Mercedes Vito Viano 2005

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<ul><li><p>Vito/Viano Body/Equipment Mounting Directives </p></li><li><p>Mercedes-Benz Body/Equipment Mounting Directives for Vito/Viano as at: 20.07.2004</p><p>! Always print out complete sections from the current version.</p><p>Contents</p><p>1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 The aim of these Directives . . . . . . . . . . . . . . . 41.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Vehicle safety. . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . 7</p><p>2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 Vehicle and model designations . . . . . . . . . . . 82.2 Overview of Vito models . . . . . . . . . . . . . . . . . 92.2.1 Seating options in the Vito. . . . . . . . . . . . . . . 102.3 Overview of Viano models . . . . . . . . . . . . . . . 112.4 Technical advice for body/equipment </p><p>manufacturers . . . . . . . . . . . . . . . . . . . . . . . . 122.4.1 Certificate of endorsement . . . . . . . . . . . . . . 122.4.2 Issuing a certificate of endorsement . . . . . . . 132.4.3 Legal claims . . . . . . . . . . . . . . . . . . . . . . . . . . 132.5 Tender drawings, technical data, </p><p>product information/Mercedes-Benz body/equipment manufacturer system (MB-AS). . . 14</p><p>2.5.1 PC program (ISDN/modem) . . . . . . . . . . . . . 142.5.2 Faxback system . . . . . . . . . . . . . . . . . . . . . . . 142.5.3 Workshop Information System (WIS) . . . . . . . 142.6 Product liability . . . . . . . . . . . . . . . . . . . . . . . 152.7 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . 162.8 Mercedes star and logo . . . . . . . . . . . . . . . . . 172.9 Accident prevention . . . . . . . . . . . . . . . . . . . . 182.10 Reprocessing components recycling . . . . . 192.11 Quality assurance system . . . . . . . . . . . . . . . 20</p><p>3 Planning conversions . . . . . . . . . . . . . . . . . 213.1 Vehicle selection . . . . . . . . . . . . . . . . . . . . . . 213.2 Vehicle modifications. . . . . . . . . . . . . . . . . . . 223.3 Dimensions and weights . . . . . . . . . . . . . . . . 233.3.1 Weight distribution. . . . . . . . . . . . . . . . . . . . . 233.4 Vehicle identification data . . . . . . . . . . . . . . . 253.5 Vehicle stability . . . . . . . . . . . . . . . . . . . . . . . 263.6 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.7 Bolted and welded connections . . . . . . . . . . . 283.7.1 Bolted connections . . . . . . . . . . . . . . . . . . . . 283.7.2 Welded connections. . . . . . . . . . . . . . . . . . . . 293.8 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . 323.9 Maintenance and repairs . . . . . . . . . . . . . . . . 333.9.1 Preparation for storing the vehicle. . . . . . . . . 333.9.2 Battery maintenance and storage . . . . . . . . . 343.9.3 Preparation for handing over the </p><p>converted vehicle. . . . . . . . . . . . . . . . . . . . . . 343.10 Optional equipment . . . . . . . . . . . . . . . . . . . . 35</p><p>4 Technical threshold values for planning. . 364.1 Basic vehicle threshold values . . . . . . . . . . . . 364.1.1 Steerability. . . . . . . . . . . . . . . . . . . . . . . . . . . 364.1.2 Extreme permissible positions of centre of </p><p>gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.1.3 Parts which must not be welded . . . . . . . . . . 364.1.4 Parts which must not be welded . . . . . . . . . . 364.1.5 Parts in which holes may not be drilled . . . . . 364.2 Chassis threshold values . . . . . . . . . . . . . . . . 374.2.1 Permissible axle loads . . . . . . . . . . . . . . . . . . 374.2.2 Approved tyre sizes . . . . . . . . . . . . . . . . . . . . 374.2.3 Turning circle diameter . . . . . . . . . . . . . . . . . 374.2.4 Modifications to the axles . . . . . . . . . . . . . . . 374.2.5 Modifications to the steering system. . . . . . . 374.2.6 Modifications to the brake system . . . . . . . . 384.2.7 Modifications to the springs/spring mountings/</p><p>shock absorbers . . . . . . . . . . . . . . . . . . . . . . 384.2.8 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . 384.3 Bodyshell threshold values . . . . . . . . . . . . . . 394.3.1 Modifications to the bodyshell. . . . . . . . . . . . 394.3.2 Vehicle roof/roof load. . . . . . . . . . . . . . . . . . 394.4 Engine periphery/drive train threshold </p><p>values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404.4.1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 404.4.2 Modifications to the engine/drive train </p><p>parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404.5 Interior threshold values . . . . . . . . . . . . . . . . 414.5.1 Modifications to the airbags and belt </p><p>tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 414.5.2 Modifications to the seats . . . . . . . . . . . . . . . 414.6 Electrical system/electronics threshold </p><p>values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424.6.1 Electrical lines/fuses . . . . . . . . . . . . . . . . . . 424.6.2 Vehicle outline and side marker lamps . . . . . 424.6.3 Retrofitting electrical equipment </p><p>("e" mark). . . . . . . . . . . . . . . . . . . . . . . . . . . . 424.6.4 Mobile communications systems. . . . . . . . . . 424.6.5 CAN bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424.6.6 Electronic Stability Program . . . . . . . . . . . . . 424.7 Additional equipment threshold values . . . . . 43</p><p>5 Damage prevention . . . . . . . . . . . . . . . . . . . 445.1 Brake hoses/cables and lines. . . . . . . . . . . . 445.2 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . 455.3 Corrosion protection measures . . . . . . . . . . . 465.4 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485.5 Towing and tow-starting. . . . . . . . . . . . . . . . . 495.6 Storing and delivering the vehicle . . . . . . . . . 505.7 Electromagnetic compatibility (EMC). . . . . . . 51</p></li><li><p>Mercedes-Benz Body/Equipment Mounting Directives for Vito/Viano as at: 20.07.2004</p><p>! Always print out complete sections from the current version.</p><p>Contents</p><p>6 Modifications to the basic vehicle. . . . . . . 526.1 Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526.1.1 Basic chassis . . . . . . . . . . . . . . . . . . . . . . . . . 526.1.2 Springs/shock absorbers . . . . . . . . . . . . . . . 526.1.3 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . 536.1.4 Pneumatic suspension . . . . . . . . . . . . . . . . . . 546.1.5 Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . 556.1.6 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 556.2 Bodyshell/bodywork . . . . . . . . . . . . . . . . . . . 566.2.1 General notes on the bodyshell/</p><p>bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566.2.2 Modifying the partition. . . . . . . . . . . . . . . . . . 576.2.3 Sidewall, windows, doors and flaps . . . . . . . . 576.2.4 Wings and wheel arches . . . . . . . . . . . . . . . . 586.2.5 Chassis end cross-member . . . . . . . . . . . . . . 586.2.6 Bodyshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586.2.7 Underbody panelling . . . . . . . . . . . . . . . . . . . 596.2.8 Roof of panel van/Traveliner . . . . . . . . . . . . 596.3 Engine periphery/drive train . . . . . . . . . . . . . 616.3.1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 616.3.2 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 616.3.3 Engine cooling . . . . . . . . . . . . . . . . . . . . . . . . 616.3.4 Engine air intake . . . . . . . . . . . . . . . . . . . . . . 626.3.5 Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . 626.4 Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636.4.2 Safety equipment. . . . . . . . . . . . . . . . . . . . . . 636.4.3 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686.4.4 Reducing noise in the vehicle interior . . . . . . 696.4.5 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.5 Electrical system/electronics . . . . . . . . . . . . 706.5.1 General notes. . . . . . . . . . . . . . . . . . . . . . . . . 706.5.2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706.5.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716.5.4 Power supply interfaces . . . . . . . . . . . . . . . 716.5.5 Retrofitting electrical equipment . . . . . . . . . . 766.5.6 Mobile communications systems. . . . . . . . . . 766.5.7 Electrical lines/CAN bus . . . . . . . . . . . . . . . . 776.5.8 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . 816.5.9 Electronic Stability Program (ESP) . . . . . . . . 826.5.10 Electromagnetic compatibility (EMC). . . . . . . 836.5.11 Retrofitting an alternator . . . . . . . . . . . . . . . . 83</p><p>6.6 Additional equipment. . . . . . . . . . . . . . . . . . . 856.6.1 Retrofitting the air conditioning . . . . . . . . . . . 856.6.2 Auxiliary heating . . . . . . . . . . . . . . . . . . . . . . 856.6.3 Power take-offs . . . . . . . . . . . . . . . . . . . . . . . 856.7 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 866.7.1 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 866.7.2 Attachment above cab. . . . . . . . . . . . . . . . . . 866.7.3 Roof rack . . . . . . . . . . . . . . . . . . . . . . . . . . . 866.7.4 Fitted shelving . . . . . . . . . . . . . . . . . . . . . . . . 866.7.5 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . 87</p><p>7 Conversion work . . . . . . . . . . . . . . . . . . . . . 887.1 Modifications to the interior . . . . . . . . . . . . . 887.1.1 Modifications to the cockpit . . . . . . . . . . . . . 887.1.2 Retrofitting additional seats. . . . . . . . . . . . . . 887.2 Modifications to closed panel vans . . . . . . . . 897.3 Refrigerated vehicles . . . . . . . . . . . . . . . . . . . 917.4 Motor caravans . . . . . . . . . . . . . . . . . . . . . . . 927.5 Retrofitting a raised roof . . . . . . . . . . . . . . . . 937.6 Increasing the roof height . . . . . . . . . . . . . . . 94</p><p>8 Technical data . . . . . . . . . . . . . . . . . . . . . . . 958.1 Vito 109 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 958.2 Vito 111 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 978.3 Vito 115 CDI . . . . . . . . . . . . . . . . . . . . . . . . . 998.4 Vito 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018.5 Vito 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1038.6 Viano CDI 2.0/CDI 2.2 . . . . . . . . . . . . . . . . 1058.7 Viano 3.0/3.2 . . . . . . . . . . . . . . . . . . . . . . . 107</p></li><li><p>Mercedes-Benz Body/Equipment Mounting Directives for Vito/Viano as at: 20.07.2004</p><p>! Always print out complete sections from the current version.4</p><p>1 Introduction</p><p>These Body/Equipment Mounting Directives provide the body manufacturers with important technical infor-mation about the basic vehicle. This information must be observed by the body manufacturer in the production of bodies and their equipment, fittings and conversions. </p><p>Due to the great number of body manufacturers and body types, DaimlerChrysler AG cannot foresee all pos-sible changes, e.g. to road performance, stability, load distribution, the vehicle's centre of gravity and its han-dling characteristics, caused by bodies and their equip-ment, fittings and conversions. For this reason, DaimlerChrysler AG can assume no liability for accidents or injuries caused by such modifications to your vehicle, even if these modifications have an adverse affect on the complete vehicle. As a manufacturer, DaimlerChrysler AG is accordingly only liable for its own designs and products. The body manufacturer itself, as manufacturer of the complete vehicle, is obliged to make sure that bodies and their equipment, fittings and con-versions are not faulty and that they cannot lead to faults or hazards on the complete vehicle. If this obligation is violated in any way, the body manufacturer will assume full product liability. By drawing up these Body/ Equip-ment Mounting Directives, DaimlerChrysler AG fulfils its obligation to brief the body manufacturers and inform them of important aspects to observe when carrying out conversions. </p><p>These Body/Equipment Mounting Directives are intend-ed primarily for professional manufacturers of bodies and add-on equipment and who carry out fittings and conversions of our vehicles. For this reason, these Body/Equipment Mounting Directives assume that the body manufacturer possesses the necessary back-ground knowledge. If you intend to carry out work on bodies and their equipment, fittings or conversions, please be aware that certain types of work (e.g. welding work on load-bearing components) may only be carried out by qualified personnel. This will avoid the risk of inju-ry and will attain the degree of quality required for bodies and their equipment, fittings and conversions.</p><p>1.1 The aim of these Directives The following Body/Equipment Mounting Directives are divided into 8 related sections to help you to find infor-mation quickly:</p><p>1. Introduction</p><p>2. General</p><p>3. Planning conversions</p><p>4. Technical threshold values for planning</p><p>5. Damage prevention</p><p>6. Modifications to the basic vehicle</p><p>7. Conversion work</p><p>8. Technical data</p><p>Appendix:</p><p>- Index</p><p>You can obtain further information and technical data from the tender drawings in the Mercedes-Benz body/equipment manufacturer system ( page 14).The index, in PDF format, is linked to help you find infor-mation quickly.</p><p>The threshold values chosen in section 4 must be ad-hered to and must form the basis of planning. </p><p>The sections entitled "Modifications to the basic vehicle" and "Conversions specifications" are the main source of technical information contained in these Body/ Equip-ment Mounting Directives. </p></li><li><p>Mercedes-Benz Body/Equipment Mounting Directives for Vito/Viano as at: 20.07.2004</p><p>! Always print out complete section from the current version.</p><p>1.2 Symbols</p><p>1 Introduction</p><p>5</p><p>1.2 SymbolsYou will find the following symbols used in these direc-tives: </p><p> page This symbol indicates the page on which you will find further information on the subject.</p><p>This continuation symbol indicates an inter-rupted sequence of actions that will be con-tinued on the next page.</p><p>Warning GA warning draws your attention to possible risks of ac-cident and injury to yourself and others.</p><p>Environmental note HAn environmental note gives you tips on the protec-tion of the environment.</p><p>!This note draws your attention to possible hazards to your vehicle.</p><p>iThis tip contains advice or further information you may find useful.</p></li><li><p>Mercedes-Benz Body/Equipment Mounting Directives for Vito/Viano as at: 20.07.2004</p><p>! Always print out complete section from the current version.</p><p>1.3 Vehicle safety</p><p>1 Introduction</p><p>6</p><p>1.3 Vehicle safety</p><p>Notes on vehicle safety</p><p>We recommend the following:</p><p>Use only parts and assemblies or recommended conver-sion parts and ac...</p></li></ul>

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