SUPPLEMENT TO THE CONVERSION GUIDELINE MOVANO – …

MOVANO (X62)200 – CONVERSION LIMIT: DIMENSIONS

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source ofup-to-date data on body guidelines (online body guidelines). Data status September 2014

SUPPLEMENT TO THE CONVERSION GUIDELINE MOVANO – CHAPTER 200

1. INTRODUCTION

For all conversions it is necessary to observe the following chapters of the Conversion Guideline:

Chapter 7 – MAIN VIEWS AND DIMENSIONS

Chapter 22 – WHEELBASE EXTENSION FOR CHASSIS CAB AND PLATFORM CAB

Chapter 23 – MODIFYING THE REAR OVERHANG

Chapter 40 – CONVERSION LIMITS WITH ESP

Chapter 79 – MAXIMUM AUTHORIZED LOAD PER AXLE

Chapter 148 – DETERMINING THE CENTER OF GRAVITY

Note:

The permissible axle loads, gross vehicle weights and center of gravity locations must becomplied with. Further information regarding permissible weights is contained on the vehicletype identification plates on the vehicle itself.

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

It is prohibited to cut the rear attachment of the leaf spring and the rear end cross member.

When installing a new coupling, plan for a validation, in compliance with regulatory requirements.

Conversions (extension or shortening of the overhang) must not disrupt the correct operation ofthe ESP (load distribution variation).



2. MODIFICATION OF THE REAR OVERHANG [Summary of chapter 23 - MODIFYING THE REAR OVERHANG]

2.1. CHASSIS SINGLE CAB AND CREW CAB

2.1.1. Extension of the rear overhangThe extension area is located between the rear suspension attachments (3) and the rear end crossmember (5).For Rear-wheel-drive versions, the maximum authorised overhang for the loading compartment (D2) ismore restrictive than the maximum-extension overhang (D1); see table in Section 5. The space betweenthe end of the loading compartment and the maximum extension may only be employed to installcomponents solely used statically; example: tailgate.The reinforcements in the side members (point 6) must be kept. If a modification is made, these sidemembers must be reinforced by equivalent parts.An extension of more than 385 mm requires one or more cross members to be added.The rear tow eye function must be kept.

REAR CHASSIS: AERIAL VIEW (WITH CLOSURE ELEMENTS REMOVED)

1 2 3 4

5

6

It is essential that the extension to the overhang keep or add additional reinforcements to each sidemember (see 6, view above), located in line with the rear leaf spring attachments (see 3, view above).

1: Rear axle front attachment

2: Rear axle + wheel

3: Rear axle rear attachment

4: Cutting area

5: Rear end cross member

6: Side member internal reinforcement



CHASSIS SINGLE CAB and CREW CAB

front axle rear axle

1 = Crew Cab2 = Extension of rear overhangD = Standard rear overhangD1 = Maximum rear overhangD2 = Loading compartment rear overhangZ4 = Distance between the centre of gravity of the loading and the rear axle

The dimensions ( D; D1; D2; Z4) of the vehicle see chapter 7.

D 2

D1

Z4 D2F1



2.1.2. Shortening of the rear overhang

The shortening of the rear overhang shall apply to the versions with rear-wheel drive for the chassis withsingle cab and crew cab.

The shortening area is located between the rear bracket of the rear suspension (3) and the rear crossmember (5). See first picture “REAR CHASSIS: AERIAL VIEW”.

If a tow bar is installed, reinforcements should be planned accordingly.

CHASSIS SINGLE CAB and CREW CAB (with RWD)


1 = Crew Cab2 = Shortened rear overhangD = Standard rear overhangZ4 = Distance between the centre of gravity of the loading and the rear axle

The dimensions (D; Z4) of the vehicle, see chapter 7.

2

Z4 DF1



2.2.PLATFORM CAB

It is prohibited to cut the rear attachment of the leaf spring and the rear end cross-member in the platformcab version.

In the case of the fitting of a tow bar it is the responsibility of the converter to observe the regulations.

Depending on the overhang extension, one or more under-floor reinforcing cross members may be addedbetween the main side members.


2 = Extension of rear overhangD = Standard rear overhangD1 = Maximum rear overhangZ4 = Distance between the centre of gravity of the loading and the rear axle

The dimensions (D; D1; Z4) of the vehicle, see chapter 7.

Z4 D1

D 2

F



3. EXTENSION OF THE WHEELBASE [Summary of chapter 22 - WHEELBASE EXTENSION FOR CHASSIS CAB ANDPLATFORM CAB]

Opel / Vauxhall does not allow any lengthening of the wheelbase on its rear-wheel-drive vehicles.

For front-wheel drive vehicles with a wheelbase of 4332 mm, lengthening by 10% is possible, except onthe version with ESP.

Changing the wheelbase leads to a variation in the distribution of loads on the axles.

For any wheelbase lengthening operation, this variation must be taken into account and it must beensured that the maximum permissible load values per axle are respected. (cf. chapter 79)

The converter is solely liable for impacts relating to the conversion on the basic vehicle.

The following instructions must be followed with regard to the braking control system:

• No changes to the hoses• No change to the handbrake cables, but lengthened control rod.• Compliance with the handbrake adjustment procedure.

3.1. CHASSIS SINGLE-CAB & CREW-CAB WITHOUT ESP

The recommended splice line has been determined based on considerations of structural soundness(maintenance of tank and exhaust interfaces) and the existence of cross-members and reinforcements.

CHASSIS SINGLE CAB and CREW CAB

rear axle

2615 mm X


X = Wheelbase extension



3.2. PLATFORM CAB without ESP

The recommended splice line has been determined based on considerations of structural soundness(maintenance of the tank and exhaust interfaces) and the location of cross members and reinforcements.The splice line is located 2460 mm behind the front axle.

For a large extension to the wheelbase (10% max.), depending on the floor panel used, one or two underfloor reinforcement cross members may be added between the main side members

PLATFORM CAB

rear axle

2460 mm X


X = Wheelbase extension



4. CONVERSION LIMITS WITH ESP [Summary of chapter 40 – CONVERSION LIMITS WITH ESP]

COMPLIANCE WITH THE CENTRE OF GRAVITYCalculating the centre of gravity



4.1. CENTRE OF GRAVITY POSITION OF THE CONVERTED VEHICLE

The centre of gravity of the converted vehicle must be calculated when the vehicle is:

- Laden = GVW (Gross Vehicle Weight) with technical maximum permitted on one axle

To ensure that the ESP functions properly, the centre of gravity position of the converted vehicle, whenladen, must remain within the limits of the red frame V.

The tolerance for X and Y is ± 8%

Only the Z position of the centre of gravity when laden (GVW) should be taken into consideration.

Please refer to the following tables for the limits "V" of each vehicle type.

FRONT WHEEL DRIVE

Wheelbase X mini/maxi (mm) Y (mm) Z maxi (mm)

Panel Van andPlatform Cab,GVW = 3,5t,

3182 1657/2097

Y ± 85

1100

3682 1770/2435 1100

4006camper van

1945/23301100 or

1150 (wider axle)

4332 1774/2742 1100

Opelair suspension As above 1000

Bus GVW = 3,9t 4332 As above 1050



REAR WHEEL DRIVE


Panel vanGVW = 3,5t,single wheels

3682 1857/2652

Y ± 85

1050

Panel vanGVW = 4,5ttwin wheels

3682 1887/2975 1100

4332 2068/3412 1100

FRONT WHEEL DRIVE


Chassis Cab andCrew CabGVW = 3,5t

3682 1603*/2548

Y ± 85

1100

4006camper van

1945/2330 1100 or1150 (wider axle)

4332 1756/2992 1100

Opelair suspension As above 1000

REAR WHEEL DRIVE


Chassis Caband Crew CabGVW = 3,5tsingle wheels

3682 1852/2522

Y ± 85

1050

4332 1972/2907 1050

Chassis Cab andCrew CabGVW = 4,5ttwin wheels

3682 1782/3059 1100

4332 1835/3502 1100

Note:- For the calculation of the centre of gravity and its position on the basic vehicle, see

chapter 148.- The X dimensions are given in relation to the centre of the FRONT wheel- The Y dimensions are given in relation to the centreline of the vehicle- The Z dimensions are measured



4.2.MODIFICATIONS AFFECTING THE OPERATION OF THE ESP

The table below details the modifications of parts or functions:

* : the operation of ESP is greatly affected by this type of transformation

** : the operation of ESP is likely to be affected if the corresponding comments are not compliedwith.

Modification Detail s * ** Comments

Structure

Wheelbase X

Body stiffness X

Maximum 30% reduction in bodytorsional stiffness along the Xaxis (measured between the twoaxles) pre- and post-conversion.

Tracks X

Chassis

Suspension (springs, travellimits, anti-roll bars, shockabsorbers)

XAnything that changes thestiffness and/or elasto-kinematics of the suspension.

Tyres (dimensions,stiffness, etc.) X

Only tyres with characteristicsidentical to standard tyres(dimensions, load index, speedcode)

Only if different fromstandard tyres

Ratio of the steering wheeland wheels X

Braking system XOnly one modification of therigid pipe routing is permitted.

Power train Engine, gearbox X

Electromagnetic retarder X

The sensors connected to theESP (steering wheel angle, wheelspeed, lateral acceleration, yawangle)

Displacement andmodification of theinstallation

X

CAN - Bus X

Roof rack XComply with the permitted loadon the standard version.

Trailer(semi-trailer) X

Modifications to the sensors(steering angle sensor, yaw ratesensor, wheel rotational speedsensor).

X

Modifications to the permissiblegross vehicle weight. X



4.3.DEACTIVATION OF THE "ESP" OPTION

The deactivation consists of removing the traction-control and stability-control functions.If ESP has been deactivated, the driver will then have to adapt his / her style of driving accordingly.Otherwise the driver could lose control of the vehicle and cause an accident, especially when drivingnear the system's limits.For this reason, the converter will have to put a well visible warning sticker on the dashboard that theESP has been disabled. The converter must point to the changed handling characteristics of thevehicle. The label is to be developed and put in place by the converter

Proposed location of the warning sticker



5. USEFUL DIMENSIONS [Summary of chapter 7 - MAIN VIEWS AND DIMENSIONS ]

On the rear-wheel-drive versions the basic values to be taken into account for the length conversionsare D2, Z3.1 and Y, on the front-wheel-drive versions they are D1, Z3 and Z4.



CHASSIS CAB

FRONT-WHEEL DRIVE

LENGTH L2 L3 L25

ROOF HEIGHT H1 H1 H1

GVW Gross Vehicle Weight [kg] 3,500 3,500 3,500

Leng

th

Basi

cve

hicl

e

A Wheelbase [mm] 3,682 4,332 4,006

C Front overhang [mm] 842 842 842

ADAP01 Cabin length [mm] 1,616 1,616 1,616

D Rear overhang [mm] 1,119 1,119 1,119

B Overall length [mm] 5,643 6,293 5,967

Max

imum

exte

nsio

n

D1 Maximum rear overhang [mm] 1,400 2,124 1,774

Z3 Extendible length- Dimension without gap/cabin.For conversions, werecommends a gap > 30mmOverall cargo area length

Min./Max.[mm]

3,184/3,466

3,834/4,840

3,508/4,164

Z4 Centre of gravity of the loadedconversion/Rear wheel axis

the mostadvanced 905 948 927

the mostretracted 331 294 306

Wid

th Basi

cve

hicl

e G Overall width(without rearview mirrors)

[mm] 2,070 2,070 2,070

G1 Overall width withseries rearview mirrors/extended rearview mirrors

[mm]2,470/2,654

2,470/2,654

2,470/2,654

Max

imum

exte

nsio

n G2 Maximum overall cargo-areawidth forseries rearview mirrors/extended rearview mirrors

[mm]2,170/2,350

2,170/2,350

2,170/2,350

Hei

ght

Basi

cve

hicl

e

H overall height(at kerb weight)

Min./max.[mm]

2,259/2,265

2,252/2,258

2,256/2,261

Max

imum

exte

nsio

n

H1 Maximum- overall height(at kerb weight)

[mm] 3,500 3,500 3,500



CHASSIS CAB

REAR -WHEEL DRIVE

LENGTHL2

SINGLEWHEEL

L3SINGLEWHEEL

L2TWIN

WHEELS

L3TWIN

WHEELS

L4TWIN

WHEELS

ROOF HEIGHT H1 H1 H1 H1 H1

GVW Gross Vehicle Weight [kg] 3,500 3,500 3,500/4,500

3,500/4,500

3,500/4,500

Leng

th

Basi

cve

hicl

e

A Wheelbase [mm] 3,682 4,332 3,682 3,682 4,332

C Front overhang [mm] 842 842 842 842 842

ADAP01 Cabin length [mm] 1,616 1,616 1,616 1,616 1,616

D Rear overhang [mm] 1,119 1,119 1,119 1,669 1,669

B Overall length [mm] 5,643 6,293 5,643 6,193 6,843

Max

imum

exte

nsio

n

D1 Maximum rear overhang [mm] 2,230 2,210 2,210 2,210 2,754

Z3 Extendible length- Dimension without gap/ cabin. Forconversions, Opel/ Vauxhallrecommends a gap > 30mmOverall cargo area length

Min./ Max.[mm]

3,184/4,295

3,834/4,926

3,184/4,276

3,734/4,275

4,384/5,470

Load

ing-

com

part

men

tm

axim

umex

tens

ion

D2 Rear overhang (loadingcompartment)

[mm] 2,100 2,100 2,100 2,100 2,100

Z3.1 Loading-compartment extendiblebody length - Dimension withoutgap/cabin. For conversions, werecommends a gap > 30mmOverall cargo area length

Min./ Max.[mm]

3,184/4,165

3,834/4,816

3,184/4,165

3,734/4,166

4,384/4,816

Z4 Centre of gravity of the loadedconversion/ Rear wheel axis

[mm]

the mostadvanced 1,007 1,062 578 578 562

the mostretracted -83 -160 68 68 -21

Wid

th

Basi

cve

hicl

e

G Overall width(without rearview mirrors)

[mm] 2,070 2,070 2,070 2,070 2,070

G1 Overall width withseries rear view mirrors/extended rear view mirrors

[mm]2,470/2,654

2,470/2,654

2,470/2,654

2,470/2,654

2,470/2,654

Max

imum

exte

nsio

n

G2 Maximum overall cargo-area widthfor series rearview mirrors/extended rearview mirrors

[mm]2,170/2,350

2,170/2,350

2,170/2,350

2,170/2,350

2,170/2,350

Hei

ght

Basi

cve

hicl

e


Min./max.[mm]

2,279/2,284

2,270/2,276

2,278/2,283

2,278/2,283

2,267/2,273

Max

imum

exte

nsio

n

H1 Maximum-overall height(at kerb weight)

[mm] 3,500 3,500 3,500 3,500 3,500



CHASSIS CREW CAB

FRONT-WHEEL DRIVE

LENGTH L2 L3

ROOF HEIGHT H1 H1

GVW Gross Vehicle Weight [kg] 3,500 3,500

Leng

th

Basi

cve

hicl

e

A Wheelbase [mm] 3,682 4332

C Front overhang [mm] 842 842

ADAP01 Cabin length [mm] 2,366 2,366

D Rear overhang [mm] 1,119 1,119

B Overall length [mm] 5,643 6,293

Max

imum

exte

nsio

n

D1 Maximum rear overhang [mm] 1,200 2,078

Z3 Extendible length- Dimension without gap/cabin.For conversions, werecommends a gap > 30mmOverall cargo area length

Min./Max.[mm]

2,434/2,516

3,084/4,044

Z4 Centre of gravity of the loadedconversion/Rear wheel axis

the mostadvanced 483 24

the mostretracted 97 -58

Wid

th

Basi

cve

hicl

e


[mm] 2,070 2,070

G1 Overall width withseries rearview mirrors/extended rearview mirrors

[mm]2,470/2,654

2,470/2,654

Max

imum

exte

nsio

n G2 Maximum overall cargo-areawidth forseries rearview mirrors/extended rearview mirrors

[mm]2,170/2,350

2,170/2,350

Hei

ght

Basi

cve

hicl

e


Min./max.[mm]

2,266/2,272

2,258/2,263

Max

imum

exte

nsio

n

H1 Maximum- overall height(at kerb weight)

[mm] 3,500 3,500



CHASSIS CREW CAB

REAR -WHEEL DRIVE

LENGTHL2

SINGLEWHEEL

L3SINGLEWHEEL

L3TWIN

WHEELS

L4TWIN

WHEELS

ROOF HEIGHT H1 H1 H1 H1

GVW Gross Vehicle Weight [kg] 3,500 3,500 3,500/4,500

3,500/4,500

Leng

th

Basi

cve

hicl

e

A Wheelbase [mm] 3,682 4,332 3,682 4,332

C Front overhang [mm] 842 842 842 842

ADAP01 Cabin length [mm] 2,366 2,366 2,366 2,366

D Rear overhang [mm] 1,119 1,119 1,669 1,669

B Overall length [mm] 5,643 6,293 6,193 6,843

Max

imum

exte

nsio

n

D1 Maximum rear overhang [mm] 1,917 2,960 2,100 2,471

Z3 Extendible length- Dimension without gap/ cabin.For conversions, we recommends agap > 30mmOverall cargo area length

Min./ Max.[mm]

2,434/3,232

3,084/4,926

2,985/3,416

3,635/4,436

Load

ing-

com

part

men

tm

axim

umex

tens

ion

D2 Rear overhang (loadingcompartment)

[mm] 1,917 2,100 2,100 2,100

Z3.1 Loading-compartment extendiblebody length - Dimension withoutgap/cabin. For conversions, werecommends a gap > 30mmOverall cargo area length

Min./ Max.[mm]

2,434/3,232

3,084/4,066

2,985/3,416

3,635/4,065

Z4 Centre of gravity of the loadedconversion/ Rear wheel axis.

[mm]

the mostadvanced 648 152 263 -1

the mostretracted -200 -200 -131 -200

Wid

th

Basi

cve

hicl

e


[mm] 2,070 2,070 2,070 2,070

G1 Overall width withseries rear view mirrors/extended rear view mirrors

[mm]2,470/2,654

2,470/2,654

2,470/2,654

2,470/2,654

Max

imum

exte

nsio

n


[mm]2,170/2,350

2,170/2,350

2,170/2,350

2,170/2,350

Hei

ght

Basi

cve

hicl

e


Min./max.[mm]

2,290/2,295

2,280/2,285

2,295/2,301

2,282/2,286

Max

imum

exte

nsio

n


[mm] 3,500 3,500 3,500 3,500



PLATFORM CAB

FRONT -WHEEL DRIVE

LENGTH L1 L2 L3

ROOF HEIGHT H1 H1 H2 H1 H2

GVW Gross Vehicle Weight [kg] 3,500 3,500 3,500 3,500 3,500

Leng

th

Basi

cVe

hicl

e

A Wheelbase [mm] 3,182 3,682 3,682 4,332 4,332

C Front overhang [mm] 842 842 842 842 842

ADAP01 Cabin length [mm] 1,596 1,596 1,596 1,596 1,596

D Rear overhang [mm] 1,006 1,006 1,006 1,006 1,006

B Overall length (C+A+D) [mm] 5,030 5,530 5,530 6,180 6,180

Max

imum

exte

nsio

n

B1 Maximum-overall length of thevehicle (C+A+D1)

[mm] 5,030 5,751 5,790 7,364 7,364

D1 Maximum rear overhang [mm] 1,006 1,227 1,266 2,190 2,190

Z3 Extendible body lengthOverall cargo area length

Min./ Max.[mm]

2,591/2,591

3,091/3,313

3,091/3,352

3,741/4,926

3,741/4,926

Z4 Centre of gravity of the loadedconversion/ Rear wheel axis.

[mm]

the mostadvanced 851 999 981 1,092 1,068

the mostretracted 279 418 398 433 408

Wid

th

Basi

cve

hicl

e


[mm] 2,070 2,070 2,070 2,070 2,070

G1 Overall width with series rear viewmirrors/ extended rear view mirrors

[mm]2,470/2,654

2,470/2,654

2,470/2,654

2,470/2,654

2,470/2,654

Max

imum

exte

nsio

n


[mm]2,170/2,350

2,170/2,350

2,170/2,350

2,170/2,350

2,170/2,350

Hei

ght

Basi

cve

hicl

e


Min./max.[mm]

2,270/2,276

2,264/2,270

2,457/2,463

2,258/2,264

2,451/2,457

Max

imum

exte

nsio

n


[mm] 3,500 3,500 3,500 3,500 3,500

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SUPPLEMENT TO THE CONVERSION GUIDELINE MOVANO – …