight.

The permitted number of vehicle occupants and a suf-ficient margin for the payload must also be taken into account. The weight of the total luggage must also be considered here.

Take the weight of special equipment into consideration when making calculations.

National regulations and guidelines must be observed.


3.4 Vehicle type identification data


3.4 Vehicle type identification data

The identification plate with the chassis number is located in the door frame on the driver side.

1 Vehicle identification plate on the B-pillar on the driver side

Example of an identification plate for a passenger car model series with trailer coupling

1 Vehicle identification plate

2 Vehicle manufacturer (Daimler AG)

3 EC operating permit number (only for certain countries)

4 VIN

5 Permissible gross vehicle weight (kg)

6 Permissible total mass of the tractor/trailer combi-nation (kg) (only for certain countries)

7 Permissible front axle load (kg)

8 Permissible rear axle load (kg)

9 Paint code

VIN in engine compartment

! Note

The vehicle identification number (VIN) and the vehi-cle identification plate may neither be changed nor fitted to a different point on the vehicle.


3.5 Vehicle stability


3.5 Vehicle stability

For approval of the vehicle with the body mounted, calculated proof of the height of the centre of gravity of the laden vehicle must be submitted in accordance with. EC Brakes Directive 71/320/EEC and ECE R 13. Observe 4.1.2 “Maximum permissible positions of cen-tre of gravity” (e Page 46).

Daimler AG will make no statements concerning:

• driving characteristics

• braking characteristics

• steering characteristics

• behaviour during ESP intervention

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 manufacturer.

a WARNING

On vehicles with ESP which experience extreme centre of gravity displacement as a result of body mounting work, the ESP system may need to be deactivated. Since the introduction of the general ESP requirement, this is now only possible for vehi-cles with specific purposes.

Information is provided by the responsible depart-ment (e Page 10). If ESP has been deactivated, the driver will then have to adapt is/her style of driving accordingly (reducing cornering speed, avoiding sudden steering wheel movements, etc.). When driving dynamics become critical the vehicle behaves like a vehicle without ESP. The permissi-ble 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 carried out may the permissible wheel/axle loads, or gross vehicle weights ever be exceeded.

a WARNING

Make sure that you do not exceed the permissible axle loads. Doing so would prevent the ESP system from functioning correctly on vehicles which are equipped with this feature. The driver could lose control of the vehicle and cause an accident.


Additional information on permissible weights is available in the identification data on the vehicle (e Page 35).


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 anti-skid chains are fitted and the suspension is fully compressed (also allowing for axle twist) (e Page 68) 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 48).

a WARNING

Exceeding the specified tyre load 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 capacity required for your vehicle and the tyre speed rating.

In particular, comply with national regulations concerning 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 approved 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 guar-anteed

• the wheel brakes or components of the suspen-sion system may no longer function correctly.


For more information, see (e See page 13) and (e See page 48).


3.7 Threaded and welded connections



3.7.1 Bolted connectionsIf it is necessary to replace standard bolts / nuts, only use bolts / nuts

• of the same diameter

• of the same strength grade

• of the same bolt standard/type

• of the same surface coating (corrosion protection, friction factor)

• with the same thread pitch

.

We recommend the use of standard Mercedes-Benz parts.

a WARNING

Do not modify any bolted connections that are relevant to safety, e.g. that are required for wheel control, steering or braking functions. They may oth-erwise no longer function correctly. The driver could lose control of the vehicle and cause an accident.

Parts must be refitted in accordance with Mercedes-Benz service instructions and using suitable standard parts. We recommend the use of genuine Mercedes-Benz parts.

• VDI guideline 2862 must be applied to all installa-tion work.

• It is prohibited to shorten the free clamping length, change to a stretch shank or use bolts with a shorter free thread.

• The settling behaviour of bolted connections must be taken into account.

• Using Mercedes-Benz tightening torques requires the corresponding part that has to be screwed to have a total friction factor in the range of µtot=0.08 to 0.14.

• If screws/bolts are tightened to the required torque and tightening angle by Mercedes-Benz, a construc-tive modification is not possible.

• The Mercedes-Benz Workshop Information System (WIS) must be used to determine whether screws/bolts and nuts of suspension components must only be tightened when the vehicle is in ready-to-drive condition.

• Additional tensioned parts of the body must be of equal or greater strength than the preceding ten-sioned assembly.


Information is available from any Mercedes-Benz Service Centre.

a WARNING

Screws/bolts or nuts with locking splines, micro-en-capsulated screws/bolts and self-locking nuts must always be replaced after a single use. Before new micro-encapsulated screws/bolts are screwed in, the mating thread must be recut or the nuts replaced to remove all residual screw locking com-pound. Finally, the recut through-tapped or blind-tapped holes must be blown out with air because any adhesive residue in the thread would prevent correct tightening of the screws/bolts.

If these instructions are not observed, bending forces could act on the screw/bolt due to the lack of pretension and cause the screw/bolt to break. The driver could lose control of the vehicle and cause an accident.




a WARNING

There is an increased risk of injury when microen-capsulated screws/bolts are loosened because of the sudden loosening of the screws/bolts. For this reason, ensure you have sufficient freedom of move-ment when loosening microencapsulated screws/bolts.


The Mercedes-Benz Workshop Information Sys-tem (WIS) or the "Body technical advice" team can provide information on special threaded connections (e Page 10).

3.7.2 Welded connections

General

In order to maintain the high standard of welding demanded by Mercedes-Benz, the work must only be carried out by appropriately qualified welders.

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 welding splashes or removed if necessary.

Choice of welding method

The mechanical properties of weld seams depend on selection of the welding method and on the geometry of the elements to be joined.

If overlapping sheets are to be welded, the choice of welding method will depend on whether only one or both sides of the workpiece is/are accessible:

Accessible sides

1 Gas-shielded plug welding

2 Resistance spot welding

Resistance spot welding

Resistance spot welding is used for welding overlapping parts which are accessible from both sides. Spot weld-ing of more than two sheet layers must be avoided.

Distance between spot welds

To avoid shunt effects, the specified distances between the spot welds must be maintained (d = 10e + 10 mm).

d Distance between spot welds

e Sheet thickness




Distance from sheet edge

To avoid melting core damage, the specified distances to the sheet edge must be maintained (L = 3e + 2 mm).

�

e Sheet thickness

L Distance from sheet edge

Gas-shielded plug welding

If overlapping sheets is only accessible from one side, 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.

D = Plug hole diameter [mm] 4.5 5 5.5 6 6.5 7

e = Sheet thickness [mm]

0.6 0.7 1 1.25 1.5 2




Mechanical quality can be additionally improved by the use of "elongated holes" (l = 2b).

b Width of slotted hole

I Length of slotted hole

Tack welding

In case of sheet thicknesses > 2 mm, overlapping sheets may also be joined by tack welding (30 mm < L < 40e; d > 2L).

Dimensions for tack welds

d Distance between tack weld centres

e Sheet thickness

L Length of tack weld

Non-weldable parts

No welding work may be performed on the following components/major assemblies:

• Vehicle frame

• Engine, transmission, axles etc.


For further information, refer to Sections 4 “Tech-nical threshold values for planning” (e Page 46), 5 “Damage prevention” (e Page 55), Sub-sec-tion 6.2 “Bodyshell/body” (e Page 64) and the Mercedes-Benz Workshop Information System (WIS).

Corrosion protection after welding

On completion of all welding work on the vehicle, you must comply with the specified corrosion protection measures (e Page 57).

! Note

The instructions in section 5 “Damage prevention” (e Page 55) and 6 “Modifications to the basic vehicle” (e Page 60) must also be observed for welding.


3.8 Soundproofing


3.8 Soundproofing

Noise measurements must be carried out if modifi-cations are made to noise-relevant parts, such as the following:

• Engine

• Exhaust system

• Air intake system

• Tyres, etc.

National regulations and guidelines must be observed.

In Germany, the EU Directive 70/157/EEC and Section 49.3 StVZO (geräuscharm) (Section 49.3 of the German Road Traffic Licensing Regulations (low-noise vehicles)) must be observed.

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

• The level of interior noise must not be adversely affected.

! Note

All modifications to the vehicle must comply with vehicle sound levels as defined in EU Directive 70/157/EEC.

! 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 82).


3.9 Maintenance and repairs



Maintenance and repair of the vehicle should not be made unnecessarily difficult by the body.

Maintenance points and major assemblies must be easily accessible.

Observe the operating instructions.

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

The battery compartment must be sufficiently venti-lated, with provision for air to enter and exit. A battery vent must be installed if necessary.

Check the condition and capacity of batteries and service them in accordance with the manufacturer's specifications (e Page 44).

! Note

Leaving the vehicle parked up for long periods of time can lead to battery damage. This can be avoided by disconnecting the battery and storing it in an appropriate manner (e Page 44).

Any additional work which arises due to the body in terms of

warranty-related work, maintenance or repair work will not be paid for by Daimler AG.

The following must be observed by the body manufac-turer before delivery of the vehicle:

• Check the headlamp setting or have this checked at a qualified specialist workshop. We recommend a Mercedes-Benz Service Centre.

• Retighten the wheel nuts/bolts to the specified torque.

• Daimler AG recommends adapting the scopes of maintenance work on the body to each individual body using the relevant Mercedes-Benz mainte-nance systems. This applies both to the scope and type of service work, and for determining the service due dates for servicing intervals based on time elapsed and distance covered.

The body manufacturer must provide the vehicle with operating instructions and maintenance instructions for the body and any additional assemblies installed. These instructions must be in the language of the country in which the vehicle is to be used.

3.9.1 Storing the vehicle

Storage in enclosed premises• Clean the entire vehicle

• Check the oil and coolant levels

• Inflate the tyres to 0.5 bar above the specified tyre pressures

• Release parking brake and prevent vehicle from rolling away with chocks

• Disconnect the battery in a charged state (at least 80 %) and lubricate the cable lugs and terminals

Storing the vehicle in the open (< 1 month)• 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)• Carry out the same procedure as for storing in an

enclosed space

• Fold the windscreen wipers away from the wind-screen

• Close all air inlets and set the heating system to “Off”

• Remove the battery and store it in accordance with the manufacturer's specifications (e Page 44)




Maintenance work on stored vehicles (in storage for > 1 month):

• Check the oil level once a month

• Check the coolant once a month

• Check the tyre pressures once a month

Removing the vehicle from storage• Check the fluid levels in the vehicle

• Adjust the tyre pressures to the manufacturer's specifications

• Check the battery charge and install the battery

• Clean the entire vehicle

3.9.2 Battery maintenance and storageFor long idle times or storage periods, it must be ensured that the battery is always in a charged state (at least 80 % - corresponds to an open circuit voltage of approx. 12.55 V). To avoid damage to the battery, disconnect the battery if the vehicle is to be parked up for a period longer than one week. Always disconnect both terminals.

If the vehicle is parked up for periods of longer than one month, remove the battery and store it in a dry place at temperatures between 0 °C and 30 °C.

Store the battery in an upright position.

The battery voltage must be kept above 12.55 V at all times.

If the battery voltage drops below 12.55 V but not below 12.1 V, the battery must be recharged.

! Note

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

3.9.3 Work before handing over the modified vehicle

The manufacturer must confirm the work and modifi-cations carried out by making an entry in the Mainte-nance Booklet.

Checking the overall vehicle

Check that the vehicle is in perfect condition. Repair any damage if necessary.

Checking the brake system

If it is not known how long the vehicle has been in stor-age, the brake fluid must be renewed.

Check electrical and hydraulic lines for all types of damage and repair or replace if necessary.

Check the pneumatic system for all types of damage and repair or replace if necessary.

The brake fluid must be renewed every two years.

Checking the vehicle electrical system

After all work on the electrical or electronic system, the fault memory of the control units must be read out and, if necessary, erased.

Checking the battery

Test the battery charge before handing over the vehi-cle (e Page 44). The battery must be recharged if necessary.

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 is contained in the Mercedes-Benz Workshop Information System (WIS).


3.10 Special equipment


3.10 Special equipment

a WARNING

The use of parts, assemblies, conversion compo-nents or accessories which have not been approved may jeopardise the safety of the vehicle.

Before starting work on the vehicle, please read the relevant sections of the vehicle operator's manual and the operating and assembly instructions from the manufacturers of the accessories and special equipment. You could otherwise fail to recognise dangers, which could result in injury to yourself or others.

We recommend using special equipment available as option codes to adapt the body to the vehicle optimally.


More information on special equipment can be obtained from:

• Mercedes-Benz Service Centre

• PIT (Product Information Tool for Vans) in the Bodybuilder Portal(e Page 16)

• “Technical advice on the basic vehicle” (e Page 11)

On the Mercedes-Benz homepage, you can assemble vehicles in the Configurator and view the available items of special equipment:


Special equipment (e.g. reinforced springs, frame reinforcements, additional tanks, stabilizer bars etc.) or retrofitted equipment may alter the curb weight of the vehicle. In addition, special equipment can cause changes to the centre of gravity, installation space conditions and component clearances. For this reason, attention must be paid to maintaining the function-ality of the overall vehicle and complying with limits (e Page 46) whenever work is performed.

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

Not all special equipment can be installed in every vehicle without problems. This applies in particular for retrofitted equipment because the installation space may already be occupied by other components or the special equipment may require other components.


The "Body technical advice" team is available to answer your questions (e Page 10).



4.1 Threshold values of the basic vehicle

4 Technical threshold values for planning

4.1 Threshold values of the basic vehicle

! Note

This section contains the basic vehicle technical threshold values which are important for planning work. In addition, you will find more information in the other sections of the current version of the body/equipment mounting directives.

4.1.1 Steerability• The front axle load must always be at least 35 % of

the respective current gross vehicle weight in all load states when the vehicle is moving.

• Make sure that you do not exceed the permissible axle loads.

4.1.2 Maximum permissible positions of centre of gravity

x-axis: Where R1 = 3200 mm < 1700 mm (approx. 53% rear axle share of load)

Where R2 = 3430 mm < 1800 mm (approx. 53% rear axle share of load)

y-axis: The maximum wheel load (1/2 the axle load) of the laden vehicle may only be exceeded by 4%.


For more information see 9.1.2 “Determina-tion of the centre of gravity in the z-direction” (e Page 126).

4.1.3 Maximum vehicle dimensions

Permissible vehicle width

In accordance with EC Directives 97/27/EC, 96/53/EC and 92/21/EC

General: 2550 mm

Passenger car: 2500 mm

Without addition of additional headlamps, with 1928 mm standard vehicle width (excluding outside

mirrors):

2249 mm (ECE R48):

Vehicle height


4000 mm

Vehicle length



4.2 Suspension threshold values



4.2.1 Permissible axle loads

a WARNING

Make sure that you do not exceed the permissible axle loads. Doing so would prevent the ESP system from functioning correctly on vehicles which are equipped with this feature. Furthermore, any over-loading may result in damage to the suspension and structural parts. The driver could lose control of the vehicle and cause an accident.

For information on axle loads and maximum permis-sible gross vehicle weight, see “Technical advice on the basic vehicle” (e Page 11).


For further information on permissible axle loads, refer to 2 “General” (e Page 10).

Vito

Axle loads [t] Panel van Mixto Tourer

Front axle [kg]

Rear axle [kg]

Front axle [kg]

Rear axle [kg]

Front axle [kg]

Rear axle [kg]

2.5 1400 1400 X X X X

2.8 1490 1490 1490 1490 1490 1490

3.05 (M1) 1550 1650 1550 1550 1550 1550

3.05 (N1) 1550 1650 1550 1650 1550 1550

3.2 1550 1750 1550 1750 1550 1750

Axle loads [t] V-Class

Front axle [kg] Rear axle [kg]

2.8 1490 1490

3.05 1550 1550




4.2.2 Approved tyre sizes


Information about the tyres/rims assigned to the vehicle model and any limitations can be obtained:

• from your contact persons, see 2.1 “Advice for body manufacturers” (e Page 10)

• from the vehicle configurator at http://www.mercedes-benz.com





Approved tyre sizes for Vito

Wheel Tyres Code Load index Use 2.5 t 2.8 t 3.05 t 3.2 t

6.5 J x 16H2 ET 52 steel

195/65 R16 C RG6

100/108 T Summer X X (3.4) - -

104/102 T (100T)

Summer X X (3.4) X (1,3,4) -

Winter X X (3.4) X (1,3,4) -

6.5 J x 16H2 ET 52

steel/alu.

205/65 R16 C RG1

103/101 H Summer X X (4) X (4) -

1047/105 T(103H)

Winter X X (4) X (4) -

107/105T(103H)

All season X X (4) X (4) -

225/60 R16 C RG2 105/103 H Summer X X (4) X (4) -

6.5 J x 17H2

ET50 steelET51 alu.

225/55 R17 C

RG7

109/107 H(104H)

Summer X X X X

104/102 H All season X X X -

109/107 T(104T)

Winter X X X X

225/55 R17 RF 101V

Summer - X (2.5) X (2.5) -

Winter - X (2.5) X (2.5) -

7.5 J x 18H2

ET 52 alu.

245/45 R18 XL RH4 100W Summer - X (2) X (1.2) -

8 J x 19H2ET 52 alu.

245/45 R19 XL RK1 102Y Summer - X (2.5) X (2.5) -

X Approved- Not approved1 Only for M1 registration and/or Tourer2 Not for MX1/MX23 Not for MG34 Not for MG45 Only for Tourer

T - Up to 190 km/hH - Up to 210 km/hV - Up to 240 km/hW - Up to 270 km/hA deviation of 6 % from the maxi-mum speed is normally taken into account in the design phase.




Approved tyre sizes for V-Class

Wheel Tyres Code Load index Use 2.8 t 3.05 t

6.5 J x 16H2 ET 52 steel

195/65 R16 C RG6

100/108 T Summer X (3.4) -

104/102 T (100T)

Summer X (3.4) -

Winter X (3.4) -

6.5 J x 16H2 ET 52 steel/

alu.

205/65 R16 C RG1

103/101 H Summer X (4) X (4)

1047/105 T(103H)

Winter X (4) X (4)

107/105T(103H)

All season X (4) X (4)

225/60 R16 C RG2 105/103 H Summer X X (4)

6.5 J x 17H2ET50 steelET51 alu.

225/55 R17 C

RG7

109/107 H(104H)

Summer - -

104/102 H All season - -

109/107 T(104T)

Winter - -

225/55 R17 RF 101V

Summer X X

Winter X X

7.5 J x 18H2ET 52 alu.

245/45 R18 XL RH4 100W Summer X X

8 J x 19H2ET 52 alu.

245/45 R19 XL RK1 102Y Summer X X

X Approved- Not approved1 Only for M1 registration and/or Tourer2 Not for MX1/MX23 Not for MG34 Not for MG45 Only for Tourer

T - Up to 190 km/hH - Up to 210 km/hV - Up to 240 km/hW - Up to 270 km/hA deviation of 6 % from the maximum speed is normally taken into account in the design phase.




4.2.3 Diameter of turning circleThe table provides a rough overview of the turning cir-cle diameters (in metres) depending on the drive type and vehicle length (version).

Version Front-wheel drive

Rear-wheel drive

All-wheel drive

A1 12.9 11.8 12.7

A2 12.9 11.8 12.7

A3 13.7 12.5 13.5

The size of your vehicle's turning circle can be found in the data sheets and tender drawings. Both data sources can be accessed using the Product Information Tool for vans (PIT) (e Page 16) or the Bodybuilder Portal (e Page 13).

The international and national regulations for vehicle approval and registration shall be complied with. These include:

• ECE-R 79

• European Union: 97/27/EC (applicable until 31.10.2014)

• European Union: 96/53/EC


4.3 Bodyshell threshold values


4.3 Bodyshell threshold values

4.3.1 Modifications to the bodyshellWhen modifications are made to the load-bearing struc-ture, the total rigidity of the structure fitted by the body manufacturer must correspond to at least the rigidity of the standard vehicle.

4.3.2 Vehicle roof/roof loadMaximum roof load for standard roof [kg]

150 (with at least three pairs of support feet)

The figures indicated are applicable for even load distri-bution across the entire roof area.

With a shorter roof carrier, the load must be reduced proportionally. The highest possible load per pair of roof carrier support feet is 50 kg.

The highest possible load of a railing carrier is 100 kg.

6.2.6 “Modifications to the roof structure” (e Page 69) must be observed when making modifi-cations to the roof structure.

4.3.3 Threshold values for fastening points

The maximum tensile loading of the tie-down points only applies if the following conditions are fulfilled:

• The load located on the load compartment floor is secured at two tie-down points on the rail and

• The distance to the next load securing point on the same rail is approx. 1 m

Maximum load forces [daN]

Code VV2 Load retainer rail system 500

Code UR1 Seat rail system 350

Code V42 Tie-down rails, sidewall to belt rail 100


4.4 Limits for electrical/electronic system


4.4 Limits for electrical/electronic system


See also 8 “Electrical system” (e Page 95).

4.4.1 Electric wiring/fusesThe following table is valid for cables with an operating temperature limit of more than 105 °C for the insula-tion.

Max. perma-nent current

[A]

Fuse rating [A] Line cross-section

[mm2]

0 - 4.9 5 0.5

5 - 9.9 10 1

10 - 18 20 2.5

19 - 28 30 4

29 - 35 40 6

36 - 48 50 10

49 - 69 70 46

70 - 98 100 25

99 - 123 125 35

124 - 148 150 50

4.4.2 Vehicle position and side marker lamps

End-outline marker lamps as per ECE-R48 are pre-scribed for all vehicles with an overall width of more than 2.10 m (in addition to the vehicle position lamps).

Side marker lamps as per ECE-R48 are necessary for all vehicles with an overall length of more than 6 m.


4.5 Additional assembly threshold values


4.5 Additional assembly threshold values

If auxiliary equipment (e.g. additional air-conditioning compressors, pumps, etc.) is retrofitted, the following must be observed:

• The operation of vehicle components must not be adversely affected.

• Unobstructed movement of the vehicle and attach-ments must be ensured in every driving situation.


5.1 Brake hoses/cables and lines

5 Damage prevention

5.1 Brake hoses/cables and lines

! Note

Any work carried out on the vehicle must comply with accident prevention regulations.

! Note

Comply with all national regulations and laws.

Cover plastic lines and brake hoses before carrying out any welding, drilling and grinding work or before work-ing with cutting discs. If necessary, the plastic lines and brake hoses should be removed.

Test each of the systems for pressure loss and leaks after installing compressed-air lines and hydraulic lines.

No other lines may be attached to brake hoses.

Lines must be protected from heat by means of insula-tion.

Line routing must be designed to prevent any increase in pressure loss.

a WARNING

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.


5.2 Welding work

5 Damage prevention

5.2 Welding work

a WARNING

Welding in the vicinity of the restraint systems (air-bag or belts) can cause these systems to no longer function correctly. Welding is therefore not permit-ted in the vicinity of the restraint systems.

a WARNING

Welding work that is not performed correctly could lead to failure of components relevant to safety. It would then not be possible to rule out the risk of an accident. For this reason, the following safety pre-cautions must always be observed during any work involving welding:

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

• Before carrying out welding work, components which may contain flammable or explosive gases - e.g. the fuel system - must be removed or protected against sparking with a fire-resistant covering. Components which are damaged by sparking during welding work must be replaced.

• Before welding operations in the vicinity of the seat belts, airbag sensors or the airbag control unit, these components must be removed for the dura-tion of the work. You will find important information about handling, transporting and storing airbag units under 6.4 “Interior” (e Page 75).

• Before welding, cover springs and air suspension bellows to protect them from welding spatter. Do not touch springs with welding electrodes or weld-ing tongs.

• No welding work must be carried out on major assemblies such as the engine, transmission, axles or on the lower flange of the frame and at the A-pil-lar and B-pillar.

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

• Connect the welding-unit earth terminal directly to the part to be welded. Do not connect the earth terminal to assemblies such as the engine, trans-mission or axles.

• Do not touch electronic component housings (e.g. control units) and electrical lines with the welding electrode or the earth terminal of the weld-ing unit. No arc welding work may be performed on the Vito E-Cell.

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

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

• Use only completely dry basic-coated electrodes (diameter 2.5 mm).

• MIG welding is possible.

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

• The yield point and tensile strength of the welding material must be at least equal to that of the mate-rial to be welded.

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

• Welds must be ground down and reinforced with angular profiles to prevent notching from welding penetration.

• Do not perform any welding work in bends.

• There must be at least 15 mm between the weld and the outer edges.


For further information on welding, refer to Sec-tion 3.7 “Threaded and welded connections” (e Page 38) and the Mercedes-Benz Workshop Information System (WIS).


5.3 Corrosion protection measures

5 Damage prevention


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

! Note

Only protective agents tested and approved by Daimler AG may be used for any corrosion protection measures performed.


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

Corrosion protection measures should be included in the planning and design stages by selecting suitable materials and designing components accordingly.


A conductive connection occurs if two different met-als are brought into contact with each other through an electrolyte (e.g. air humidity). This causes elec-trochemical corrosion and the less noble of the two metals is damaged. The further apart the two metals are in the electrochemical potential series, the more intense electrochemical corrosion becomes.

For this reason, electrochemical corrosion must be prevented by insulation or by treating the compo-nents accordingly, or it can be minimised by select-ing suitable materials.

Preventing contact corrosion by means of electrical insulation

Preventing contact corrosion

1 Insulating washer

2 Insulating sleeve

Contact corrosion can be prevented by using electrical insulation such as washers, sleeves or bushings.

Avoid welding work on inaccessible cavities.



5 Damage prevention

Component design measures

Corrosion can be prevented by design measures, in particular the design of joints between identical or different materials.

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

Design measures for counteracting corrosion should be implemented using inclined surfaces and drains, and by avoiding gaps in the joints between components.

Gaps inherent in the design of welded connections and how to avoid them

Examples of types of welded connections

A = correct(through-welded)

B = incorrect(gap)

Coating measures

The vehicle can be protected against corrosion by applying protective coatings (e.g. galvanisation, paint-ing, preservation or zinc coating applied by flame) (e Page 59).

After all work on the vehicle:• Remove drilling chips.

• Deburr sharp edges.

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

• Prime and paint all unprotected parts.

• Preserve cavities with wax preservative.

• Carry out corrosion protection measures on the underbody and frame parts.

• On vehicles with Code Z90 (no underbody preserva-tion), the chassis must be preserved in accordance with Daimler AG specifications.


5.4 Painting work/preservation work

5 Damage prevention

5.4 Painting work/preservation work

! Note

To dry the paint, an air circulation temperature of 80°C and a component temperature of 60°C must not be exceeded. Control units or other components can be damaged at higher temperatures.

Paintwork or preservation agent damaged by the body manufacturer must be repaired by the body manufac-turer.

Observe the following points:

• Daimler AG quality standards for initial painting and paintwork repairs must be adhered to.

• Only materials tested and approved by Daimler AG or equivalently suitable materials may be used for any painting or preservation work performed.

• The body manufacturer must observe the coat thickness for each individual coat as specified by the factory.

• Paint compatibility must be guaranteed when repainting.


You can obtain information on the paint mate-rials and coat thicknesses used at the factory and Mercedes-Benz paint numbers from any Mercedes-Benz Service Centre.

Mask the following areas before painting:

• Disc brakes

• Brake hoses

• Brake fluid reservoir

• Gearing unit for parking brake

• Contact surfaces between disc wheels and wheel hubs/brake discs

• Contact surfaces of wheel nuts/wheel bolts

• Airbags and seat belts

• Sealing surfaces

• Windows, mirror glass

• Illumination openings

• Breathers on transmissions, axles, etc.

• Door locks

• Door catches in the hinges of the hinged rear door

• Contact surfaces on the guide rails for the sliding doors

• Door retainers and opening limiters in the centre guide rails

• Moving parts of the sliding door carriage

• Coupling flanges of drive shafts and power take-offs

• Piston rods e.g. on gas-operated springs of liftgate

• Pneumatic control valves (compressed air system/vacuum system)

• Spring/spring mounting area

• Parktronic sensors


Additional information on paintwork and preserva-tion can be found in the "Guidelines for painting" under

https://aftersales.mercedes-benz.com

.

https://aftersales.mercedes-benz.com


6.1 Chassis

6 Modifications to the basic vehicle

6.1 Chassis

6.1.1 General information on the chassis

a WARNING

Impermissible modifications to components of the chassis can result in impaired and unstable vehicle handling characteristics. For this reason, no modifi-cations whatsoever may be made to components of the suspension system.

This is especially valid for:

• Front transverse control arms: Changes to wheel alignment settings are not permitted.

• Front axle tree bolster: It is not permitted to modify or use the front axle tree bolster to mount addi-tional equipment or make other modifications.

• Anti-roll bars: any modifications to anti-roll bars (diameter, material) at the front and rear, and the retrofitting of the same, require a certificate of non-objection from the responsible department (e Page 10).

• Rear axle: modifications are not permitted.

• Brakes: modifications are not permitted.

• Units, sensors, line routing for ESP/ABS: modifica-tions are not permitted.

• New screws/bolts must be used when installing the front axle. All screws/bolts and threaded connec-tions are to be tightened in accordance with the Mercedes-Benz tightening instructions. Information on this is available from your Mercedes-Benz Ser-vice Centre.

• VDI guideline 2862, in particular the section enti-tled "Bolted connections with special safety rele-vance", must be implemented for all installations.

• It is prohibited to shorten the free clamping length, change to a stretch shank or use bolts with a shorter free thread.

• The settling behaviour of bolted connections must be taken into account

• Additionally tensioned parts must exhibit an identi-cal or higher strength than the previous tensioned assembly.

• The use of Mercedes-Benz tightening torques assumes coefficients of friction for the screws/bolts in the tolerance range of [=0.08 to 0.14].

• We recommend the use of standard Mercedes-Benz parts.


You can obtain further information, particularly with regard to Mercedes-Benz tightening instructions and settling properties of threaded connections, from every Mercedes-Benz Service Centre.

6.1.2 Springs/shock absorbersModifications to springs, shock absorbers and stabilizer bars can only be made in the combinations specified by Daimler AG on the front and rear axle. In this case a certificate of non-objection is not required. For any further modifications, the front and the rear axles must be adapted to each other and a certificate of non-ob-jection is required.

• We recommend genuine Mercedes-Benz springs

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

• Before carrying out welding work, springs must be covered to protect them against welding spatter.

• Do not touch springs with welding electrodes or welding tongs.

On no account should springs or shock absorbers be used if they do not correspond to the character-istics of standard parts or parts obtainable as spe-cial equipment. We recommend the use of standard Mercedes-Benz parts.

a WARNING

On no account should springs and shock absorbers be used if they do not correspond to the characteris-tics of standard parts or parts obtainable as special equipment. Alterations may mean that the ESP no longer works correctly and ultimately fails. 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 45).


6.1 Chassis


6.1.3 Brake system

a WARNING

Incorrectly executed work on brake components or lines in the brake system (this includes lines for hydraulic components, air or electrical control signals) can impair the function of the brake sys-tem. This can cause the brake system to no longer operate correctly and ultimately fail. Only have work on brake components, their hoses, lines and cables carried out by an authorised specialist workshop.

After completion of the work, check that the brake system is working correctly. We recommend that the brake system be inspected and approved by a technical inspection centre.

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

Hydraulic brake system• Hydraulic brake lines are to be completely replaced

by approved 4.75 mm x 0.7 or 6 mm x 0.7 mm rolled laminated tube.

• The bending radius must be > 17.5 mm.

• Lines must only be shaped in a bending machine. The cross-section must not be reduced.

• Attach nuts to the ends of lines (part no. 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.

• For routing between two components which move in relation to each other, a flexible line (hose, Stahl-flex, etc.) must be used.

Installation of lines

a WARNING

A sufficient distance must be maintained between brake lines and heat sources, sharp-edged or moving parts. Otherwise, the brake system function could be impaired or the brake system could suffer total failure as a result of bubbles forming in the brake fluid or from chafing points in the brake lines.

• We recommend the use of genuine Mercedes-Benz brake line brackets for the attachment of the brake lines.

• The maximum permissible distance between loops is 500 mm.

• The brake lines must be routed without kinks.

• There must be no angle changes at the end pieces of the brake cable conduit (free strands).

Routing lines along the brake hoses

No other lines may be attached to brake hoses.

Brake cable for the parking brake/modifying the length of the brake cable

If a new brake cable is required for the parking brake, the new length of the cable must be determined and a new suitable cable must be procured.

The brake cable retainers are moment-optimised; modi-fications are not permitted.

The brake cables must be routed without kinks.


Please address all queries regarding produc-tion brake cables to the department responsible (e Page 11).


6.1 Chassis


Disc brakes

Cooling must not be impaired by attaching spoilers below the bumper, additional hub caps or brake disc covers, etc.

a WARNING

On no account should modifications be made to the 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 vehicle and cause an accident.

Brake system overheating will not only impair brak-ing ability, it can also cause tyre damage.

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

a WARNING

On no account should modifications be made to brake components (e.g. brake callipers, brake disks, etc.) or sensors. Any modifications to brake compo-nents may result in these systems not functioning correctly and ultimately failing. The driver could lose control of the vehicle and cause an accident.

Auxiliary brakes/retarders

Retrofitting auxiliary brakes requires a certificate of non-objection from the responsible department (e Page 10).

6.1.4 Air suspension

a WARNING

Retrofitting air suspension may lead to the ESP no longer functioning correctly. The driver could lose control of the vehicle and cause an accident. In order to retrofit air suspension systems, coordina-tion with the responsible department (e Page 10) and a certificate of non-objection are therefore required.

6.1.5 Wheels and tyres

a WARNING

Only use tyre types and sizes which are approved for the corresponding vehicle model. Observe the tyre load capacity and speed rating required for the vehicle.

In particular, comply with national regulations concerning the approval of tyres. These regulations may define a specific type of tyre for the vehicle or may forbid the use of certain tyre types which are approved in other countries.

If different wheels are mounted, the following dan-gers may arise:

• Brakes or suspension components may be dam-aged

• The clearance of the wheels will no longer be guaranteed

• Brakes or suspension components may no longer function correctly.


6.1 Chassis


The body manufacturer must ensure that the following requirements are fulfilled:

• There must be sufficient space between the tyre and the mudguard or wheel well even with snow or anti-skid chains fitted and the suspension com-pletely compressed (allowing for axle twist). The relevant specifications in the tender drawings must be observed.

• Only approved tyres and tyre sizes may be used (see motor vehicle registration certificate, tender drawings (e Page 13), or tables under 4.2.2 “Approved tyre sizes” (e Page 48)).


You can obtain more information about tyres and wheels from any Mercedes-Benz Service Centre or under 3.10 “Special equipment” (e Page 45).

6.1.6 Spare wheel Country-specific equipment or special equipment may contain a spare wheel.

For the attachment, the following requirements shall be complied with in addition to the legal directives:

• The attachment shall take place under the frame as per the tender drawing.

• Good accessibility and ease of operation must be ensured.

• The spare wheel must be doubly secured to prevent loss.


6.2 Bodyshell/body


6.2 Bodyshell/body

6.2.1 General information on the bodyshell/body

Modifications must not have a negative effect on the function or strength of vehicle equipment or controls or on the strength of load-bearing parts.

In the case of modified vehicles, it is not permissible to make modifications that affect the function or freedom of movement of vehicle parts (e.g. during maintenance and inspection work) or accessibility of these parts.

Observe the following:

• All modifications must be presented in advance in the form of drawings and calculations and certified by the vehicle manufacturer.

• Changes to the wheelbase are not permitted.

• The maximum permissible axle loads must not be exceeded.

• On no account should any modifications (such as drilling or welding) be carried out on the support structure from the front through to the rear of the B-pillar.

• Modifications to the windscreen and windscreen frame, and to the A-pillar and B-pillar, are not per-missible.

• Holes on the longitudinal frame member are the result of the production process and are not suit-able for securing bodies, as there is otherwise a risk of damage to the frame.

• It is not permissible to make cuts in the C or D-pil-lar (rear portal), including the associated roof bow.

• Modification of vehicles with windowbag is not permissible in the roof area of the B-pillar.

• Partitions may be totally or partially removed.

• The clearances for the fuel filler neck and for the tank and fuel lines must be maintained, see 6.3.1 “Fuel system” (e Page 71).

• Avoid sharp-edged corners.

• Trailer connections must be checked for correct operation.

• If a trailer coupling is installed, the necessary rein-forcements must be present (e Page 86).

• 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.

• The function of the tyre pressure monitoring system (TPMS) must not be impaired by modifications made in the direct proximity of the aerials and wheels.

Welding work on the bodyshell

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

When performing welding work, Section 5.2 “Welding work” (e Page 56) must be observed. In addition, you can find information on the design of weld joints in Section 3.7 “Threaded and welded connections” (e Page 38).


6.2 Bodyshell/body


Drilling work on the bodyshell

! Note

No drilling must take place in the following areas:

• A-pillars and B-pillars

• The lower flange of the frame

• In the vicinity of the rear axle, which is responsi-ble for bearing functions

• In the vicinity of components which are mounted on the frame

• Load application points (e.g. spring brackets, brackets)

Drilling in the longitudinal member web is only possible in accordance with the following figure and if spacer bushings welded to the longitudinal member are used:

Drilling work on the longitudinal frame members

1 Chassis frame

2 Spacer bushes

a Distance of at least 20 % of the frame height

b Distance between drill holes at least 50 mm

After drilling, deburr and countersink all holes, remove chips from the frame and treat the holes with body cavity sealing.

! Note

Existing holes in the longitudinal frame member result from the production process and may only be used if approved by means of a technical certificate from the department responsible (e Page 11).

6.2.2 Modifying the partition wallIf it is necessary to cut through the partition, it is possible to do this in connection with a continuous surrounding frame.

If the vehicle is equipped with windowbags for the driver and front passengers, modifications to the partition wall in the area illustrated (e Page 66) are not permitted, so as to guarantee that the windowbags deploy correctly.

Partitions may be totally or partially removed.

a WARNING

On no account should subsequent modifications be made to the headliner or roof panel if the vehicle is equipped with windowbags. Otherwise, the window-bag may no longer work correctly (e.g. windowbag deployment is delayed or incomplete).


6.2 Bodyshell/body


1

3

1 1

2

Areas which must not be modified on vehicles with windowbags

2 Vertical dimension (from the highest point of the vehicle roof, interior, at the height of the B-pillar): 650 mm

3 Horizontal dimension: 800 mm


6.2 Bodyshell/body


6.2.3 Sidewall, windows, doors and flaps

Sidewall

If modifications are made to the sidewall of the panel van or the passenger van, the rigidity of the modified 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.

Refer to 8.7.2 “Crosswind Assist” (e Page 110) for modifications on the projected lateral face.

A certificate of non-objection is required from the department responsible (e Page 10).

! Note

Upon completion of all work on the vehicle, you must comply with the specified corrosion prevention measures (e Page 57).


Additional information on modifications to the sidewall can be found under6.6.3 “Fitted shelving” (e Page 85)

Windows

Windows must be inserted with a stable frame. The frame must then be joined by a non-positive attach-ment to other body elements.

If modifications need to be carried out to the support-ing structure of the basic vehicle (pillars, reinforce-ments, attachment of roof bows) in order to retrofit windows (panorama glazing), the rigidity of the modi-fied body must be equal to that of the basic vehicle.

Doors and flaps

If modifications need to be carried out to the support-ing 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

Any modifications to the rear door opening including the roof area are only permitted in exceptional cases and require a certificate of non-objection from the department responsible (e Page 10).


6.2 Bodyshell/body


N23.00-2031-00

1 Rear portal area (certificate of non-objection required)

• 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.

• The maximum permitted height of the bottom step above the road surface is 400 mm.

• Fittings must allow sufficient clearance to the inte-rior door handles regardless of the position of the cargo area sliding door (anti-pinch protection).

• On no account should modifications be made to the central locking system or to the immediate area around the door or in the area of the pillars or cross members.

! Note

Upon completion of all work on the vehicle, you must comply with the specified corrosion prevention measures (e Page 57).

6.2.4 Mudguards and wheel wells

a WARNING

Lowering the wheel arches is not permissible. Oth-erwise, the vehicle could be damaged (e.g. wheel arches and tyres).

6.2.5 Underfloor panellingIf parts of the standard underfloor panelling are removed, additional corrosion protection is required in the entire underfloor area.

If trim parts are removed, this can cause wind noises.


6.2 Bodyshell/body


6.2.6 Modifications to the roof structure

! Note

Modifications to the roof structure, including the rear portal, are only permissible in exceptional cases and only with a valid certificate of non-objection from the responsible department (e Page 10).

a WARNING


• Roof bows or supporting parts may not be removed or damaged without being replaced.

• If the roof panel and roof bow are separated and if a continuous section frame is not possible, at least two additional roof bows in front of and behind the position of the removed bow are required.

• The bows must be secured to the side panels in such a way that a non-positive connection is guar-anteed (bend-resistant connection of bows and roof panel).

• The maximum roof load must be observed.

• The maximum permissible location of the centre of gravity must not be exceeded (e Page 46)

• When mounting a carrier system directly to the rivet nuts, only mounting consoles approved by Daim-ler AG or mounting consoles which correspond to drawings of Daimler AG may be used as a direct connection to the roof. Other carrier systems may only be mounted on these. The load of 25 kg per support foot and the maximum roof load must not be exceeded.

• The following body-specific notes on roof structure modifications must be adhered to.

Maximum roof load for standard roof [kg]

150

The maximum permissible centre of gravity position must not be exceeded, see 4.1.2 “Maximum permissi-ble positions of centre of gravity” (e Page 46).

Location of roof bows• to the rear of the front doors (B-pillar)

• in the centre of the vehicle behind the load com-partment sliding door (C-pillar)

Isometric view of the roof bows

The strength of the new roof structure must correspond to that of the standard roof. The minimum moment of inertia required per roof bow is Ix = 4000 mm4.


6.2 Bodyshell/body


Roof height increase

The height of the roof may only be increased in con-junction with integrated bows and reinforcement frames.

Roof loads are not permissible when roof height exten-sions are fixed to the body.

Refer to 8.7.2 “Crosswind Assist” (e Page 110) for modifications on the projected lateral face.

Retrofitting a pop-up roof/roof hatch

Plastic roofs are suitable for the installation of roof hatches only to a limited extent.

The roof load-bearing capacity is limited (e Page 52). In the event of deviations, approval is required from the department responsible (e Page 10).

If a pop-up roof is fitted, at least two-thirds of the orig-inal roof area must be retained. Struts or load-bearing parts may not be removed.

Modifications to cab roof

a WARNING

Modifications to the cab must not impair the func-tion of any components relevant to safety (e.g. airbag units, sensors, pedals, gearshift lever, lines or others). This may lead to the failure of components or parts relevant to safety.



6.3 Engine peripherals / drivetrain



6.3.1 Fuel systemModifications to the fuel system may only be carried out with the approval of the department responsible (e Page 10).

The clearance of the fuel filler neck, fuel tank and fuel lines must be maintained.

The attachment of heat-conducting components or components which restrict installation space is not permitted.

! Note

Non-approved modifications to the fuel system (fuel tank, lines, etc.) may lead to impaired performance and engine emergency running mode.

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


Modifications carried out incorrectly to the fuel system may have a detrimental effect on the envi-ronment.

6.3.2 SCR systemIn order to fulfil the EURO6 emissions regulations for diesel engines, an SCR system (Selective Catalytic Reduction) is available. The SCR system is an exhaust aftertreatment system which aims at reducing nitrogen oxide (NOx).

The increase in kerb weight of a vehicle with an exhaust system and SCR system is 37 kg as compared to a vehicle with an exhaust system without SCR system.

Apart from electronic control units and sensors, the SCR system requires a catalytic converter and the additive AdBlue®.

AdBlue®

AdBlue® is a mixture of urea (33 %) and water (67 %). AdBlue® is a non-combustible, non-toxic, colourless, odourless and water-soluble fluid.

AdBlue® has a limited shelf life, which is affected by the ambient temperature and air humidity. This must be observed when filling it in from containers.

Information on handling AdBlue® and its material char-acteristics can be found in ISO 22241.

Country-specific laws and regulations for proper and correct disposal must be observed.

The SCR system is the most significant component for fulfilling the EURO6 emissions regulations. Modifying or changing the location of components of the SCR sys-tem is not permitted. This includes the SCR tank, SCR lines and all other SCR system components.

If AdBlue® comes into contact with painted surfaces or aluminium, the affected area must immediately be cleaned with water.

Any AdBlue® pumped out of the SCR tank may not be reused. As the AdBlue® that is pumped out is not always pure, it must be properly disposed of.

! Note

If components containing AdBlue® are opened, a hermetic seal protecting against the ambient air must be made afterwards. Otherwise, AdBlue® can crystallise and clog the system components.


For further information, observe the operator's man-ual of the vehicle.




SCR tank

The tank flange module with pumps, heater and sensors, which is part of the SCR system, is welded together with the SCR tank. The SCR tank is located beneath the bodyshell at the height of the left front seat in the direction of travel. The filler neck is located next to the left front door in the direction of travel.

Bodyshell, left side of vehicle

1 SCR tank

2 AdBlue® filler neck with cap

Arrow Direction of travel

Bodyshell, top view

1 SCR tank

2 SCR lines


Bodyshell, from below

1 SCR tank

2 AdBlue® filler neck with cap

3 SCR line





6.3.3 Exhaust systemOn no account may any modifications be made to the 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, unless they are made of heat-resistant material.

6.3.4 Engine cooling systemModifications to the cooling system (radiator, radiator grille, air ducts, coolant circuit etc.) are not permitted. The cross-sectional areas of the coolant air intakes must be kept free (danger of engine limp-home mode).

Do not obstruct the radiator air inlet.

Do not affix warning signs, labels or decorative objects in the area in front of the radiator.

If required, flashing lamps at the front of the vehicle are to be mounted at the side of the radiator grille area (sealing of radiator section), on or between the horizon-tal fins. The vertical bars of the radiator grille may not be modified, as the stability of the radiator grille will otherwise no longer be guaranteed.

Provision for additional cooling equipment for assem-blies shall be made for when the vehicle is stationary and if a high continuous output is demanded.

Disc brakes

Cooling must not be impaired by attaching spoilers below the bumper, additional hub caps or brake disc covers, etc.

a WARNING

Modifications to the air flow of the brake system can negatively affect the braking power.

In extreme cases, brake system overheating will not 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 permissi-ble in consultation with Daimler AG (e Page 10).




6.3.5 Engine air intakeModifications to the engine air intake are not permissi-ble.

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

Warm air• The intake of warm air will lead to a loss of engine

power. A bulkhead between the intake point and the engine compartment is therefore essential.

• The intake temperature should not exceed the out-side temperature by more than 10 °C.

Water• Make sure that water cannot reach the intake

points through any fresh-air inlets. The flow rate at the intake points must not be increased by modifi-cations to the opening of the intake points.

Dust/dirt• The area of the intake must be shielded against

swirling dust from the wheel arch.

• Increased dust intake will lead to shorter mainte-nance intervals for the air filter.

6.3.6 Propeller shafts

! Note

On no account should modifications be made to the drivetrain.


6.4 Interior


6.4 Interior

6.4.1 General informationThe legal requirements detailed in this section relate to current legislation in Germany. The relevant national legislation must be observed in all other countries.

a WARNING

Airbag and emergency tensioning retractor units are pyrotechnical objects. There is a risk of explosion when handling pyrotechnical objects. This can lead to people sustaining injuries.

Handling (installation, removal, transportation, storage and disposal) of airbags and emergency ten-sioning retractor units may therefore only be carried out by personnel who are appropriately qualified. Accident prevention regulations must be observed.

The handling, transportation and storage of pyrotech-nical objects are subject to legislation concerning potentially explosive substances (for example, the "Gesetz über explosionsgefährliche Stoffe" in Germany) and must therefore be reported to the relevant trade supervisory authority.

a WARNING

Modifications to the restraint systems (seatbelts and anchoring, emergency tensioning retractors or airbags) or their wiring may lead to the restraint systems no longer functioning correctly. A restraint system can fail or unintentionally activate. This can lead to people sustaining injuries. Modifications to restraint systems are therefore not permitted.

a WARNING

Paint or surface treatment is not permissible on the instrument panel, steering wheel impact absorber or airbag tear seams. Otherwise, chemical reac-tions may occur on the treated surfaces. This could weaken or damage the materials meaning that the restraint systems no longer operate properly. A restraint system can fail or unintentionally activate. This can lead to people sustaining injuries.

Modifications in the cockpit area and above the dash-board (including additional installed equipment, wood décor, cell phone holders, bottle holders etc.) must ful-fil the criteria of the head impact tests specified in ECE R14 and FMVSS 201. This applies in particular to the deployment areas of the airbags. See the illustrations of the airbag deployment areas for more information (e Page 76).

The permissible centre of gravity and maximum permis-sible axle loads must not be exceeded.

Information on converting camper vans can be found under 7.4 “Motor caravans” (e Page 91).

• For the modification of vehicles in the Federal Republic of Germany, appropriate information sheets can be requested from the relevant techni-cal inspection authorities for motor vehicles (e.g. TÜV (Technical Inspection Association), DEKRA).

• The interior must be designed with soft edges and surfaces.

• Fittings must be made of flame-resistant materials and be fitted securely.

• Unimpeded access to the seats must be ensured. There must not be any protruding parts, edges or corners which could cause injury in the area of the seats.


6.4 Interior


6.4.2 Safety equipment

a WARNING

When the following alterations are made to the structure of the vehicle, the safe operation of restraint systems is no longer guaranteed:

• Modifications to the seats

• modifications to the frame front end

• installation of parts in the vicinity of airbag infla-tion points or in airbag deployment areas

• installation of non-MB seats

• modifications to the A-pillar and B-pillar, the roof frame and its lining

• modifications to the doors

These modifications are therefore not permitted. This could otherwise result in personal injury.

! Note

Attachments with rigid connections to the front, side and rear of the vehicle at the height of possible accident zones could modify the characteristics of the vehicle's passive safety.

Seat belts

Vehicles that are designed for a maximum speed of over 25 km/h must be equipped with seat belts.

The ECE R14, R16 and R17 regulations must be observed and compliance must be demonstrated for seat belts, emergency tensioning retractors and seat belt anchorage points.

Airbags and emergency tensioning retractor units

All airbag units are labelled with the word "Airbag":

• The driver airbag on the padded boss is recognis-able by the inscribed word "Airbag".

• The front passenger airbag can also be recognised by the word "Airbag" inscribed on the dashboard panelling.

• The windowbags are identified by the "Airbag" inscription on the side of the headliner.

• The thoraxbag is marked with the inscription "Air-bag" at the side of the seat seam facing the exterior of the vehicle.

An additional identifying feature is the red indicator lamp on the instrument cluster.

Airbags installed in vehicle

The installed airbag units comprise the driver airbag, front passenger airbag, windowbag and thoraxbag in the driver and front passenger seats.

You can obtain further information on the airbags available as standard equipment and special equip-ment from your Mercedes-Benz Service Centre, in the responsible department “Technical advice on the basic vehicle” (e Page 11) or under 3.10 “Special equip-ment” (e Page 45).

These components/assemblies may only be modified with the agreement of Daimler AG.

The following illustrations show the position and deployment area of the driver airbag, front passenger airbag, windowbag and thoraxbag.

! Note

Modifications to the floor structure in the area of the airbag control unit are not permitted.


6.4 Interior


Airbag deployment areas using the example of the V-Class equipped with A-D windowbags

1 Driver airbag (standard equipment)

2 Front passenger airbag

3 A-D windowbag,

Airbag deployment areas using the V-Class as an example

1 Windowbag

2 Driver airbag (standard equipment)

3 Front passenger airbag

4 Thoraxbag

Difference between A-B and A-D windowbags

1 Deployment and coverage areas of the A-B window-bags

2 Deployment and coverage areas of the A-D window-bags

Airbag control unit and side crash sensors, pressure sensors

It is not permitted to modify the standard installation location, installation position and attachment of airbag control units for occupant safety systems and side crash sensors on vehicles equipped with windowbags.

Other vehicle components may not be placed on or attached to the airbag control unit, the side crash sen-sors or its attachment points.


6.4 Interior


a WARNING

Vehicle parts which produce vibrations may not be mounted in the vicinity of the airbag control unit or the sensor installation points. Otherwise, the safe function of the airbag and emergency tensioning retractor units can no longer be guaranteed. This could result in personal injury.

The position of the airbag control unit, triggering sen-sors and ESP turn rate sensor is behind the panelling in the footwell/centre console.

1 Airbag control unit with integrated ESP turn rate sensor


The removed airbag control unit is susceptible to shock and must be stored in an area free of vibrations.

a WARNING

An airbag sensor system, ESP turn rate sensors or airbag control units that have fallen to the ground may not be installed due to safety reasons. These parts must be replaced with the corresponding gen-uine Mercedes-Benz replacement parts. Otherwise, proper and safe functioning of these systems cannot be ensured and it could result in personal injury.

The side crash sensors are located in the lower area of the B-pillar behind the trim on both sides (same as on left side of vehicle).

N54.21-2110-00

1 Side crash sensor

2 Direction of travel


6.4 Interior


Handling airbag and emergency tensioning retractor units

a WARNING

Removed airbag units must always be stored in such a way that the upholstered side faces upwards. If the upholstered side faces downwards, the airbag unit will be catapulted through the air if it is triggered accidentally. This can lead to people sustaining injury.

Test and installation work may only be carried out and/or supervised by trained personnel.

Airbag and emergency tensioning retractor units may only be subjected to electrical tests using the specified testers when the airbag and emergency tensioning retractor units have been fitted. We recommend that tests be carried out at a Mercedes-Benz Service Cen-tre.

The assembly and disassembly of airbag and emer-gency tensioning retractor units may only be carried out when the battery is disconnected, the negative terminal or negative pole is covered up and the test connector/connector is disconnected.

Airbag and emergency tensioning retractor units may only be removed from storage immediately before assembly. After disassembly, airbag and emergency tensioning retractor units must be put into storage immediately.

If work is interrupted, the airbag and emergency ten-sioning retractor units must be locked away again.

Airbag and emergency tensioning retractor units may not be treated with grease, cleaning agents or other similar products.

The airbag and emergency tensioning retractor units may not be exposed to temperatures above 100 °C, even for a short period of time.

Airbag and emergency tensioning retractor units must be replaced if they are dropped from a height of more than 0.5 m.

Transporting and storing airbag units and emergency tensioning retractor units

Transporting pyrotechnical airbag units and emergency tensioning retractor units in the passenger compart-ment is not permitted.

Transportation should always be carried out using the spare parts packaging and utilising the vehicle luggage compartment or load compartment.

a WARNING

Removed airbag units must always be stored in such a way that the upholstered side faces upwards. If the upholstered side faces downwards, the airbag unit will be catapulted through the air if it is triggered accidentally. This can lead to people sustaining injury.

Class T1 pyrotechnic materials may only be stored in limited quantities on premises used for commercial purposes.

Annex 6 of the appendix to the second ordinance of the German Explosives Law specifies that the following maximum storage quantities are permissible without obtaining special approval from the relevant authority, where materials are stored on premises used for com-mercial purposes and certain conditions are fulfilled (e.g. steel cabinet):

• General storage space: 20 kg gross

• The gross mass of the component which has been approved in accordance with the act concerning explosives is used to calculate the actual stored mass.


6.4 Interior


Gross mass of pyrotechnical components in the Vito [kg]

Driver airbag 1.14

Front passenger airbag 2.82

A-B windowbag 1.12

A-D windowbag 3.98

Thoraxbag 0.43

Emergency tensioning retractor

1.2 (integrated in belt reel)

Gross mass of pyrotechnical components in the V-Class [kg]

Driver airbag 1.14

Front passenger airbag 2.1

A-B windowbag 1.12

A-D windowbag 3.98

Thoraxbag 0.43

Emergency tensioning retractor

1.2 (integrated in belt reel)

Disposing of airbag and emergency tensioning retractor units

Pyrotechnical airbag and emergency tensioning retrac-tor units must be disposed of in accordance with coun-try-specific laws and directives. In the Federal Republic of Germany, it is stipulated that pyrotechnical airbag or emergency tensioning retractor units must be neutral-ized by means of electrical ignition before disposal.

These safety measures are necessary because pyro-technical materials could cause injury if activated incorrectly.

Hazards arise from disposal using cutting torches, by smelting, or if primed parts are disposed of on open fires or smouldering fires on waste disposal sites.

We recommend having disposal of the pyrotechnical objects carried out by a disposal specialist who can satisfy the required safety measures (e.g. 10 m safe distance, special ignition equipment).

When the materials are handed over, the waste dis-posal company must sign a declaration containing the obligation to dispose of the pyrotechnical materials in accordance with accident prevention regulations. Agreements of this kind must ensure that it is not pos-sible to extract pyrotechnical materials after disposal and to pass them on for repairs.

• If emergency tensioning retractors that have not been triggered require detonation for disposal pur-poses, place them in the footwell of a vehicle which has been sent for scrapping, and connect them directly using a 2-pin plug.

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


6.4 Interior


6.4.3 SeatsApproval from the department responsible “Techni-cal advice on body compatibility” (e Page 10) is required if seats other than those fitted at the factory are fitted.

Proof of the strength of the seats delivered from the factory is only valid if the seats are secured in original mountings. Any deviation must be coordinated with the responsible department “Technical advice on body compatibility” (e Page 10).

If rear seats with two-point or three-point seat belts deviate from the standard seat design, they must com-ply with the requirements of ECE R14.

Seats without seat belts are not permissible. The ECE R14 test certificate (tensile test including floor assem-bly) is required for approval by Daimler AG. Test certifi-cates for seats on a rigid plate will not be accepted.

When seat belts and seats (including seat bases) are reinstalled, the specified bolts must be tightened to the specified torque.

a 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 thoraxbags. Otherwise, thoraxbags 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.


Information on retrofitting seats can be found in section 7 “Design of bodies” (e Page 87).


6.4 Interior


6.4.4 Reducing noise in the vehicle interiorNoise-insulating material can be installed in order to reduce the noise level in the vehicle interior. It must be barely inflammable.

Floor area

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

! Note

Insulating foils, e.g. bituminous felt, have limited temperature resistance. They should therefore not be installed in the immediate vicinity of the engine or exhaust system.

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

Roof and side panels

Apart from providing insulation, the materials used for insulation should exhibit the following properties:

• Not hygroscopic

• Not water-retaining

• Not water-absorbing

• Not water-attracting

• Water-repellent

Arrangements are to be made for the rapid and unhin-dered drainage of accumulated moisture or condensa-tion in order to avoid conditions that promote corro-sion.

The standard drain holes must be preserved intact. If necessary, additional drain holes must be created after consultation with the relevant department “Technical advice on body compatibility” (e Page 10).

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

a WARNING



6.4 Interior


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.

In addition, manufacturers or suppliers of soundproof-ing materials should be consulted. They will be able to provide you with suggestions on how to design opti-mum noise insulation for your modified vehicle body.

6.4.5 VentilationThe passenger compartment and the driver's seat must have adequate ventilation with provision for air to enter and exit.

The windscreen and side window demisting function must remain operational, especially if the driver's area forms part of the passenger compartment or if the layout and design of the interior does not correspond to that of the standard equipment.

New vehicles can be delivered with various heater/ven-tilation options and air conditioning systems as special equipment. Additional information on special equip-ment can be obtained from your Mercedes-Benz Ser-vice Centre, in the relevant department (e Page 11) or under 3.10 “Special equipment” (e Page 45).


6.5 Additional assemblies


6.5 Additional assemblies

The information in sections 5.3 “Corrosion protection measures” (e Page 57) and 5.4 “Painting work/preservation work” (e Page 59) must be observed.

6.5.1 Auxiliary heating The floor of the vehicle must be airtight if exhaust gases are routed out under the vehicle.

Openings in the vehicle floor provided for control ele-ments must be sealed with rubber sleeves.

Retrofitting auxiliary heaters

When retrofitting an auxiliary heating system, the speci-fications for fire protection, impact performance and accident protection must be observed. The danger of 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

All pipes, hoses and electrical lines should be routed so that they are free of mechanical stress.


Contact the "Body Technical Advice" team before installing auxiliary/stationary heaters (e Page 10).

Additional information can be found under 3.10 “Spe-cial equipment” (e Page 45).


6.6 Attachments


6.6 Attachments

A certificate of non-objection from the department responsible is required for attachments to the frame (e Page 10).

The permissible centre of gravity locations and axle loads must always be adhered to, see Section 4 “Tech-nical threshold values for planning” (e Page 46).

Note that this may interfere with driving assistance systems; see 8.7 “Driving assistance systems” (e Page 108).

Attachments must not impair the function of vehicle parts.

Comply with national legal requirements.

6.6.1 Attachment above cab • The permissible centre of gravity, see 4.1 “Thresh-

old values of the basic vehicle” (e Page 46) and front axle load, see 4.2 “Suspension threshold values” (e Page 47) must be observed.

• The roof connection must be designed as per 6.2.6 “Modifications to the roof structure” (e Page 69).

6.6.2 Roof racks • Make sure that the load is distributed evenly across

the entire roof area.

• Installation of an anti-roll bar on the front axle is recommended.

• Support feet must be spaced at regular intervals. The load per support foot may not exceed 25 kg.

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

Roof rack threshold values

Max. Roof loads

Minimum number of

support feet

Normal roof 150 kg 6

6.6.3 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.


6.6 Attachments


6.6.4 Trailer couplingWe 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.

• Country-specific clearance dimensions must be observed: e.g. as per ECE-R55 within the EU.

• If there are any deviations from the German acci-dent prevention regulations (UVV), a technical certificate must be requested in Germany from the Berufsgenossenschaft für Fahrzeughaltung, 22757 Hamburg, Germany (tel. +49 (0)40-381091):

http://www.bgf.de/

Technically, there is no problem retrofitting a trailer coupling when a preinstallation (Code E 57) is already fitted.

If a trailer control unit was not pre-installed at the factory, it must be installed and connected in addition to the retrofitted cable set. In addition, variant cod-ing of the electronic ignition lock must be performed otherwise malfunctions could occur. Variant coding is performed using a Mercedes-Benz diagnostic unit. We recommend having the variant coding performed at a Mercedes-Benz Service Centre.

http://www.bgf.de


7.1 Modifications to the interior

7 Design of bodies


This section contains information concerning the body to be produced by the body manufacturer.

7.1.1 Modifications in the cockpit areaModifications in the cockpit area and above the wais-trail are not permitted. This applies in particular to the deployment areas of the airbags (wooden trim, addi-tional fittings, mobile phone holders, bottle holders, etc.).

See the illustrations of the airbag deployment areas for more information (e Page 76).

7.1.2 Retrofitting additional seats Daimler AG will issue a certificate of non-objection at its discretion for modifications to the seat attachments (including seat bases) and seat belt anchorages or for the installation of seats other than those available from the factory (e Page 11).

Proof of the strength of the seats delivered from the factory is only valid if the seats are secured in original mountings.

When retrofitting seats, it is absolutely essential to keep to the H-point. You can obtain up-to-date documentation from the department responsible (e Page 10).

When re-installing seat belts, the specified bolts must be tightened to the original torque.

a WARNING

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.

Passenger cabin/cargo area

On panel vans, the bodyshell floor assembly is avail-able from the factory as special equipment under code V40 (passenger van floor assembly) for retrofitting bench seats. The number of mounting options for the passenger van floor assembly depends on the model series and the equipment and registration variants (the mounting shells for the bench seats are not included in the scope of delivery).

Additional information on special equipment code V40 can be obtained from your Mercedes-Benz Service Centre, in the relevant department (e Page 10) or Section 3.10 “Special equipment” (e Page 45).

a WARNING

On no account may seats be mounted on the wheel arches. In the event of an accident, persons could be injured if the seats become detached from their anchorages, and this could result in further damage to the vehicle.

If rear seats with two-point or three-point seat belts deviate from the standard seat design, they must com-ply with the requirements of ECE R14.

Seats without seat belts are not permissible. The ECE R14 test certificate (tensile test including floor assem-bly) is required for approval by Daimler AG. Test certifi-cates for seats on a rigid plate will not be accepted.



7 Design of bodies

a 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.

Please also refer to the additional information in the operator's manual of your vehicle.

You can obtain more information about special equip-ment from your Mercedes-Benz Service Centre, in the responsible department (e Page 10) or from Section 3.10 “Special equipment” (e Page 45).

Vehicle roof

Information on roof modifications can be found under 6.2.6 “Modifications to the roof structure” (e Page 69).


7.2 Refrigerated vehicles/temperature-controlled vehicles

7 Design of bodies

7.2 Refrigerated vehicles/temperature-controlled vehicles

A certificate of non-objection is required for vehi-cles which are converted into refrigerated vehicles (e Page 12).

Refer also to the following sections:

• 6.2.6 “Modifications to the roof structure” (e Page 69)

• 6.4.4 “Reducing noise in the vehicle interior” (e Page 82)

• 8.4.4 “Connecting additional electrical consumers” (e Page 101)

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.


7.3 Vehicles for transportation of technical gases

7 Design of bodies

7.3 Vehicles for transportation of technical gases

Tanks and lines for liquefied gases must be equipped with adequate heat insulation from the rest of the vehicle. This is even more important for lines that are passed through the vehicle chassis or the bodyshell.

To allow venting of supercooled liquefied gases, a minimum distance 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.

Any escaping condensation must be caught is a suit-able container.


7.4 Motor caravans

7 Design of bodies

7.4 Motor caravans

Prior to conversion into a camper van, please note the following:

• Legal requirements

• Minimum requirement for interior design and equip-ment for camper vans

• Permissible centre of gravity position and axle loads

For the modification of vehicles in the Federal Repub-lic of Germany, appropriate information sheets can be requested from the relevant technical inspection authorities for motor vehicles (e.g. TÜV (Technical Inspection Association), DEKRA).

Particular attention must be paid to the following sec-tions of the body/equipment mounting directives:

• 3.3 “Dimensions and weights” (e Page 34).

• 6 “Modifications to the basic vehicle” (e Page 60).

• 6.2.4 “Mudguards and wheel wells” (e Page 68)

• 8 “Electrical system” (e Page 95)

• 8.7 “Driving assistance systems” (e Page 108)

Modifications or conversions to standard vehicles (e.g. the installation of a pop-up roof) may invalidate the operating permit. The approval conditions and requirements of the European type approval (ETA) must be met (e Page 15). In Germany, modifications to the vehicle must therefore be inspected by the relevant technical authorities in accordance with Section 19, Paragraph 2 of the StVZO (German Road Traffic Licens-ing Regulations). Part I and Part II of the vehicle regis-tration certificates (previously vehicle title of ownership and registration documents) must be presented for this purpose. After the modifications have been entered, the vehicle registration certificates (Part I and Part II) must be submitted to the responsible registration office so that a new operating permit can be issued.

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

Fittings must be made of flame-resistant materials and be fitted securely. Unimpeded access to the seats must be ensured. There must not be any protruding parts, edges or corners which could cause injury in the area of the seats.


7.5 Retrofitting a pop-up roof

7 Design of bodies

7.5 Retrofitting a pop-up roof

Observe the information under “Retrofitting a pop-up roof/roof hatch” (e Page 70) for retrofitting a pop-up roof.


7.6 Roof height increase

7 Design of bodies

7.6 Roof height increase

For increasing the height of the vehicle roof post-de-livery, observe the information under “Roof height increase” (e Page 70).


7.7 Government vehicles

7 Design of bodies

7.7 Government vehicles

The following sections of the body/equipment mount-ing directives must be observed:

• 3.3 “Dimensions and weights” (e Page 34)

• 6 “Modifications to the basic vehicle” (e Page 60)

• 6.3.4 “Engine cooling system” (e Page 73)

• 8.2 “Electromagnetic compatibility (EMC)” (e Page 96)

• 8.4.4 “Connecting additional electrical consumers” (e Page 101)

Recommended special equipment (code) for conversion to a government vehicle

• Code ED5: PSM (parametrizable special module)

• Code MW1: Continuous engine operation feature


You can obtain further information on recommended special equipment from the responsible department (e Page 11).


8.1 General information

8 Electrical system

8.1 General information

a WARNING

Work incorrectly carried out on equipment and its software can prevent this equipment from working correctly. Since the electronic systems are net-worked, this can also affect systems that have not been modified.

Malfunctions in the electronic systems can seriously jeopardise the operating safety of your 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 Mercedes-Benz Service Centre for this purpose.

In particular, when working on safety-related sys-tems, service by a qualified specialist workshop is indispensable.

! Note

When connecting additional electrical consumers (e Page 101), a positive total charge balance must be ensured.

Do not release or remove the battery terminals when the engine is running.

Rapid-charge the batteries only after disconnecting them from the vehicle's electrical system. Both the positive and negative terminals must be discon-nected.

• Electrical and electronic components must fulfil the test requirements of ISO 16750.

• Observe the notes on (e Page 97) when install-ing additional batteries.

• Cables routed in the vicinity of exhaust systems must be insulated against high temperatures, see “Installation of lines” (e Page 61).

• Cables must be routed in such a way that there are no chafing points, see “Installation of lines” (e Page 61).

• If the vehicle is to be left idle for more than a week, the battery must be disconnected. The batteries must have sufficient charge when the vehicle is put into operation again (e Page 44).

• Observe the operating instructions.


8.2 Electromagnetic compatibility (EMC)

8 Electrical system

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 systems in the vicinity, nor does it suffer any interference.

Electrical interference occurs in vehicle electri-cal circuits because of the various consumers. At Mercedes-Benz, electrical and electronic components installed at the factory are checked for their electro-magnetic 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 appliances must have a type-approval certificate as per ECE-R 10 in its current version, and be marked with the "e" mark.

The notes under 8.4.4 “Connecting additional elec-trical consumers” (e Page 101) and 4.4 “Limits for electrical/electronic system” (e Page 53) must be observed.

Information about EMC can be obtained from the fol-lowing 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-R 10


8.3 Battery

8 Electrical system

8.3 Battery

8.3.1 Main batteryThe main battery is located in the right seat base.

Installation location of the main battery

1 Main battery


Batteries available ex works

Code Battery type Capacity [Ah]

Standard Lead battery 74

ED1 AGM battery 70

ED4 AGM battery 95

EE8 (Vito only) Lead battery 100

An AGM (absorbent glass mat) battery must always be used on vehicles with "plus" ECO start/stop automatic system (code MJ8).

8.3.2 Retrofitting a battery main switch


You can obtain further information on special equip-ment in every Mercedes-Benz Service Centre, from the responsible department (e Page 11). or from 3.10 “Special equipment” (e Page 45).

8.3.3 Additional battery

! Note

Batteries with capacities of more than 100 Ah may not be directly connected with the on-board electri-cal system, as this can cause damage to the basic vehicle.

A positive total charge balance is to be assured through selection of a suitable alternator.

Only the same type of battery must be used for main and additional batteries.

The additional battery is available ex works under code E28.


You can obtain further information on special equip-ment in every Mercedes-Benz Service Centre, from the responsible department (e Page 11). or from 3.10 “Special equipment” (e Page 45).


8.3 Battery

8 Electrical system

Retrofitting an additional battery

An additional battery may only be installed in the left seat base.

An additional battery may only be connected to the vehicle on-board electrical system via a suitable cutoff relay and using an appropriate electrical fuse.

The additional battery may only be used to power defined auxiliary consumers such as auxiliary heating, loading aids or electrical equipment in camper vans (fridge, etc.).

Only the same type of battery must be used for main and additional batteries.

An AGM battery must always be used on vehicles with a start/stop automatic system.

Location of the additional battery

1 Additional battery


Other additional batteries


Retrofitting further auxiliary brakes requires a tech-nical certificate from the department responsible (e Page 10).

! Note

If the vehicle is already equipped with an additional 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.


8.3 Battery

8 Electrical system

8.3.4 Backup battery (code E34)The backup battery is located in the right seat base.

The backup battery is used to stabilise the on-board electrical system on vehicles with a start/stop auto-matic system.

Installation position of backup battery

1 Backup battery


8.3.5 Emergency batteryOn vehicles with an automatic transmission and with-out a backup battery, an emergency battery is installed in place of the backup battery. In the event of a current interruption, this enables the transmission position N or P to be engaged regardless.

8.3.6 Battery maintenance and storage Batteries must be regularly checked for voltage drop (self-discharge) - even when removed. Checking of the fluid level is not necessary for low-maintenance batter-ies.


Additional information can be found under 3.9.2 “Battery maintenance and storage” (e Page 44).


8.4 Interfaces / electrical lines

8 Electrical system


a WARNING

As all consumers are networked and internally monitored, no modifications should be made to the CAN bus (e.g. breaking, extending or tapping). Any modification to the cable harness in terms of length, cross-section or resistance can lead to the failure of safety-relevant components and consequently to accidents or damage to the vehicle.

8.4.1 Electric wiring/fusesOnly unleaded, PVC-coated cables with an insulation operating temperature limit of more than 105 °C may be used. Lines and connections used must be designed to be watertight and fit for the specialist application, and must be protected against runout, heat and being torn away. The line must be dimensioned in accordance with the current level drawn and protected with fuses, see 4.4.1 “Electric wiring/fuses” (e Page 53).

Installation of lines

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

The cable duct must not be damaged or re-routed when carrying out modifications in the area of the transmis-sion tunnel

The cable duct in the cargo area/passenger compart-ment is located in the centre along the longitudinal vehicle axis in the vicinity of the rear-end door/liftgate. When modifications are performed in this area, the cable routing must be carried out so that the overall length of the individual cable harnesses is maintained.

1 Cable duct


8.4.2 Cable extensionAn identical or larger cable cross-section is to be used for cable extensions. We recommend the use of cables that conform with DIN 72551 or ISO 6722-3. The protective effect of retaining elements must not be impaired.

All connections must be made professionally and water-tight in accordance with IP 69k (resistant to high-pressure cleaning).



8 Electrical system

8.4.3 CAN bus and networkingThe electronic systems available in the engine/passen-ger compartments are connected to one another via networks (bus systems). Gateways are used to transfer data between the individual bus systems.

These bus systems include:

• LIN bus (Local Interconnect Network)

• Ethernet

• MOST bus (Media Oriented Systems Transport)

• CAN bus (Controller Area Network) including:

• Body CAN

• Head unit CAN

• Chassis CAN

• Diagnostic CAN

• ABH CAN (e Page 120))

• CIA CAN

a WARNING

Interference with the bus systems (e.g. by discon-necting, extending or "tapping") is not permissible. Any modifications to the bus systems can lead to failure of safety-relevant components and conse-quently to accidents or damage to the vehicle.

The ring-shaped MOST network in the V-Class uses a fibre-optic cable as a data carrier for transferring audio and control signals. This system supports the synchro-nous transfer of data at high baud rates, is insensitive to electromagnetic interference (EMC), does not itself cause electromagnetic interference and can transfer both audio and control data simultaneously. The system is also available with the ignition OFF and is activated by a separate wake-up line.

Internal and external vehicle diagnosis can be carried out by means of the OBD diagnostic socket (SAE 1962). Every control unit is capable of self-diagnosis and is equipped with an internal fault memory.

Communication with the relevant control unit can be established using the Xentry Kit tester and the software developed for this unit.

Individual data available through the CAN bus can be accessed via the parametrizable special module (PSM) (code ED5) (Page 110).


You can obtain further information on this topic from a Mercedes-Benz Service Centre.

8.4.4 Connecting additional electrical con-sumers

a WARNING

Tampering with and unauthorised installations in the vehicle electrical/electronic systems can impair the functioning of these systems. This can lead to failure 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.

The following must be observed when retrofitting addi-tional electrical consumers:

• The alternator and batteries must feature sufficient dimensions (positive charge balance). Batteries with a larger capacity (Section 8.3) and more powerful alternators (see 8.4.6) available as special equipment must be provided for this purpose.

• No additional consumers may be connected to assigned fuses.



8 Electrical system

• No additional lines may be connected to existing lines (e.g. with cut-and-clamp connections).

• Additional electrical consumers must be sufficiently fused using additional electrical fuses.

• The line cross-section must be dimensioned according to the current intensity drawn, see 4.4.1 “Electric wiring/fuses” (e Page 53).

• Electrical lines must be routed correctly, see 8.4.1 “Electric wiring/fuses” (e Page 100).

• There must be no impairment of the accessibility or easy maintenance of installed equipment.

• The necessary air supply and cooling of the engine may not be impaired, see 6.3.4 “Engine cooling system” (e Page 73).

• The guidelines of the equipment manufacturer for compatibility with the basic vehicle must be observed.

• The operating instructions and the maintenance manual for the additional assemblies must be sup-plied when handing over the vehicle.

• All installed electrical consumers must be tested as per ECE-R 10 in its currently valid version and must be labelled with the "e" mark, see 8.2 “Electromag-netic compatibility (EMC)” (e Page 96).

• A certificate from the manufacturer or a CE mark are sufficient for retrofitted electrical equipment if the equipment has no effect on immunity to inter-ference.

• The connection of additional electrical auxiliary consumers must be carried out using the terminal strip for auxiliary consumers (code EK1) available ex works, see 8.4.5 “Current consumption via ter-minal strip” (e Page 102).

8.4.5 Current consumption via terminal stripThe terminal strip for auxiliary consumers (special equipment, code EK1) is located at the A-pillar under the cockpit at the right-hand side in direction of travel, and has three connections:

1 Terminal strip


Position Terminal designa-

tion

Fuse Fuse rating

[A]

S2-6 15 F318 20

S4 30 F321 25

ED4 61 F319 15



8 Electrical system

8.4.6 Retrofitting an alternatorWhen retrofitting additional electrical consumers, the increased current requirement can be met by using a more powerful alternator.

The following alternators are available as special equip-ment (option codes) from the factory:

Vito

Code I [A]/U [V] Engine OM622

(MX1, MX2)

Engine OM651

(MG3, MG4, MG7)

M39 150 / 14.3 - Standard*

M44 185 / 14.3 Standard -

M49 180 / 14.3 - Optional

M40 200 / 14.3 - Optional

M60 250 / 14.3 - Optional

* Not for Vito Tourer SELECT

V-Class

Code I [A]/U [V] Engine OM622

(MX1, MX2)

Engine OM651

(MG3, MG4, MG7)

M49 180 / 14.3 - Optional

M40 200 / 14.3 - Optional

M60 250 / 14.3 - Optional

All electrical equipment fitted must be tested in accor-dance with EU Directive 72/245/EEC and must bear the "e" mark.

The following points must be observed if you intend to have other alternators retrofitted:

• On no account should the installation of an alterna-tor impair vehicle parts or their function.

• The battery (e Page 97) must have sufficient capacity and the alternator (e Page 103) must generate sufficient power.

• The alternator circuit must be provided with addi-tional fuse protection 4.4.1 “Electric wiring/fuses” (e Page 53).

• The line cross-section must be dimensioned according to the current level drawn, see 4.4.1 “Electric wiring/fuses” (e Page 53). The higher power draw may necessitate the replacement of the starter/alternator wiring harness. For this, we rec-ommend the use of genuine Mercedes-Benz parts.

• Electrical lines must be routed correctly (e Page 100).

• There must be no impairment of the accessibility or easy maintenance of installed equipment.

• There must be no impairment of the required engine air supply and cooling (e Page 73).

• The guidelines of the equipment manufacturer for compatibility with the basic vehicle must be observed.

• The operating instructions and the maintenance manual for the additional assemblies must be sup-plied when handing over the vehicle.



8 Electrical system

8.4.7 Speed signal (Vito only)The "Highline" and "Lowline" instrument clusters output an electronic speed signal at pin 9 of the instrument cluster connector.

The speed signal (positive to earth) acts as a distance and speed signal for external electronics, e.g. taxime-ters or speed-dependent volume controllers. The signal is protected against short-circuit to earth and battery voltage and is not monitored.

The signal is output at 4 pulses per metre. The pulse width is 4 ms.

At 112.5 km/h, the pulse duration is the same as the pulse pause. This 1:1 ratio is maintained for higher speeds. This means that, at higher speeds, the pulse length and the pause length become shorter at the same time.

THigh

TLOW TLOWN30.00-2014-00

Ratio of pulse duration/pulse pause

Speed signal (Imax = 20 mA):

THigh Ua≥8V

TLow Ua≤1V


8.5 Lighting

8 Electrical system

8.5 Lighting

8.5.1 Adjusting the headlampsNational regulations shall apply.

The headlamp basic setting must be observed (see vehicle identification plate).

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

• Park the vehicle on a level, horizontal surface.

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

• Correct the tyre pressures (refer to the tyre pres-sure table).

• Move the headlamp range control to the basic setting 0.

• Switch on the headlamps.

• Every headlamp must be checked separately and the second headlamp and other lamps must be blacked out while doing so.

The light-dark boundary of the low 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.

Basic setting of LED headlamps

For vehicles with LED headlamps, the basic setting must be applied in a Mercedes-Benz Service Centre using Xentry Kit.

Headlamp basic setting:

1 % = 10 cm, 1.5 % = 15 cm, 2 % = 20 cm

etc.

a WARNING

There is a risk of fatal injuries from the high voltage in the xenon headlamps. Do not touch any com-ponents under high voltage. On no account may persons with electronic implants (e.g. pacemakers) carry out any work on xenon headlamps.

8.5.2 Covering of lighting equipmentNational regulations shall apply.

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

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

Detailed information about the installation of illumina-tion and signalling equipment and on the requirements with respect to coverage of illumination and signalling equipment by moving vehicle parts can be found in ECE directive No. 48.

8.5.3 Vehicle perimeter lamps/clearance lamps

End-outline marker lamps increase passive safety and are required by law on vehicles with a width of over 2.10 m. They may be installed for a width starting from 1.80 m (ECE R48 directive).


8.5 Lighting

8 Electrical system

8.5.4 Exterior lamps

Lamp monitoring

The signal acquisition and actuation module (SAM) monitors all outputs for open load (wire break) and short circuit. If a lamp is not connected or is over-loaded, a fault entry is stored in the memory of the SAM control unit. The vehicle owner or the driver must be informed. It is recommended that an entry be made in the service booklet. The fault entry must be addressed during a service if read using Xentry Kit.

Additional lamps

Additional lamps must be connected via the PSM or a separate cube relay. A standard cubic relay (Ri > 80 Ohms) can optionally be connected in parallel with the exterior lamps (with the exception of the centre high-mounted brake lamp, turn signals, licence plate illumi-nation, side markers and end-outline marker lamps). This will not have any negative effect on lamp monitor-ing.

EK1/ED5/U

R >80

BAT

N82.10-2485-00

B

A

i

Connection of an additional lamp

A Scope of the basic vehicle

B Scope of the body manufacturer

8.5.5 Interior lampsAll interior lamps can be replaced by other body-manu-facturer-specific lamps. The interior lamps are operated via read-back switches networked by the SAM (signal acquisition and actuation module).

The system is only monitored for short circuits, max-imum load 80 W. The lights are dimmed as standard. Dimming must be deactivated in the SAM if fluorescent lighting or relief relays are used.

The read-back switch must always be connected to the SAM, otherwise the interior lamps cannot function.

U

AUTO

ON

SAMN82.20-2182-00

A

BAT

Read-back switch switching principle

UBAT Interior lighting power supply (+ 12 V)

AUTO Lighting controlled by SAM, e.g. when door opened

ON Interior lamp permanently lit

A Read-back switch (interior lighting)


8.6 Mobile communications systems

8 Electrical system

8.6 Mobile communications systems

If mobile communication systems (e.g. telephone, CB radio) are retrofitted, the following requirements must be fulfilled in order to avoid malfunctions developing on the vehicle at a later stage.

All installed electrical appliances require a type-ap-proval certificate as per EU Directive 72/245/EEC and must be labelled with the "e" mark.

8.6.1 EquipmentThe maximum transmission output (PEAK) at the base point of the aerial must not exceed the following values. Moreover, country-specific laws regarding the maximum permissible transmission output must be observed.

Waveband Maximum transmis-sion output [W]

Short wave (f < 54 MHz) 100

4 m band 30

2 m band 50

Trunked radio/Tetra 35

70 cm band 35

GSM 900/AMPS 10

GSM 1800 10

UMTS/LTE 10

• The mobile communication systems and brackets must not be positioned in the deployment areas of the airbags (e Page 76).

• Equipment must be permanently installed. Porta-ble 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 reflection-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.

8.6.2 Connecting and routing the wiring for the aerial (radio)

• Comply with manufacturer's notes and installation instructions.

• An aerial can be installed anywhere on the vehicle roof. The maximum transmission output must not be exceeded.

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

• The wiring routes must be kept as short as possi-ble. The wires must be twisted and screened (coax-ial cable). Chafing points must be avoided.

• Ensure that the system has a good earth connec-tion to the body (aerial and equipment).

• The aerial and connecting cables between the transmitter, receiver and operating panel must be routed separately from the vehicle wiring harness in the vicinity of the body earth.

• Route the aerial cable in such a way that it is not kinked or pinched.

• GGVSE (Hazardous freight ordinance for road and rail) and ADR (European Agreement Concerning the International Carriage of Dangerous Goods by Road) regulations must be observed.

The information in section 5.3 “Corrosion protection measures” (e Page 57) and 5.4 “Painting work/preservation work” (e Page 59) must be observed.


8.7 Driving assistance systems

8 Electrical system


a WARNING

If you fail to adapt your driving style or if you are inattentive, the driving safety systems and driving assistance systems can neither reduce the risk of an accident nor override the laws of physics. Driving safety and assistance systems are merely aids. The driver is responsible for maintaining a safe distance, the speed and braking in good time. The driving style must always be adapted to suit the prevailing road and weather conditions, a safe distance must be maintained and a careful driving style adopted.

The driving safety systems described only work as effectively as possible when there is adequate contact between the tyres and the road surface. Please pay special attention to the notes on tyres, recommended minimum tyre tread depths, etc. under 3.6 “Tyres” (e Page 37), 4.4.2 “Vehicle position and side marker lamps” (e Page 53) and 6.2.4 “Mudguards and wheel wells” (e Page 68). In wintry driving conditions, always use winter tyres (M+S tyres) and, if necessary, snow chains. Only in this way will the driving safety systems described in this section work as effectively as possible.


Further information on equipping the vehicle with driving assistance systems and their possible combi-nations can be obtained from the department “Tech-nical advice on the basic vehicle” (e Page 11).

8.7.1 Electronic Stability Program (ESP)ESP is a dynamic vehicle control system which regu-lates both the longitudinal and lateral dynamics of the vehicle.

Greater driving stability is provided by ESP with an extended sensor system that constantly compares the current actual vehicle direction with the desired direc-tion of movement.

ESP improves vehicle stability in all driving situations, e.g. when accelerating, braking and coasting, when driving in a straight line and cornering.

Together with the signals of other sensors, a processor monitors that the direction specified by the driver is maintained.

If the vehicle deviates from the correct path (over-steer-ing or under-steering), the system produces a stabilis-ing counteraction by applying the brakes on individual wheels.



8 Electrical system

a WARNING

On no account may any of the following modifica-tions be made to vehicles equipped with ESP:

• Modifications to the permissible gross vehicle weight

• Changes to the wheelbase

• Modifications to the sensors (steering angle sensor, yaw rate sensor, wheel rotational speed sensor)

• Changes to the vibration characteristics at the installation location of the yaw rate sensor by modifications to the body

• Changes to the position of ESP components

• Modifications to the suspension

• Modifications to wheels and tyres

• Modifications to the engine

• Modifications to the steering system

• Modifications to the brake system

• Changes to the installation position of the hydraulic assembly, the bracket and its instal-lation on the basic vehicle, as the ESP turn rate sensor is integrated into the ESP control unit.

• Fastening of any vibration-generating devices in the vicinity of the ESP control unit.

On vehicles fitted with ESP, modifications may cause this system to cease working correctly and ultimately fail. The driver could lose control of the vehicle and cause an accident.

If the vehicle is additionally equipped with the Cross-wind Assist function, also refer to 8.7.2 “Crosswind Assist” (e Page 110).

The location, position and mounting of the ESP turn rate sensor must not be changed from the production vehicle.

The ESP turn rate sensor is integrated into the hydraulic assembly and is located in the front left of the engine compartment.

The ESP turn rate sensor is identifiable by its black square housing with white adhesive label.

1 Airbag control unit with integrated ESP turn rate sensor


a WARNING

For safety reasons, ESP turn rate sensors may no longer be installed if they are dropped on the floor. In this case, a genuine replacement part from Mercedes-Benz must be installed.



8 Electrical system

8.7.2 Crosswind AssistThe Crosswind Assist function detects the influences of the crosswind (track offset) through the available ESP components and counteracts by applying brakes on individual wheels with the help of ESP.

Any work on the vehicle body which brings about changes in the projected lateral face is only allowed to a limited extent and after having consulted the department responsible (e Page 10). If the planned conversion is possible, a certificate of non-objection should be requested (e Page 12).

The retrofitting of high roof attachments, for exam-ple, is one measure which alters the projected lateral face. A change in the lateral face leads to a change in parameters, which could influence the functioning of the system.

Crosswind Assist cannot be deactivated.


Additional information is available from the relevant department (e Page 10).

8.7.3 Collision Prevention AssistThe sensor of the Collision Prevention Assist is posi-tioned laterally offset and integrated in the front bumper.

Position of the Collision Prevention Assist sensor

1 Sensor

2 Signal funnel

So as to ensure that the functioning of the system is not affected, on no account should the following changes be made:

• Changing the position of the sensor

• Attachment of detachable parts that can shadow the area of or around the sensor. If necessary, the sensor must be deactivated.

Collision Prevention Assist can be switched on or off via the onboard computer.

a WARNING

Depending on the version and thickness, paints or film coating can cause damping of radar waves. This could lead to malfunction or system failure. The driver could lose control of the vehicle and cause an accident.

The area of or around the sensor must not be painted or covered with a film.



8 Electrical system

! Note

If the front end of the vehicle is damaged, please have the settings and function of the radar sensor checked at a qualified specialist workshop, e.g. at a Mercedes-Benz Service Centre. This also applies to mild collisions at low speeds, where no damages to the front end of the vehicle are visible.



8 Electrical system

8.7.4 Blind Spot AssistThe sensors of the Blind Spot Assist are integrated into the rear bumper. The signalling to the driver takes place optically via luminous symbols in the outside mirrors and acoustically via an acoustic warning.

Sensor positions and detecting ranges of the Blind Spot Assist

So as to ensure that the functioning of the system is not affected, on no account should the following changes be made:• Changing the position of the sensors

• Removing or modifying detachable parts in the area of the sensors

• Attachment of detachable parts that can shadow the area of or around the sensor

• Making modifications to the outside mirror

Blind Spot Assist can be deactivated using a button on the operating panel.

a WARNING

Depending on the version and thickness, paints or film coating can cause damping of radar waves. This could lead to malfunction or system failure. The driver could lose control of the vehicle and cause an accident.

The area of or around the sensor must not be painted or covered with a film.

! Note

If the areas of the sensors are damaged, please have the settings and function of the radar sensors checked at a qualified specialist workshop, e.g. at a Mercedes-Benz Service Centre. This also applies to mild collisions at low speeds, where no damages in the areas of the sensors are visible.



8 Electrical system

8.7.5 Highbeam Assist and Lane Keeping Assist

! Note

On vehicles with bodies which extend beyond the limits displayed below, the function of the camera may be impaired.

Therefore, it is not recommended to install High-beam Assist and Lane Keeping Assist on vehicles with bodies that protrude beyond this limit.

Limit for bodies on vehicles with rain/light sensor

1 Camera

2 Body limit

! Note

On no account should any modifications be made to the position of the camera or the surrounding area (e.g. changing the standard windscreen). Otherwise the camera may not be able to function properly.

The camera must be readjusted after any modifica-tions to the vehicle which alter the vehicle inclination, e.g. replacement of the suspension strut. Have the re-adjustment carried out without delay at a qual-ified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose.

Highbeam Assist can be deactivated via a menu in the instrument cluster and Lane Keeping Assist can be deactivated using a button on the operating panel.


Further information on the adjustment of the High Beam Assist and Lane Keeping Assist can be found in the Workshop Information System (WIS) (e Page 14).



8 Electrical system

8.7.6 Rain sensor/Headlamp Assist

! Note

On vehicles with bodies which extend beyond the limits displayed below, the function of the rain sen-sor/Headlamp Assist may be impaired. Therefore, it is not recommended to equip vehicles which have bodies that extend beyond these limits with a rain sensor/Headlamp Assist system.

Body limit for vehicles equipped with a rain sen-sor/Headlamp Assist system

1 Rain sensor/Headlamp Assist

2 Body limit

! Note

On no account should any modifications be made to the position of the rain sensor/Headlamp Assist or the surrounding area (e.g. changing the standard windscreen). Otherwise the rain sensor/Headlamp Assist may no longer function correctly.



8 Electrical system

8.7.7 Tyre pressure monitoring

a WARNING

Do not make any modifications in the area under the floor of the vehicle, including the vehicle axles and the system components of the tyre pressure monitor. Otherwise, the function of the tyre pressure moni-toring 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.

In accordance with the European Union regulations ((EU) 661/2009 (last changed by "(EU) 523/2012") and UN/ECE regulation no. 64, series of amendments 02, correction 1), all M1 Class vehicles (vehicles for passenger transport with a maximum of eight seats, excluding the driver's seat) which are registered for the first time after 01.11.2014 must be equipped with a precise monitoring system for the internal tyre pres-sure. This also applies in the event of conversion to winter tyres or accessory tyres and for vehicles which have been retyped as Class M1 from other classes. The affected vehicles must permanently be operated with tyre pressure sensors. Otherwise, this represents a deviation from the EU regulations and can make the vehicle's operating permit void. For this reason, vehi-cles 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 com-ply with the regulations specified above.

The wireless tyre pressure monitoring system on the front and rear axle (Code RY2) complies with the regulations specified above. It is required for the initial registration of new M1 Class vehicles as of 1 Novem-ber 2014 in the EU and EFTA Member States. For this reason, modifying the components of this system or influencing them by modifying or adding electromag-netic 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 complied with.

The system's reception module/control unit is affixed to the outside, on the vehicle floor plate above the rear axle differential. The pressure sensors are integrated into the tyre valves.

If, despite this, body work is planned for the vehicle underbody, the technical advice team 2.1 “Advice for body manufacturers” (e Page 10) at the body man-ufacturer centre must be consulted. After body work in this area, another inspection of the tyre pressure monitor by an officially recognised 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 registration capability as per this regulation still exists as the tyre pressure monitoring system has not been affected.



8 Electrical system

8.7.8 Parking assistance systems

Parktronic• If approved detachable parts are retrofitted, it is

necessary to have Parktronic coded with the appro-priate parameter record by your Mercedes-Benz partner.

• After-market painting of the bumper is not permit-ted with the Parktronic ultrasonic sensors fitted. The coat of paint impairs the emission and recep-tion of the ultrasonic signals.

! Note

Sensors which are already painted must not be re-painted or touched up.

In order to ensure that they function correctly throughout their operating life, sensors must be painted before being installed.

Unpainted sensors and sensors painted in a range of colours are available from Mercedes-Benz.

The maximum thickness the paint coat on the cover may have without impairing sensor operation is 120 µm. This also includes repeated painting applica-tions and the coat of cathodic dip paint (KTL coat). The KTL coat thickness is between 12 µm and 25 µm.

It is therefore necessary to make spot checks of the paint coat thickness to ensure faultless operation of the sensors.

It is essential that not only the cover itself but also the cylindrical edge of the sensor cover be coated with paint evenly all the way round and covering at least 2 mm.

2

1

N98.00-2170-00

Area of cylindrical edge of the sensor cover to be painted

1 Area to be painted

2 Maximum coat thickness 120 µm

! Note

The coat of paint may not be ground off mechani-cally, as this could damage the chromate layer or the cathodic dip paint layer or the sensor covering.

! Note

If the surface has been cathodically electro-primed, the paint must not be removed by chemical means as this could damage the cataphoretic electro-primer layer. A new layer cannot be applied afterwards. Nor is it permitted to touch up damaged areas chemi-cally or mechanically.

! Note

Attachment parts fitted in the detection range of the sensors may impair operation of the Parktronic sys-tem (e.g. trailer coupling, overhangs of bodies, wheel carriers, steps, brush guards).



8 Electrical system

Reversing camera

The reversing camera with 180 ° angle of vision is integrated into the liftgate above the license plate moulding.

1 License plate moulding

a WARNING

Changes made to the position of the installed cam-era or caused by bodies that extend into the angle of vision of the camera may mean that the system can no longer function correctly under certain circum-stances. This may cause people, animals or objects not to be seen in the area in which you are manoeu-vring. For this reason, do not make any changes in the area of the camera.

360 ° camera

The 360 ° camera is a camera system which evaluates pictures from four 180 ° cameras. The system detects the immediate surroundings of the vehicle as an orien-tation for manoeuvring.

Positions and detection ranges of the cameras• Front camera

• Reversing camera

• Cameras in both of the outside mirrors

a WARNING

Changes made to the position of the installed cam-era or caused by bodies that extend into the angle of vision of the camera may mean that the system can no longer function correctly under certain circum-stances. This may cause people, animals or objects not to be seen in the area in which you are manoeu-vring. For this reason, do not make any changes in the area of the camera.


8.8 Parametrizable special module (PSM)

8 Electrical system


The parametrizable special module (PSM) was devel-oped as an interface between the vehicle and body solutions, in order to allow body manufacturers to access individual CAN bus data. This PSM provides a clearly defined, diagnostics-compatible and EMC-tested interface between the vehicle and the body.

The PSM, available under code ED5, can read the mes-sages on the CAN bus and, for example, make them available as shift signals at the binary outputs provided for this purpose or as PWM (pulse width modulation) signals, and also relay them via a specified ABH CAN (e Page 120). The electronics installed by the body manufacturer then have access to the necessary sig-nals.


For further information on the topic of CAN bus systems, see 8.4.3 “CAN bus and networking” (e Page 101).

Installation position of the PSM in the left seat base

1 Parametrizable special module (PSM)


! Note

The wiring on the vehicle must not be tampered with, as this would lead to fault messages from the other control units on the CAN bus.


The parameters of the PSM are programmed using Xentry Kit (e Page 14).

Information on parameterization possibilities can be obtained in the comprehensive “PSM function description”, which is available in the Bodybuilder Portal under

https://bb-infoportal.mercedes-benz.com/ portal/kat_ze.0.html?&no_cache=1&L=

.

Information on standard parametrization possibil-ities, such as working speed control etc., can be obtained from your Mercedes-Benz Service Centre.

Information on parameterization possibilities which are not covered by the "PSM function description" can be obtained from the relevant department and from PSM Support (e Page 10).


Professional training on the PSM is available at:http://www.global-training.de

! Note

When a standard coding is written, all previous parameterization is erased. We recommend backing up data beforehand.

https://bb-infoportal.mercedes-benz.com/portal/kat_ze.0.html?&no_cache=1&L=

https://bb-infoportal.mercedes-benz.com/portal/kat_ze.0.html?&no_cache=1&L=

http://www.global-training.de



8 Electrical system

8.8.1 PSM functionsReading in from Body CAN:

• Vehicle status

E Terminal 15

E Terminal 61

E Secure from the outside, ...

• Light status

E LDS and steering column switch requests (e.g. high beams, turn signals, low beams, front fog lamps, etc.)

E Hazard warning flasher, UCP

• Window status

E Windscreen wipers and rear wipers

E Windscreen heater and rear window heater

• Central locking

E Doors open/closed, unlocked/locked

• Chassis CAN information

E Wheel speed

E Speed

E Engine speed, ...

E Cruise control operation

E Brakes applied, ...

E Transmission

E Clutch information

E Steering angle, ...

E Tachograph information as per FMS standard

• Equipment features

E Door assembly

E Sliding roof

E Transmission, ...

Output to the Body CAN

• Light control

E Parking lights

E Standing lights

E Turn signals

E High beams, ...

Alarm functions

E Alarm-triggered flashing of high beams

E Front fog lamps

E Hazard warning flashers

E Horn

• Sliding roof

E Opening and closing of the rear sliding roof

• Central locking function

E Lock/unlock front, cargo area and overall vehi-cle

• Windscreen and rear window

E Front windscreen wipers and rear wipers

E Windscreen heater and rear window heater

• Various functions

E Actuate buzzer (in passenger van) and interior lights

E Charging active

E Retarder function

• Warning signals

E PSM defective

E Undervoltage



8 Electrical system

8.8.2 PSM interfaces• I/O module

E 10 parametrizable inputs

E 19 parametrizable outputs

• Logic functions (Mini PLC)

The mini-PLC (mini programmable logic controller) is a module with freely programmable and freely interconnectable function blocks for creating any signal links that may be required:

E 96 AND/NAND/OR/EXOR/NOR/EXNOR gates

E 24 RS and D flip-flops

E 12 retriggerable/non-retriggerable timer stages

E 12 hysteresis elements with adjustable thresh-olds

E 24 threshold switches with 3 stages

E 12 counters

• Arithmetic unit

E 20 calculating blocks

E 8 filters

E 8 integrators/differentiators

E 8 comparators

E 4 characteristics

E 16 non-volatile memory options

E 20 freely definable constants

8.8.3 ABH-CANA second CAN bus is available on the PSM:

The body manufacturer CAN (ABH CAN).

• High-speed CAN Class C

• Extended CAN identifier (29-bit)

E Baud rate can be toggled between 250 kbit/s and 125 kbit/s

E Signal format: Intel (LSB first)

E All bus contents can be activated separately and independently of each other through parametrization:

- Fleet Management Standard - FMS (only in direction of transmission)

- ISO11992-2 and 3 (abridged)

- Freely assignable messages (J1939)


These body/equipment mounting directives cannot describe in full the wide variety of capabilities of the PSM. You can obtain additional information in the PSM function description and from PSM Support (e Page 10).


8.9 Continuous engine operation feature (Vito only)

8 Electrical system

8.9 Continuous engine operation feature (Vito only)

The continuous engine operation feature (code MW1) is available ex factory for special-purpose vehicles e.g. police cars, ambulances.

It is not possible to retrofit an engine run lock.

a WARNING

Retrofitting a continuous engine operation feature can cause critical vehicle issues, problems with the vehicle electronics or fault messages. Retrofitting a continuous engine operation feature is therefore not permitted.


8.10 Automatic start/stop system

8 Electrical system

8.10 Automatic start/stop system

The purpose of the automatic start/stop system is to reduce the emission levels. If the automatic start/stop system is used, an enhanced on-board electrical system is used for stabilising the on-board electrical system voltage. This includes an additional backup battery and a modified fuse box.

So as not to undershoot the defined charging capacity of the battery, the system gets automatically deacti-vated if the power consumption exceeds 140 A or if the charge state of battery is low.


8.11 Wiring diagrams

8 Electrical system

8.11 Wiring diagrams

Wiring diagrams can be made available to body manu-facturers. Enquiries should be addressed to:

Contact details

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


Wiring diagrams can also be called up in the Workshop Information System (WIS) (e Page 14).

Wiring diagrams are also available in the Bodybuilder Portal under:

MBAS-Web (Technology) / Catalogs / Wiring dia-grams:


9.1 Centre of gravity

9 Calculations


The overall height of the centre of gravity (vehicle with equipment/complete body but without load) must be kept as low as possible.

The position of the centre of gravity in the longitudinal direction of the vehicle is specified with reference to a vehicle axle.

The centre of gravity height is specified with reference to the centre of the wheel hub or the road surface.

Mercedes-Benz recommends that you have the position of the centre of gravity checked by a recognised and experienced testing institution (e.g. DEKRA, Technical Inspection Association (TÜV) etc.). Assistance in this can be obtained from the relevant department, see 2.1 “Advice for body manufacturers” (e Page 10).

If the centre of gravity is determined by the body man-ufacturer, the procedures described under 9.1.1 “Deter-mination of the centre of gravity in the x-direction” (e Page 124) and 9.1.2 “Determination of the centre of gravity in the z-direction” (e Page 126) must be fol-lowed and services of qualified persons must be used so as to achieve realistic and useful results.

9.1.1 Determination of the centre of gravity in the x-direction

CoG coordinate in x-direction (front/rear axle load distribution)

Procedure:• The vehicle should be weighed with its complete

equipment/body but without load.

• Inflate the tyres to the tyre pressure specified for the maximum permissible axle load on each axle.

• Completely fill all fluid reservoirs (fuel tank, washer fluid reservoir and, if installed, hydraulic tank, water tank etc.).

• Shut off the engine on the scales, shift the trans-mission to neutral and release the brakes.

• The vehicle must be parked horizontally on level ground for weighing.

• First weigh the individual axle loads (front and rear axle loads) and then the gross vehicle weight.

• 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

GG = GHA + GVA(1)

l = lV + lH (2)

Calculation of the centre of gravity in the x-direction

lV =GHA × l

GG

(3)

lH =GV A × l

GG

(4)

Weights:

GG Gross weight of the vehicle

GVA Front axle load on empty vehicle (specification or weighting of the chassis in question)

GHA Rear axle load on empty vehicle (specification or weighting of the chassis in question)

Dimensions

lV Distance of overall centre of gravity of empty vehicle from front axle

lH Distance of overall centre of gravity of empty vehicle from rear axle

l Wheelbase

SG Overall vehicle centre of gravity



9 Calculations

! Note

Practical determination of the centre of gravity height may only be carried out by appropriately qual-ified staff using suitable and calibrated scales.

In order to reduce measurement errors, each mea-surement value should be determined at least three times and the average should be calculated from these three values. This value is then used to per-form the calculation as per equations (3) and (4).


The wheelbase "I" is defined by the vehicle model designation (see Ordering) or must be determined by means of a length measurement according to DIN 70020, Part 1.

9.1.2 Determination of the centre of gravity in the z-direction

Centre coordinates in z-direction (height of centre of gravity hS for the overall vehicle)

For determination of the overall centre of gravity height of the vehicle hS by the body manufacturer, Mercedes-Benz recommends the following procedure after completion of the vehicle:

After conversion, the vehicle should be weighed on a plate-type scale or suitable wheel load scale in two different chassis positions in succession. Here, the axle loads measured when the vehicle stands horizontal and level (GVA and GHA, see 9.1.1 “Determination of the centre of gravity in the x-direction” (e Page 124)) and 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 overhang angle of the vehicle (also known as the angle of approach/departure). The target value is h’ > 600 mm.

In order to reduce measurement errors, at least six individual measurements must be performed for each vehicle axle when measuring the axle load: three per axle when the vehicle is in a level state and three when an axle is raised. Based on the three measurements in each condition, an average should be calculated for each axle. The mean value must be calculated from these three values and this mean value must then be used when calculating with equations (5) to (7). In order to improve the accuracy of the final result, the axle load change should be determined both with a raised rear axle and with a raised front axle.

! Note

In order to avoid erroneous measurements, please note:

• When weighing with the vehicle level, the vehicle must be exactly horizontal. Any height differ-ences between the axles caused by the scales must be compensated for accordingly.

• The axle to be weighed must be blocked to prevent suspension jounce and rebound when raising to the required lift height.

• No part of the vehicle may bottom out when raising to the required lift height.

• All vehicle wheels must be able to roll: shift mechanism in neutral position, all brakes includ-ing parking brake released, chocks placed at a sufficient distance from the wheels, if necessary.

• For turning (in order to weigh the other axle), move the vehicle under its own power so that any stresses in the vehicle are relaxed.

• Make sure that no objects inside the vehicle can move during the measurements.



9 Calculations

If the vehicle suspension cannot be blocked owing to its design or space restrictions, further axle load measure-ments must be taken at different raised positions (e.g. 600 mm, 700 mm and 800 mm). Here, errors can again be limited by averaging. The centre of gravity height is equal to the arithmetic mean of the individual centre of gravity heights for each raised position.

Example of procedure

1. The vehicle must be weighed with complete attach-ments and body, and without load.

2. Inflate tyres up to the interior tyre pressure that is specified for the relevant maximum permissible axle load.

3. Fill up all fluid reservoirs (fuel tank, window wash-ing fluid reservoir, or if necessary, hydraulic reser-voir, water tank etc.) completely.

4. On the scales, switch off the engine, shift the trans-mission to neutral and release the brakes.

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 repeat the corresponding measurement on the front axle (ini-tially GVA with the vehicle level, and then QVA with the rear axle raised).

9. Perform steps 4 to 7 three times in total (with blocked suspension).

10. Using the calculated values, the height of centre of gravity can be calculated using equations (5) to (7).

11. When calculating using the equations (3) to (9), all length measurements must be used in millimetres (mm) and all weights must be used in deca newton (1 daN = 10 N). G = 1 daN = 10 N is the weight force corresponding to the mass m = 1 kg.

12. Lift the raised axle further (by 100 mm, for exam-ple) and measure the height of centre of gravity again so as to confirm the measurement result.

! Note

Practical determination of the centre of gravity height may only be carried out by appropriately qual-ified staff using suitable and calibrated measuring equipment and measurement tools.



9 Calculations

Figure: Determining the height of the centre of gravity

hS = ha + rstat(5)

rstat Static tyre radius

QVA Front axle load with vehicle raised at rear

QHA Rear axle load with vehicle raised at front

hS Height of centre of gravity above road surface

ha Height of centre of gravity above wheel centre

h’ Height by which the vehicle was raised

SG Overall vehicle centre of gravity

1 Weighing device


The wheelbase "I" is defined by the vehicle model designation (see Ordering) or must be determined by means of a length measurement according to DIN 70020, Part 1.



9 Calculations

Formulae for raised front axle:

hS =

(l

h′ ×QHA − GHA

GG

×√

l2 − h′2) + rstat (6)

Formulae for raised rear axle:

hS =

(l

h′ ×QV A − GV A

GG

×√

l2 − h′2) + rstat (7)

! Note

The calculated centre of gravity must not exceed the limits specified under 4.1.2 “Maximum permissible positions of centre of gravity” (e Page 46).


10.1 Vehicle data

10 Technical details

10.1 Vehicle data


You can obtain further technical data about the vehicle:

• from your contact persons, see 2.1 “Advice for body manufacturers” (e Page 10)

• from 2.2.7 “Product Information Tool (PIT)” (e Page 16)

• from the vehicle configurator athttp://www.mercedes-benz.com



Index

A

ABH-CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . 21Additional assemblies . . . . . . . . . . . . . . . . . . . . . . 84Advice for body manufacturers . . . . . . . . . . . . . . . 10Air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Attachment above cab . . . . . . . . . . . . . . . . . . . . . . 85Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Automatic start/stop system . . . . . . . . . . . . . . . 122Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . 84Axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

B

Basic vehicle (modifications) . . . . . . . . . . . . . . . . . 60Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 97Blind Spot Assist . . . . . . . . . . . . . . . . . . . . . . . . . . .112Bodybuilder Portal . . . . . . . . . . . . . . . . . . . . . . . . . 13Bodyshell/body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Bodyshell threshold values . . . . . . . . . . . . . . . . . . 52Bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . 38Brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

C

Cables and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124CAN bus and networking . . . . . . . . . . . . . . . . . . . 101Centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . 124CERON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Certificate of non-objection . . . . . . . . . . . . . . . . . . .11Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Collision Prevention Assist . . . . . . . . . . . . . . . . . .110Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Corrosion protection measures . . . . . . . . . . . . . . . 57Crosswind Assist . . . . . . . . . . . . . . . . . . . . . . . . . . .110

D

Damage prevention . . . . . . . . . . . . . . . . . . . . . . . . . 55Design of bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Dimensions and weights . . . . . . . . . . . . . . . . . . . . 34Doors and flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Driving assistance systems . . . . . . . . . . . . . . . . . 108Dust/dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

E

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Electric wiring/fuses . . . . . . . . . . . . . . . . . . . . . . . 53Electromagnetic compatibility (EMC) . . . . . . . . . . 96Electronic Stability Program (ESP) . . . . . . . . . . . 108

Engine air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Engine cooling system . . . . . . . . . . . . . . . . . . . . . . 73Engine peripherals . . . . . . . . . . . . . . . . . . . . . . . . . 71Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

F

Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

G

Government vehicles . . . . . . . . . . . . . . . . . . . . . . . 94

H

Highbeam Assist and Lane Keeping Assist . . . . .113

I

Interfaces / electrical lines . . . . . . . . . . . . . . . . . 100Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 87

L

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Limits for electrical/electronic system . . . . . . . . 53

M

Maintenance and repairs . . . . . . . . . . . . . . . . . . . . 43Mobile communications systems . . . . . . . . . . . . 107Modifications to the basic vehicle . . . . . . . . . . . . 60Modifications to the bodyshell . . . . . . . . . . . . . . . 52Motor caravans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Mudguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

O

Operational safety. . . . . . . . . . . . . . . . . . . . . . . . . . . 8

P

Painting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Parametrizable special module (PSM) . . . . . . . . .118Parking assistance systems . . . . . . . . . . . . . . . . .116Partition wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Planning of bodies. . . . . . . . . . . . . . . . . . . . . . . . . . 24Pop-up roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Preservation work . . . . . . . . . . . . . . . . . . . . . . . . . . 59Product Information Tool (PIT). . . . . . . . . . . . . . . . 16Product liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75PSM functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119PSM interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Q

Quality system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23


Index

R

Rain sensor/Headlamp Assist . . . . . . . . . . . . . . . .114Reducing noise in the vehicle interior . . . . . . . . . 82Refrigerated vehicles/temperature-controlled ve-hicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Reprocessing of components - recycling . . . . . . . 22Roof height increase . . . . . . . . . . . . . . . . . . . . . . . . 93Roof racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

S

Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 76Safety-relevant features . . . . . . . . . . . . . . . . . . . . . 17SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Sidewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Soundproofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . 45Springs/shock absorbers . . . . . . . . . . . . . . . . . . . 60Steerability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Storing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 43Suspension threshold values. . . . . . . . . . . . . . . . . 47

T

Technical threshold values for planning . . . . . . . 46Threshold values of the basic vehicle . . . . . . . . . 46Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Tyre pressure monitoring . . . . . . . . . . . . . . . . . . . .115Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Tyre sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

U

Underfloor panelling . . . . . . . . . . . . . . . . . . . . . . . . 68

V

Vehicle and model designation . . . . . . . . . . . . . . . 25Vehicle dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 46Vehicle modifications . . . . . . . . . . . . . . . . . . . . . . . 33Vehicle position and side marker lamps . . . . . . . 53Vehicle roof/roof load . . . . . . . . . . . . . . . . . . . . . . 52Vehicle safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Vehicle type identification data . . . . . . . . . . . . . . 35Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

W

Welded connections . . . . . . . . . . . . . . . . . . . . . . . . 39Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Wheel wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 123Work before handing over the modified vehicle . 44Workshop Information System (WIS) . . . . . . . . . . 14

X

Xentry Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Documents

Body/Equipment Mounting Directives for Vans …...Mercedes-Benz body/equipment mounting directives for Vito/V-Class - BM 447, version 25.07.2014!Changes compared to version dated 24.01.2014