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1 Design of the Vivaro Range ................................................................................................ 1
2 Chassis number and identification plate ........................................................................ 2
3 Body frame plans and sectional drawings of the Vivaro .............................................. 5Van ...................................................................................................................................... 5Body sections ...................................................................................................................... 6Installation of windows or sheet-metal panels in the vehicle sides................................ 7Floor group – main sections .............................................................................................. 8Position of crossmembers .................................................................................................. 8Partition between cab and load compartment .............................................................. 10Lashing points .................................................................................................................... 13Load compartment sections .............................................................................................. 15Accessibility via rear doors/tailgate .................................................................................. 16Accessibility via the side sliding door................................................................................ 21Platform chassis .................................................................................................................. 22Body connection – Position of the fastening points ........................................................ 22Body connection – Side sill closing panel ........................................................................ 25Body connection – Floor group.......................................................................................... 29Rear wheel housing ............................................................................................................ 32
4 Electric .................................................................................................................................... 33Wiring and positioning of connections ............................................................................ 33Circuit diagrams .................................................................................................................. 33Relay/fuse box Vivaro ........................................................................................................ 34Fuse and relay boxes.......................................................................................................... 35Relais in driver cabine ........................................................................................................ 36Main Fuses in engine compartment.................................................................................. 37Relais in Engine compartment .......................................................................................... 38
5 Supplementary information ................................................................................................ 40Ground clearance................................................................................................................ 40Centre of gravity ................................................................................................................ 42Tyres and turning-circle diameter...................................................................................... 45Seat belt anchorage points................................................................................................ 46Seat mountings .................................................................................................................. 47Position of R points ............................................................................................................ 48Fuel supply system.............................................................................................................. 50Position of brake system .................................................................................................... 55Location of the spare wheel .............................................................................................. 57Parking brake system.......................................................................................................... 58Modification of the exhaust system .................................................................................. 59Engine cooling .................................................................................................................... 61Alternator/110 A alternator ................................................................................................ 65125 A alternator .................................................................................................................. 66
6 Options and Accessories ...................................................................................................... 67Power take-off .................................................................................................................... 67Additional Air Condition for engine versions F4R and F9Q ............................................ 68Auxiliary heater .................................................................................................................. 70Roof rack.............................................................................................................................. 71Trailer hitch .......................................................................................................................... 73
Technical Data Vivaro
1 Design of the Vivaro Range
• Overview
The Vivaro range is based on a front-wheel drive platform with a self-supporting body and a transverseengine. The main versions include vans, platform vans and vehicles for passenger transport (minibuses,etc.). Depending on the format, vehicles are available in a choice of two different TPWs (total permissibleweights), two different wheel bases and four different engines. Three turbocharged diesel (F9Q eco, F9Qand G9U) and one petrol engine (F4R) are available.
– 1 –
Technical Data Vivaro
H1 = Normal roofH2 = high roofTPW = Total Permissible Weight
2 Chassis number and identification plate
The chassis number can be viewed by levering up one of the two flaps located above the right-handcab foot board using a suitable tool (e. g. a screwdriver).
The identification plate is located on the right-hand cab door frame.
Data interpretation details are outlined on the following pages.
– 2 –
Technical Data Vivaro
Identification plate
Line 1: ManufacturerLine 2: Approval numberLine 3: Chassis numberLine 4: Total permissible weightLine 5: Perm. gross towing weightLine 6: Max. perm. front axle loadLine 7: Max. perm. rear axle loadColour codeCountry-specific information (if avail.)
– 3 –
Technical Data Vivaro
National approval numbersOnly for Van and Platform Chassis
BelgiumCzechoslovakiaGermanySpainFranceItalyPoland
Equipment Level
– 4 –
Technical Data Vivaro
CHASSIS NUMBER
REPLACEMENT CHASSIS NUMBER
WOLWOL
Chassis number
CURB WEIGHT
PERMISSIBLECOMBINATION WEIGHT
VEHICLE LENGTH
BOTTOM SURFACEVEHICLE WIDTH
TOTAL PERMISSIBLE WEIGHT
PV 0.00 t PTAC 0.00 tPTRA 0.00 t
Lon 0.00 m Lar 0.00 mS 0.00 m2
Weights and dimensions
3 Body frame plans and sectional drawings of the Vivaro
• Reference system and interpretation of dimensions
In general, the dimensions are expressed as absolute values (distance between two points) and the positions as relative values (determination of position within the reference system). The origin of the reference system is the centre of the front axle, as shown in the diagram below. The position of the front axle is constant with a deviation of ± 1 mm along the X-axis betweenunladen and laden conditions.
Van
• Superstructure
The main sections for the Vivaro are indicated in the diagram overleaf.
– 5 –
Technical Data Vivaro
Body sections
SECT
ION
1SC
ALE
1:4
SECT
ION
2SC
ALE
1:4
SECT
ION
3SC
ALE
1:8
SECT
ION
5SC
ALE
1:20
SECT
ION
4SC
ALE
1:20
SECT
ION
6SC
ALE
1:20
SECT
ION
7SC
ALE
1:20
SECT
ION
8SC
ALE
1:20
SECT
ION
9SC
ALE
1:20
SECT
ION
10
SCAL
E 1:
20
SECT
ION
11
SCAL
E 1:
20SE
CTIO
N 1
2SC
ALE
1:20
SECT
ION
13
SCAL
E 1:
20
– 6 –
Technical Data Vivaro
• Installation of windows or sheet-metal panels in the vehicle sides
It is recommended that a glazed version of the Vivaro is used as the basis for conversion. If this is not possible, the following method is recommended:– Cut out the panel along the contours– Attach the panel and reinforcement with water-tight rivets (distance between rivets: 120 mm)– Bond in standard windows (use special seal provided).
• Rear doors
The procedure is the same as for side panels.
SectionPANEL VAN
50 mm
SLIDING WINDOW
50 mm
GLAZED VAN
50 mm
SIDE PANEL
GLASS OR SHEET METAL INSERT
UPPER REINFORCEMENT
LOWER REINFORCEMENT
STRUT
ROOF STRUT
200 mm
UPPER REINFORCEMENT
– 7 –
Technical Data Vivaro
• Floor group – main sections
See also platform chassis
• Position of crossmembers
The following drawings are plan views (without floor panel). The positions of the side members andcrossmembers for vans, combis and buses are illustrated (L1, L2, RHD and LHD).
L1 Van (LHD and RHD)
L1 Combi and bus (LHD)
For further details, see drawing of L1 Van.
ONLY APPLIES TO VEHICLES WITH SLIDING DOOR ON RIGHT
FRO
NT
AXLE
2969
2644
2165
1840
196
250
2392
2790
2911
2955
3187
1954
3487
570
816
543
25
75
1354
1455
634
2411
2611
1269
516
516 63
4
3788
FRO
NT
AXLE
489
211
905
1743
2067
2392
2790
145
– 8 –
Technical Data Vivaro
L2 Van (LHD and RHD)
For further details, see drawing of L1 Van.
L2 Combi and bus (LHD)
For further details, see drawing of L1 Van.
FRO
NT
AXLE
2165
2644
2969
1840
250
196
3311
3355
3187
3587
2811
3011
4188
FRO
NT
AXLE
3887
ONLY APPLIES TO VEHICLES WITH SLIDING DOOR ON RIGHT OR NO SLIDING DOOR
ONLY APPLIES TO VEHICLES WITH SLIDING DOOR ON LEFT OR NO SLIDING DOOR
2354
– 9 –
Technical Data Vivaro
• Partition between cab and load compartment
Vans and platform chassis can be supplied with a partition (as standard in some models).
The following partitions are available:
– One third separation grille on right or left side, depending on whether the vehicle is RHD or LHD(not available for platform chassis)
– Sheet metal partition with window
– Sheet metal partition without window
The partitions are attached with bolts and rivets, but are not completely sealed.
Vehicle converters installing partitions should refer to diagrams on the following pages, which showthe ideal installation position taking account the driver’s seat suspension, cab ergonomics and thepallet loading through the side door (pallet dimensions 800 mm x 1000 mm x 1000 mm).
– 10 –
Technical Data Vivaro
• Access to load compartment via side sliding door
Full partition
Separation grille
50%
849,450
1262
,7
50
5011
71,1
50
DOOR APERTURE WITH SEAL
FULL PARTITION
FRONT ACCESS LIMIT
50%
FRONT ACCESS LIMIT
SEPARATION GRILLE
DOOR APERTURE WITH SEAL
5011
71,1
50
50 50839,4
1262
,7
– 11 –
Technical Data Vivaro
• Loading a europallet
Full partition
Separation grille
50%
1283
800 7070
8410
0050
DOOR APERTURE WITH SEAL
SEPARATION GRILLE
FRONT ACCESS LIMIT
145
50%
FRONT ACCESS LIMIT
FULL PARTITION
DOOR APERTURE WITH SEAL
5010
0084
70
1283
80 800
145
– 12 –
Technical Data Vivaro
• Lashing points
The L1 van features six lashing points, the L2 van features eight.All the rings are attached to the sheet metal panel and conform to DIN 75410. The specification for the fastening bolts is M8 x 26.5.
– 13 –
Technical Data Vivaro
Diameter 9,2 mm
Position of lashing points
L1 Van
L2 Van
FRON
T AX
LE
Z0
276
40
36 70
2633
3679
1435
Technical Data Vivaro
– 14 –
• Load compartment sections
– The main dimensions of the load compartment and the wheel housings are shown.
Main dimensions
Load compartment, L1 and L2 vans, roof H1
Y 0 Y 200 Y 400 Y 600 Y 800
Z 1600
Z 1400
Z 1200
Z 1000
Z 800
Z 600
Z 400
Z 0
Z 200
285
SECTION A-A
16731672800
803
890
802
834
827
633
833
A
A
– 15 –
Technical Data Vivaro
• Accessibility via rear doors/tailgate
Access to the load compartment via the rear door frame fulfils the EN 1789 for ambulance vehicles.The overall dimensions include details of gap dimensions and installation position (version with 250°opening angle) at various levels.Note: The height of the floor ribbing is 10 mm
– 16 –
Technical Data Vivaro
Y-400Y-800 Y800Y400Y0
Z1600
Z0
Z1200
Z800
Z400
Z 1651
1390
1314
1268
Z 285
1678
870
1642
721
678
34
39
870
• Accessibility via rear doors
172° opening angle, applies to L1H1
– 17 –
Technical Data Vivaro
1233
1641
870
1686
870
1255
678
721
• Accessibility via the rear doors
250° opening angle, applies to L2 without sliding doors
– 18 –
Technical Data Vivaro
870
1401
1641
870
1685
1440
678
721
• Accessibility via the rear doors
233° opening angle, applies to L2 with sliding doors
– 19 –
Technical Data Vivaro
• Accessibility via the rear doors
• Accessibility via the tailgate, applies to L1
(la
den /
unlad
en)
1846
/ 195
9
1141
1767
/ 185
4
2027
/ 21
28m
ax. 2
042,6
(un
laden
)
min.
405,5
(lad
en)
– 20 –
Technical Data Vivaro
• Accessibility via the side sliding door
For further details, see:
– partition wall
– insulation of the side sliding door
– 21 –
Technical Data Vivaro
min. 1003 mm
max
. 107
8 mm
• Platform chassis
Vivaro platform chassis are fitted with a connection flange with six fastening points. The seat beltanchor points are certified as such.
• Body connection – Position of fastening points
The position of the fastening points is shown below.
Note: For reasons of structural rigidity, the new body must be fastened to all fastening points. It is not sufficient to fasten them to the floor only.
– 22 –
Technical Data Vivaro
A
A
BB
CC
Section A-A
(Body fastening points)
Section B-B
PARTITION
– 23 –
Technical Data Vivaro
PARTITION
Section C-C
– 24 –
Technical Data Vivaro
PARTITION
• Body connection – side sill closing panel
The following illustrations show the sections of the side sill closing panel for platform chassis and vans. It is advisable to select a geometrical inertia which corresponds to that of the van.
– 25 –
Technical Data Vivaro
Section A-A
Section B-B
100
100
Technical Data Vivaro
– 26 –
--- -- --- -- --- - Van______________ Platform chassis
--- -- --- -- --- - Van______________ Platform chassis
100
196.3
324.7
Section C-C
Section D-D
– 27 –
Technical Data Vivaro
--- -- --- -- --- - Van______________ Platform chassis
--- -- --- -- --- - Van______________ Platform chassis
– 28 –
Technical Data Vivaro
Lower pillar lining
Sill closing panel
Area which must be closed for acoustic reasons.
Side window glazing bar
Front door frame Sidemounting
Maximum overall width
Area which must be closed for acousticreasons.
Lower door end panel
Lower pillar
lining
sill end piece
Maximumoverall width
sill beam
sill end piece
Floor panel
Section E-E
On the rear of the B pillar
Section F-F
Horizontal cut at B pillar
• Body connection – Floor group
The following illustration shows sections and fastening points for the floor group. The lower rear panelfor various vehicle versions is also illustrated.The lower rear panel performs an important load-bearing function. For modifications to the lower rearpanel, please consult the Vivaro conversion recommendations manual under “Modifying the rearoverhang”.
– 29 –
Technical Data Vivaro
A
A
B
B
C
C
ZUGA
NG
KARO
SSER
IE
DD
BO
DY
AC
CES
S
171
130SCHNITTBEREICH
100
100
SCHNITTBEREICH
Section A-A
Section B-B
– 30 –
Technical Data Vivaro
CUTTING AREA
CUTTING AREA
50 mm
100
150
100
100
Section C-C
Section D-D
– 31 –
Technical Data Vivaro
• Rear wheel housing
Use standard fastenings 1 and 2 of the rear wheel housing cover to fasten the protective plate to thenew body.The protective plate must be tensioned along the Y axis between the wheel housing cover and body,in order to ensure sufficient stability and water-tightness.For details, please consult the drawings below.
Rear wheel housing section
VAN SIDE PANEL
WHEEL HOUSING COVER FLANGE (3 mm)
2
1
Technical Data Vivaro
– 32 –
4 Electrics
• Wiring and positioning of connections
A three-dimensional view of the wiring and the connection points for the Vivaro van is shown below as well as three documents providing a general overview of the wiring for the van, combi and platformchassis.The relay/fuse box in the engine compartment has the following vacant slots:
– Position X, main fuse reserved for possible future applications
– Two vacant relay sockets
The relay/fuse box in the passenger compartment (accessible via the driver’s side flap in the instrumentpanel) has the vacant sockets: 1, 3, 4, 5, 6, 8, 18, 22, 23, 37, 38 and 39. The use of these vacant slots in production at a later date cannot be ruled out.
• Circuit diagrams
This section contains the following electrical diagrams:
– Fuse boxes and relay units
– Relais and fuses in driver cabine
– Main fuse in Engine compartment
– Relais in Engine compartment
– Wiring for Van and tailgate
– 33 –
Technical Data Vivaro
• Relay/fuse box Vivaro
– 34 –
Technical Data Vivaro
1 Not used
2 Radio3 Not used4 Not used5 Not used6 Not used7 AC, rear8 Not used9 Fog lamps
10 Central locking
11 Interior illumination12 Diagnostic plug,
immobiliser13 Rear screen heating
14 Rear screenwiper/washer system
15 Screen wipers16 Brake light17 ABS18 Not used19 Window winders20 Window winders21 Seat heating22 Not used23 Not used
24 Radio25 Heating
26 Accessories
27 High beam, left
28 High beam, right29 Low beam, left30 Low beam, right31 Tail lamp, left32 Tail lamp, right33 Rear fog lamp34 Horn35 Mirror heating36 Windscreen heating
control37 Not used38 Not used
39 Not used
Fuse assignment
• Fuse and relay boxes
In the cab
– One relay box behind the cigarette lighter.
– One fuse box on the left-hand side of the instrument panel.
– One main fuse for the power supply, located on the side of the battery.
– 35 –
Technical Data Vivaro
Note: The relay for the electronic thermostat is installed on the left-hand side of the air mixer and distributor.
• In the engine compartment
One fuse box is located on the left-hand side of the engine compartment.
– 36 –
Technical Data Vivaro
• Relais in driver cabine
A Relay for the rear screen heating
B Time-out for rear screen wipers
C Relay for the rear screen wipers
D Relay + after-contact
E AC tripping relay
F Relay for the heatable windscreen
G Relay for the fog lamps
H “Headlight” relay for low beam
H “Headlight” relay for parking lights
J “Headlight” main relay
K Relay for the electronic thermostat
• Main Fuses in engine compartment
– 37 –
Technical Data Vivaro
• Relais in Engine compartment
1 2 or 3 add-on heater (auxiliary heater)/parking heater (diesel) relay
2 Relay for fuel injection computer (diesel)/ injection interrupt (petrol)
3 Diesel pump relay4 Fuel pump/diesel pre-heating relay.5 Relay for fan unit, second speed level
(Diesel parking heater)6 Coupling relay: AC compressor7 1 add-on heater (thermo-plunger) relay8 2 or 3 add-on heater (thermo-plungers)/
parking heater (petrol) relay9 Fan unit (diesel)/Relay for second speed level
with AC (diesel)/first speed level with AC (petrol)10 Fan unit (petrol)/Relay for first speed level of the
fan with AC (diesel)/second speed level with AC (petrol).
11 Not used.12 Relay for heatable windscreen.13 Relay for heatable windscreen.
Diesel vehicles equipped with cab/parking heater.
Note: In the diesel version the vehicle is either equipped with an auxiliary heater or with a parking heater.
The Vivaro multiplex network enables the 4 computers (CPU cab, fuel injection, airbag and instrumentpanel) to exchange data.
The network is connected with the connection for the diagnostics plug and uses the CAN (Controller Area Network) protocol
– 38 –
Technical Data Vivaro
Bundled (multiplex) network
1 Instruments – dashboard/instrument panel
2 Airbag computer
3 CPU cab
4 Connection for diagnostics plug
5 Fuel injection computer
• Wiring harnesses
– 39 –
Technical Data Vivaro
5 Supplementary information
• Ground clearance
The specified ground clearance given for the van, combi and platform chassis relate to vehicles at total permissible weight.
L1 version
L2 version18
3
179
165
SPARE WHEEL WELL
ENGINE SUPPORT
MUFFLER
20° 22°
ANGLE OF INCLINATION 15°
TPW only
TPW only 24° 21°
165 173
ANGLE OF INCLINATION 24°
MULDE SPARE WHEEL WELLMUFFLER
ENGINE SUPPORT
171
– 40 –
Technical Data Vivaro
Platform chassis version
18° 20°
ANGLE OF INCLINATION 14°
184
178
160
TPW only
SPARE WHEEL WELL
ENGINE SUPPORT
MUFFLER
– 41 –
Technical Data Vivaro
• Centre of gravity
The specified centres of gravity relate to the unladen vehicle, ready to drive.
L1 Van
L2 Van
1333,3
370,
7
5 mm LEFT OF LONGITUDINAL AXIS
1198,8
366,
2
5 mm LEFT OF LONGITUDINAL AXIS
– 42 –
Technical Data Vivaro
L1 Combi and bus
L2 Combi
11.2 mm LEFT OF LONGITUDINAL AXIS
386.
3
394,
6
KOMBI (6-SITZER)8.6 mm LEFT OF LONGITUDINAL AXIS
1467,2 COMBI (8/9-SEATER)
1418,1 COMBI (6-SEATER)
KOMB
I (8/9
-SEA
TER)
KOMBI 8/9-SITZER
KOMB
I (6-SE
ATER
)
1336,5
391,5
11.2 mm LEFT OF THE VEHICLE’S LONGITUDINAL AXIS
393.
2BU
S
1345,2 BUS
BUS7.6 mm LEFT OF LONGITUDINAL AXIS
– 43 –
Technical Data Vivaro
Platform chassis
1044,4
284,
4
18.4 mm LEFT OF LONGITUDINAL AXIS
– 44 –
Technical Data Vivaro
• Tyres and turning circle diameter
The rebound clearance envelope of the rear wheels is specified as a section with dimensions.The section is shown with an asymmetrical rebound clearance and fully compressed stops.It is recommended that a clearance of 10 mm should be added for each body position.
• Turning circle diameter
The specified turning circle diameters relate to wheel bases L1 and L2 and vehicles with extendedwheel base.
– 45 –
Technical Data Vivaro
TPW Tyre size Rolling circumference Rims Speed index Load index2,7 t 195 / 65 R16 2000 mm 6J16 R 100/98R2,9 t 205 / 65 R16 2042 mm 6J16 R 107/105R
Option 215 / 65 R16 2085 mm 6J16 R 106/104R
TURNING CIRCLE
BETWEEN WALLS
BETWEEN PAVEMENTS
WHEEL BASE (MM)
• Seat belt anchorage points
Seat belt anchorage points for L1 vans, combis and buses
Seat belt anchorage points for L2 vans and combis
50%
379
276
Z0
1219
294
1311
1245
474 21
9
1450
2720
3300
1425
2708
3077
FRON
T AX
LE
50%
FRON
T AX
LE
3519
2708
1425
3300
2720
1450
195
474
1245 13
11
294
1219
Z0
276379
– 46 –
Technical Data Vivaro
• Seat mountings:
Seat mounting points for vans and combis
Seat mounting points for buses
LONGITUDINAL AXIS
X905Y-616
X905Y-254
X905Y254
X905Y616
X1319Y516
X1319Y254
X1319Y-254
X1319Y-516
X1840Y-250
X2164,8Y-250
X1840Y-516
X2164,8Y-516
X2968,8Y-250
X2968,8Y-516
X2644Y-250
X2644Y-516
X2968,8Y250
X2968,8Y516
X2644Y516
X1840Y516
X1840Y250
X2164,8Y250
X2164,8Y516
X2644Y250
X1319Y0
LONGITUDINAL AXIS
X905Y-616
X905Y-254
X905Y0
X905Y616
X1319Y516
X1319Y329
X1319Y-254
X1319Y-516
X1840Y-250
X2164,8Y-250
X1840Y-516
X2164,8Y-516
X2968,8Y-250
X2968,8Y-516
X2644Y-250
X2644Y-516
X2968,8Y250
X2968,8Y516
X2644Y516
X1840Y516
X1840Y250
X2164,8Y250
X2164,8Y516
X2644Y250
– 47 –
Technical Data Vivaro
50%
45441
6
Z0
276
379
• Position of R points
R points for combis and buses
(LHD)
– 48 –
Technical Data Vivaro
R points for combis
(LHD)
R points for buses
(LHD)
LONGITUDINAL AXIS
FRON
T AX
LE
1077
2053
2857
435
435
383
356
LONGITUDINAL AXIS
FRON
T AX
LE
1147
1077
2053
2857
435
523
123
500
500
– 49 –
Technical Data Vivaro
• Fuel supply system
The fuel supply system is identical for all versions, regardless of whether they are LHD or RHD. The fuel tank filler pipe (passenger vehicle model, according to SAE J 1140) is described overleaf. Any changes to the fuel lines or the fuel tank require re-certification. The fuel tank has a capacity of 90 litres.
• Changing position of the filler pipe
This modification is not recommended as the routing of the tank filler pipe is very complex. If changesare absolutely necessary, the result must comply with all applicable regulations and allow unimpairedfilling.
• Add-on heater
The add-on heater can be ordered ex works. When retrofitting, the feed line must be replaced by partnumber 91166223. These modifications ensure sufficient fuel supply to the engine, regardless of tanklevel and vehicle dynamics.
Note: The fuel lines are made from PA11/PA12.
Position of fuel supply system
(Petrol version)
FRON
T AX
LE
LONGITUDINAL AXIS
– 50 –
Technical Data Vivaro
100 mm
BODY
MAX
IMUM
290
89
BB
FRON
T AX
LE
LONGITUDINAL AXIS
Technical Data Vivaro
– 51 –
Position of the fuel supply system
(Diesel version)
Section A-A
Tank filler pipe (according to SAE J 1140)
Section B-B
Tank filler pipe (according to SAE J 1140)
100 mm
150
90
80
BODY MAXIMUM
– 52 –
Technical Data Vivaro
• Fuel tank versions
– 53 –
Technical Data Vivaro
Fuel tank (petrol) without add-on heater
Line with solenoid valve
Engine feed line
Supply unit
Feed hose, Sleeve, seal
Charcoal canister
Filter
Tank
Clamp
Ground cable
Fuel tank (petrol) with add-on heater
Line with solenoid valve
Engine feed line
Supply unit
Feed hose, Sleeve, seal
Charcoal canister
Filter
Tank
Clamp
Ground cable
Feed hose,Add-on heater
• Fuel tank versions
– 54 –
Technical Data Vivaro
Fuel tank (diesel) without add-on heater
Feed line
Supply unit
Return line
Filter Tank
Clamp
Feed hose, Sleeve, seal
Fuel tank (diesel) with add-on heater
Feed line,Add-on heater
Supply unit
Return line
Filter
Tank
Clamp
Feed hose, Sleeve, seal
Feed line
• Position of brake system
The position of the brake system is shown in the following illustrations. Two different brake servos unitsare used, depending on the engine and vehicle version. One is a 10 inch brake servo for LHD vehicleswith F9Q engine, the other is a 9/10 inch brake servo for versions with F4R or G9U engines and for allRHD vehicles.
Note: For safety reasons, all vehicles with extended wheel base must be equipped with an ABSbrake system.
10-inch brake servo (without ABS)
10-inch brake servo (with ABS)
LONGITUDINAL AXIS
FRON
T AX
LEFR
ONT
AXLE
LONGITUDINAL AXIS
– 55 –
Technical Data Vivaro
9/10-inch brake servo (without ABS)
9/10-inch brake servo (with ABS)
LONGITUDINAL AXIS
FRON
T AX
LE
LONGITUDINAL AXIS
FRON
T AX
LE
– 56 –
Technical Data Vivaro
• Location of the spare wheel
– 57 –
Technical Data Vivaro
LONGITUDINAL AXIS
FRON
T AX
LE
X 3431Y-127Z 140
• Parking brake system
LHD
RHD
LONGITUDINAL AXIS
FRON
T AX
LE
LONGITUDINAL AXIS
FRON
T AX
LE
– 58 –
Technical Data Vivaro
• Modification of the exhaust system
The exhaust pipe must be extended in length in the central section (diameter 50/47 mm).The extension must be made from stainless steel, in accordance with the warranty against corrosion.
F4R engine
F9Q engine
LONGITUDINAL AXIS
FRON
T AX
LE
LONGITUDINAL AXIS
FRON
T AX
LE
– 59 –
Technical Data Vivaro
G9U engine
LONGITUDINAL AXIS
FRON
T AX
LE
– 60 –
Technical Data Vivaro
• Engine cooling
The illustrations below show the coolant circuits for the engine versions F4R, F9Q and G9U as well as the A/C circuits for the engine versions F4R and F9Q.
F4R engine coolant circuit
HO
SE C
LAM
P |A
16
RADI
ATO
R
RADI
ATO
R FE
ED H
OSE
HEA
T EX
CHAN
GER
FEED
HO
SE
DEG
ASSI
NG
HOSE
HO
SE C
LAM
P |A
18
HO
SE C
LAM
P |A
20
COO
LAN
T CO
MPE
NSA
TIO
N T
ANK
HO
SE C
LAM
P |A
20
HOSE
CLA
MP
|A 1
2
HO
SE C
LAM
P |A
12
HO
SE C
LAM
P |A
32
HOSE
CLA
MP
|A 3
2
RADI
ATO
R O
UTLE
T HO
SE
– 61 –
Technical Data Vivaro
F9Q engine coolant circuit
RADI
ATO
R O
UTLE
T HO
SE
HOSE
CLA
MP
|A 3
2
HO
SE C
LAM
P |A
32
HO
SE C
LAM
P |A
12
HOSE
CLA
MP
|A 1
2
HO
SE C
LAM
P |A
20
COO
LAN
T CO
MPE
NSA
TIO
N T
ANK
HO
SE C
LAM
P |A
20
HO
SE C
LAM
P |A
18
DE
GASS
ING
HOSE
HEA
T EX
CHAN
GER
FEED
HO
SE
RADI
ATO
R FE
ED H
OSE
AUX
. ON
HEA
TER
FEED
HO
SE
RADI
ATO
R
HEA
TER
OUT
LET
HOSE
HO
SE C
LAM
P |A
24
HO
SE C
LAM
P |A
16
– 62 –
Technical Data Vivaro
– 63 –
Technical Data Vivaro
Non-AC radiatorAlumeca
G9U engine coolant circuit
G9U engine AC circuit
Radiator outlet pipe
Spring clamping ring, diameter 18
Spring clamping ring,diameter 18
Spring clamping ring, diameter 12
Spring clamping ring,diameter 12
Inlet pipe, heater4-auxiliary heater
Inlet pipe,heater
Outlet pipe, Compensation tank
Outlet pipe, heater
Spring clamping ring, diameter 20
Spring clamping ring, diameter 20
Spring clamping ring, diameter 20
Inlet pipe, Compensation tank
Compensation tank
Spring clamping ring, diameter 32
Spring clamping ring, diameter 32
Water outletmodule
Radiator inlet pipe
Condenser
High-pressure pipeCondenser compressor
Low-pressure pipe, evaporatorcoolant collector,
High-pressure pipe, condenserEvaporator
Receiver drier,assembled
Compressor
Low-pressure pipe, receiver drier, compressor
• AC circuit
F4R and F9Q engines
CONDENSER
COMPRESSOR
RECEIVER DRIER
CONDENSER – EVAPORATOR HIGH PRESSURE HOSE
EVAPORATOR – RECEIVER DRIER LOW PRESSURE HOSERECEIVER DRIER – COMPRESSOR LOW PRESSURE HOSE
COMPRESSOR – CONDENSER HIGH PRESSURE HOSE
– 64 –
Technical Data Vivaro
Additional heating circuit for G9U engine
radiator outlet pipe
radiator inlet pipe clamp
clamp
clampunder body ridgid pipes
clamp
radiator
heater unit
add. Heating
return pipe
Alternator
Depending on the version and connections, the X83 vehicles can be equipped with one of the twofollowing generators:
– 110 A alternator (F4R engine)– 125 A alternator (F4R, F9Q and G9U engines)
110 A alternator
MINIMUM OUTPUT AT 13.5 VOLT (INSTANTANEOUS VALUE) AFTER WARM-UP FOR Ω HOUR AT 3000 RPM AT 13.5 V
– 65 –
Technical Data Vivaro
Output curve
125 A alternator
MINIMUM OUTPUT AT 13.5 VOLT (INSTANTANEOUS VALUE); AFTER WARM-UP PERIOD FOR Ω HOURAT 3000 RPM AT 13.5 V
– 66 –
Technical Data Vivaro
Output curve
6 Options and Accessories
• Power take-off
The vehicle can be ordered with an optional power take-off in the form of a belt-driven pulley. A drive belt with the following specification is employed:
– Number of ribs: 6– Width (mm): 21.36 ± 0.5
– Length: 1795 ± 0,5
– Service life: 120,000 km (for standard compression characteristics)– Static tension of the belt in operation: 250 N per strand at 20 °C
Pulley and drive belt
Note: The output and torques which can be reached are considerably in excess of the specifiedvalues. Systematic calculations are necessary to determine the following values relating to the drive belt and pulley:
– Tension
– Service life
Contact the belt manufacturer in order to determine these values.
– 67 –
Technical Data Vivaro
Drive belt
pulley
• Additional Air Condition for engine versions F4R and F9Q
(only in conjunction with AC and power take-off).
An additional AC is available as an option for the combi and bus versions. In order to equip the vanwith an additional AC unit it must be retrofitted using combi components.
Procedure:
1 Use original condenser2 Use evaporator and condenser lines.3 Cut holes in floor panel (see illustration overleaf).4 Attach AC to rear panel inner lining (use existing bores)
(Note: Care is required with part numbers for intermediate pipe for L1 / L2 versions)
– 68 –
Technical Data Vivaro
TUBE
UNIT
LOW PRESSURE LINE
HIGH PRESSURE LINE
INTERMEDIATE LINE
CONDENSOR – EVAPORATOR DRIER HIGH-PRESSURE PIPE
EVAPROATOR – RECIVER DRIER LOW PRESSURE PIPE
CONDENSER
• Cutouts for additional AC lines, right side of vehicle, behind the rear wheel housing.
– 69 –
Technical Data Vivaro
4R = 5
1 TO 7,2
1 BO 7,2 x 14,249
75
67,3
35,5 35,5
68,5
• Auxiliary heater
An auxiliary heater is available as an option for the combi and bus versions. In order to equip the vanversion with an auxiliary heater, combi parts must be used.
Procedure:
1 For F4R engine, replace radiator outlet line with part number 91166712; for F9Q engine, replacethermostat outlet line with part number 91166712.
2 Replace the original heating radiator feed line with part number 91166713.
3 Connect heater unit to the new pipes in the engine compartment (route fixed lines under body,part number 91166732).
4 Install auxiliary heater unit (part number 91167501). For details of the tank filler pipe, see fuelsupply system.
(Note: For details of electrical connections, see section on “Electrics”)
Overall view
RADIATOR OUTLET HOSEVERSION WITH AUXILIARY HEATER
UNDERBODY LINE
HEAT EXCHANGER OUTLET HOSEVERSION WITH AUXILIARY HEATER
5 KW HEATER UNIT
– 70 –
Technical Data Vivaro
A A
FRO
NT A
XLE
1218
2079
2865
3345
1451
• Roof rack
Vivaro vehicles are fitted with roof rack fastening points, which constitute the only permissible fasteningpoints. The maximum permissible roof load is 200 kg for all vehicle versions. All the fastening pointsmust be used. If a shorter roof rack is used, the maximum permitted roof load is reduced by 25 kg foreach fastening point not used.It is recommend to use original parts (roof rack). If other manufacturers’ products are used, the attaching points must be identical to the original parts.The centre of gravity of the roof load must not be higher than 100 mm above the roof rack, i.e. approx. 200 mm above the van roof.
• Wind deflector
Important: Vivaro vehicles are not designed to be fitted with a roof spoiler, this option is thereforenot advisable.The roof would otherwise need to be fitted with suitable fastenings in order to avoid damage causedby vibration and wind pressure.
L1H1 van
– 71 –
Technical Data Vivaro
L2H1 van
Section A-A
(applies to versions L1 and L2)
88
|A 8,2
1451
3745
A A
FRO
NT A
XLE
1218
2079
2865
– 72 –
Technical Data Vivaro
• Trailer hitch
The maximum permissible trailer weight is 2000 kg (braked) and 750 kg (unbraked).The van and combi versions can be ordered with a pre-installed trailer hitch. All versions (including platform chassis) can be retrofitted with a trailer hitch.The maximum permissible tongue load is 80 kg. A telltale lamp indicating faulty trailer turn signallamps, is located on the instrument panel.
• Liftgate
The fastening holes for the trailer hitch can also be used as additional fastening points for a liftgate.These must not, however, be used as the only fastening points, as the forces exposured in this areawill result in damages of the underbody structure.
• Trailer hitch fastening points
– 73 –
Technical Data Vivaro
REAR SIDE MEMBER
REINFORCEMENT
3 M10 NUTS
LINK ELEMENT
DISTANCE FROM VEHICLE CENTRE
• Trailer hitch fastening points
– 74 –
Technical Data Vivaro
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