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Mercedes-Benz Metris BM 447, Body & Equipment Manualline

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Mercedes-Benz Metris BM 447 Body & Equipment Manualline Download Page 95

Mercedes-Benz Body & Equipment Guideline for Metris - BM 447, Version November 27, 2015.

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Please observe the revision notes compared to 09/18/2015 ! Only print out complete sections of the current version!

95

8.4 Retrofitting a pop-up roof

8 Design of bodies

8.4 

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.

Summary of Contents for Metris BM 447

Page 1: ...Body Equipment Guideline for Vans Metris Date of Publication November 2015 2015 Mercedes Benz USA LLC ...

Page 2: ...eaded connections 38 4 7 2 Welded connections 39 4 8 Soundproofing 42 4 9 Maintenance and repairs 43 4 9 1 Storing the vehicle 44 4 9 2 Battery maintenance and storage 45 4 9 3 Work before handing over the modified vehicle 45 4 10 Special equipment 46 5 Technical threshold values for planning 47 5 1 Threshold values of basic vehicle 47 5 1 1 Steerability 47 5 1 2 Maximum permissible positions of c...

Page 3: ...ttery main switch 99 9 3 3 Additional battery 99 9 3 4 Backup battery code E34 101 9 3 5 Emergency battery 101 9 3 6 Battery maintenance and storage 101 9 4 Interfaces electrical lines 102 9 4 1 Electrical lines fuses 102 9 4 2 Cable extension 102 9 4 3 CAN bus and networking 103 9 4 4 Connecting additional electrical consumers 104 9 4 5 Current consumption via terminal strip 105 9 4 6 Retrofittin...

Page 4: ...ust obtain legal advice to ensure their compliance with the applicable laws and regulations This manual is updated regularly when new products are introduced and additional information is made available on these products The upfitter is responsible for ensuring that they always use the current valid version Read the Body Equipment Guideline before modifying or installing equipment in or on a Metri...

Page 5: ...ody Equipment Guideline is divided into 10 interlinked chapters to help you find the information you require quickly 1 Introduction e Page 4 2 General and regulatory e Page 15 3 Product information e Page 24 4 Planning of bodies e Page 31 5 Technical threshold values for planning e Page 47 6 Damage prevention e Page 55 7 Modifications to the basic vehicle e Page 61 8 Design of bodies e Page 91 9 E...

Page 6: ...e used in this guideline a a WARNING Warning notes draw attention to issues which could endanger the health or life of yourself or others H H Environmental note An environmental note gives you recommendation on the protection of the environment Note This note draws attention to possible damages to the vehicle i i Additional information This note points out any additional information e Page This sy...

Page 7: ...e not recommended as these may compromise safety durability or product integrity Note Please ensure that you observe the national vehi cle certification regulations because body related vehicle modifications can result in the upfitter being legally obliged to have the vehicle recertified This applies in particular to modifications which change the vehicle category under certification legislation m...

Page 8: ...ing technical data drawings and product brochures Nevertheless the upfitter is responsible for ensuring that their modifi cations do not impair the safety of the vehicle MBUSA and MBCAN represented by UPFITTER MAN AGEMENT VANS are not responsible for approving or rejecting modifications or equipment installations on the Metris which are carried out by upfitters dealers or other parties This is bec...

Page 9: ...nly print out complete sections of the current version 9 1 6 Contact 1 Introduction 1 6 Contact Please contact the representative of MBUSA and MBCAN for technical support and further information UPFITTER MANAGEMENT VANS USA Canada Contact person Department UPFITTER MANAGEMENT VANS Contact Via website or e mail Website www UpfitterPortal com ...

Page 10: ...r other party involved in the manufacturing and marketing of new motor vehicles and equipment DG parts DG parts Daimler Group are genuine parts and genu ine accessories intended for installation or attachment in or on vehicles components major assemblies and modules including exchange and replacement parts which are supplied by MBUSA and MBCAN or a parent company subsidiary or company owned sales ...

Page 11: ...he parts major assem blies conversion parts and accessories that are rec ommended by MBUSA and MBCAN for the vehicle model concerned All vehicle modifications which affect the certifi cation of the vehicle may result in hazards to road users or could have an adverse effect on exhaust and noise emissions The use of parts major assemblies conversion parts or accessories which have not been recommend...

Page 12: ...icle In this case no warranty can be provided 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 Metris Service Center for this purpose In particular work relevant to safety or on safety re lated systems must be carried...

Page 13: ...van This ensures that upfitters continue to comply with the legal regulations covering these components or equip ment items while also ensuring the ongoing safe operation of Metris vehicles In areas which are not subject to legal regulations upfitters may use other components conversion parts and accessory parts and adopt the warranty provided by the manufac turer of these parts If conversion part...

Page 14: ...configuration suspension track width tire width and tire pressure The load type and weight payload size shape and center of gravity height are also very important factors Modifications or the installation of additional accessories on or in a Metris vehicle by an upfitter or vehicle alterer can therefore affect the rollover stability of the vehicle The Office of Vehicle Safety Research of the NHTSA...

Page 15: ...the Environmental Protection Agency EPA and the California Air Resources Board CARB For further information on US vehicle safety standards please contact the National Highway Traffic Safety Administration NHTSA Information on the Canadian standards can be obtained from the Canadian environ mental and transport authorities Transport Canada Upon completion of a modified vehicle the upfitter is legal...

Page 16: ... VANS will not approve and does not recommend any modifications or installa tions on Metris vehicles which impair compliance with EPA CARB FMVSS or CMVSS standards or jeopardize the safety of the vehicle If you have any questions about the content of this sec tion please contact the MBUSA and MBCAN represen tatives listed below Contact person Name Michael D Scott Title Department Manager Depart me...

Page 17: ...ngines of the Metris are certified in accordance with the requirements of the US Environmental Protection Agency EPA the Cana dian environmental authorities and the CARB and fulfill the national exhaust emission standards in accor dance with Title II Section 206 of the Clean Air Act and 40 C F R 86 Proof of certification is provided by means of a Vehicle Emission Control Information VECI certifica...

Page 18: ...nd regulatory 2 2 3 Vehicle noise emission control infor mation All Metris vehicles are equipped with extensive NVH accessories Upfitters should consult an attorney regarding the applicable laws and regulations to determine whether modifications carried out on the Metris by the upfitter could jeopardize the certification of the vehicle The upfitter is also responsible for ensuring that the modific...

Page 19: ...e regarding these obligations For all other modifications and installations made by an upfitter the following applies Do not modify Metris components which are located in front of the rear panel of the cab on Metris models with a partition or in front of the seating reference point of Metris vehicles unless you are installing approved components e g air conditioning system radio which have been ap...

Page 20: ...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 b...

Page 21: ...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 ...

Page 22: ...y 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 upfitters 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 the...

Page 23: ...ete sections of the current version 23 2 6 Trademarks 2 General and regulatory 2 6 Trademarks The Mercedes Benz star and Mercedes Benz badge are trademarks of Daimler AG Mercedes Benz trademarks may not be removed or applied to another point without approval Mercedes Benz trademarks supplied separately must be attached at the points specified by Mercedes Benz ...

Page 24: ...ion 3 1 Vehicle and models 3 1 1 Vehicle and model designations Mercedes model Description M1PV126 Metris passenger van 126 inch wheelbase M1CA126 Metris cargo van 126 inch wheelbase 3 1 2 Vehicle and model illustrations Metris cargo van with 6 724 lbs 3 05 t gross vehicle weight rating GVWR 447 603 126 inch 3 200 mm wheelbase Metris passenger van with 6 724 lbs 3 05 t gross vehicle weight rating ...

Page 25: ... version 25 3 1 Vehicle and models 3 Product information Note Further information including data sheets and CAD data can be found online at www upfitterportal com 3 1 3 Load capacity van classification Mercedes model gross vehicle weight rating GVWR Load capacity Weight class Metris cargo van 6 724 Ibs 3 05 t 3 4 t Light Metris passenger van 6 724 Ibs 3 05 t Not specified Not specified ...

Page 26: ...nd 3 Code Manufacturer Brand Model WD3 Daimler AG Mercedes Benz Truck Cargo Van WD4 Daimler AG Mercedes Benz MPV Passenger Van Chassis configuration VIN digit 4 Code Chassis configuration target market P All 4x2 vehicle models USA B All 4x2 vehicle models Canada Model wheelbase gross vehicle weight rating GVWR VIN digits 5 and 6 Code Wheelbase Length gross vehicle weight rating GVWR G2 3 200 mm 5 ...

Page 27: ... version 27 3 2 Breakdown of Vehicle Identification Number VIN 3 Product information Check digit VIN digit 9 Calculated from the other VIN numbers based on a mathematical formula Model year VIN digit 10 Code Model year G 2016 Manufacturing plant VIN digit 11 Code Manufacturing location 3 Vitoria Spain Vehicle serial number VIN digit 12 17 Vehicle serial number from manufacturing plant ...

Page 28: ...r certifica tion purposes they simply illustrate the corresponding position Please consult the website of the NHTSA for information on vehicle labeling requirements www nhtsa gov www tc gc ca and the website of the EPA www epa gov 1 VIN label 2 Information on safety compliance 3 Identification plate with notice logo indicating con formity with safety standards 4 Airbag warning notice 5 Tire and ri...

Page 29: ...out complete sections of the current version 29 3 3 Labels 3 Product information 3 Identification plate with notice logo indicating con formity with safety standards example US vehicles Canada vehicles Position Driver side B pillar Unloaded vehicle weight information 4 Airbag warning notice Position Sun visor Position Passenger side glove compartment ...

Page 30: ...viate from the data shown in the illustrations Please see the informa tion in your vehicle for its actual data This label is applied to vehicles with a gross vehicle weight rating GVWR of less than 10 000 lbs 4 53 t a a WARNING Upfitters must attach new labels if equipment is installed which changes the payload of the vehicle Further information on wheels and loads can be found in chapter 4 6 Tire...

Page 31: ...lection of a suit able basic vehicle or chassis when planning work on the vehicle body Observe the following points Customized 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 Note In addition to a user friendly and easily maintained design the planning proc...

Page 32: ...g GVWR Position of the center of gravity Note Before carrying out body modifications the deliv ered vehicle must be submitted to a check to verify whether it fulfills the necessary requirements Further information on chassis and body types can be found in chapter 3 1 Vehicle and models e Page 24 or contact UPFITTER MANAGEMENT VANS 4 1 1 Selecting the suspension package Suspension package Passenger...

Page 33: ...des Benz USA LLC and Daimler Vans USA LLC and by access ing product information and technical data from the communications system see chapter 1 1 Overview e Page 4 Please also specify which additional equipment is being installed by the manufacturer www UpfitterPortal com National laws regulations and registration require ments must be complied with Note Adequate clearances must be maintained in o...

Page 34: ...l dimension and weight specifications 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 The gross axle weight rating GAWR and gross vehicle weight rating GVWR may not be exceeded Infor mation on the permissible axle load and permissible vehicle weight can be found in section 5 Technic...

Page 35: ...ion plate may neither be changed nor fitted to a different point on the vehicle The VIN is stamped into the longitudinal member in the engine compart ment next to the fuse box The identification plate with the VIN and information on the permissible weights is located on the B pillar on the driver side see chap ter Vehicle serial number from manufacturing plant e Page 27 Vehicle identification data...

Page 36: ...cle modifications intended for operation with loads with unfavorable centers of gravity e g loads at the rear end high loads and side loads as these aspects are primarily influenced by vehicle modification work and can therefore be assessed exclu sively by the upfitter a a WARNING When driving dynamics become critical the vehicle behaves like a vehicle without ESP The GAWR GVWR and center of gravi...

Page 37: ...nsion is fully com pressed also allowing for axle twist and that the relevant data in the 2D drawings from the web site are observed see chapter 1 1 Overview e Page 4 Only permissible tire sizes with the appropriate tire load capacity are used a a WARNING The tire load capacity must not be exceeded under any circumstances If the tire load capacity is exceeded this can impair the functionality of t...

Page 38: ...aimler AG The settling behavior of threaded connections must be taken into account Information about Metris after sales instructions is available from any qualified Mercedes Benz Metris dealer Additional components must exhibit an identical or higher strength than the previous clamped assembly The use of Metris tightening torque specifications requires a friction factor in the range of 0 08 to 0 1...

Page 39: ...the airbag control unit airbag sensors and seat belts must be protected from welding spatter or removed if necessary Parts of the floor and roof are laser welded The side wall cover is laser soldered to the roof side cover Choice of welding method The mechanical properties of weld seams depend on selecting an adequate welding method and on the geometry of the elements to be joined If overlapping s...

Page 40: ...e e Sheet thickness L Distance from sheet edge Gas shielded plug welding If overlapping sheets are only accessible from one side use either gas shielded 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 Ratio of sheet thickness to plug hole diameter D Plug hole diameter mm 4 5 5...

Page 41: ...ckness L Length of tack weld Do not perform any welding work on the following components Major assemblies such as the engine transmission axles etc Chassis except for frame extensions i i Additional information Further information can be found in chapters 5 Technical threshold values for planning e Page 47 and 6 Damage prevention e Page 55 as well as in section 7 2 Bodyshell body e Page 65 Corrosi...

Page 42: ...uch as the following Engine Exhaust system Intake air system Tires etc Noise measurements must be carried out and all national and state regulations and guidelines must be complied with Soundproofing parts must not be removed or modified This ensures that the vehicle continues to comply with the FMVSS CMVSS regulations on noise control Note The level of interior noise must not be adversely affecte...

Page 43: ... or removable rear panels The battery compartment must be sufficiently ven tilated with provision for air to enter and exit Check the condition and capacity of batteries and service them in accordance with the manufacturer s specifications e Page 45 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...

Page 44: ... maintenance instructions for the body and any additional assemblies installed 4 9 1 Storing the vehicle Storage in enclosed premises Clean the entire vehicle Check the oil and coolant levels Inflate the tires to 0 5 bar or 7 25 psi above the specified tire pressures Release parking brake and prevent vehicle from rolling away with chocks Disconnect the battery in a charged state at least 80 and lu...

Page 45: ...ged and it will have to be replaced 4 9 3 Work before handing over the modified vehicle Checking the overall vehicle Check that the vehicle is in perfect condition Repair any damage if necessary Checking the brake system The brake fluid must be renewed every two years If it is not known how long the vehicle has been in storage the brake fluid must be renewed Check electrical and hydraulic lines fo...

Page 46: ...ment We recommend the special equipment available from the manufacturer Please contact your qualified Mercedes Benz Metris dealer for more information on special equipment Special equipment or retrofitted equipment can change the unloaded vehicle weight The actual vehicle weight and axle loads must be deter mined by weighing before mounting Not all special equipment can be installed in every vehic...

Page 47: ...nformation in the other chapters of the current version of the Body Equipment Guideline 5 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 gross axle weight rating GAWR 5 1 2 Maximum permissible positions of center of gravity x axis SGx 1 700 mm where R1 ...

Page 48: ...lting in serious injury or death Furthermore any overloading may result in damage to the suspension and structural parts Information on the axle loads and maximum gross vehicle weight rating GVWR can be found in section 1 5 Technical support e Page 8 i i Additional information For further information on permissible axle loads refer to 2 General and regulatory e Page 15 a a WARNING The maximum cent...

Page 49: ...nformation about the tires rims assigned to the vehicle model and any limitations can be obtained from your contact persons see 1 6 Contact e Page 9 from the vehicle configurator at http www mercedes benz com GVWR lbs t Rim Tire size Load index 6 724 3 05 6 5 JX 17 225 55R17 101 6 724 3 05 7 J 17 225 55R17 101 Optional RL8 Aluminum wheel 5 2 3 Diameter of turning circle Wheelbase mm in Turning cir...

Page 50: ...s to the brake system On no account should modifications be made to the brake system On no account should modifications be made to the air inlet and air outlet vents for brake disks 5 2 7 Modifications to springs suspension strut mounts shock absorbers Only use springs and shock absorbers which match the properties of the series production parts or which are available as special equipment We recom...

Page 51: ...tions are not permissible on the front crossmember structure of the vehicle up to and including the B pillar If modifications are made to the load bearing struc ture the overall stability of the structure designed by the upfitter must at least match that of the series production vehicle Clearances for fuel filler necks fuel tank lines and fuel lines must be maintained Drilling or welding is not pe...

Page 52: ...plicable 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 110 lbs The highest possible load of a railing carrier is 100 kg 202 lbs 7 2 6 Modifications to the roof structure e Page 69 must be observed when making modifi cations to the roof structure 5 4...

Page 53: ...ues for planning 5 5 Threshold values for electrics electronics i i Additional information Also see chapter 9 Electrical system e Page 97 5 5 1 Electric wiring fuses The following table is valid for cables with an operating temperature limit of more than 105 C 189 F for the insulation 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...

Page 54: ...ld values for additional assemblies 5 Technical threshold values for planning 5 6 Threshold values for additional assemblies 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 drivin...

Page 55: ...t any welding drilling and grinding work or before work ing with cutting disks 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 No other lines may be attached to brake lines other than those installed as standard Lines must be ...

Page 56: ...s 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 7 4 Interior e Page 73 Before welding cover springs and air suspension bellows to protect them from welding spatter Do not touch springs with welding electrodes or ...

Page 57: ... 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 i i Additional information For further information on weldi...

Page 58: ...s should be included in the planning and design stages by selecting suitable materials and designing components accordingly i i Additional information 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...

Page 59: ...ding 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 galvanization paint ing preservation or zinc coating applied by flame e Page 60 After all work on the ve...

Page 60: ...ckness for each individual coat as specified by the factory Paint compatibility must be guaranteed when repainting i i Additional information 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 Center Mask the following areas before painting Disk brakes Brake hoses Brake fluid reservoir Gearing u...

Page 61: ...cordance with the Mercedes Benz tightening instructions Information on this is available from your Mercedes Benz Ser vice Center It is prohibited to shorten the free clamping length change to a stretch shank or use screws bolts with a shorter free thread The settling behavior of threaded connections must be taken into account Additionally clamped components must exhibit an identical or higher stre...

Page 62: ...technical inspection center 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 must be replaced without additional connecting points using MB approved double walled wrapped tubes of 4 75 mm x 0 7 mm or fully assembled brake lines with connecting parts genuine Mercedes Benz replacement...

Page 63: ...gth 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 suitable new cable must be procured The brake cable brackets are moment optimized modi fications are not permitted The brake cables must be routed without kinks There must be no angle changes at the end pieces of the brake cable conduit free strands i i Additional info...

Page 64: ...ountries If different wheels are mounted the following dan gers may arise Brakes or suspension components may be dam aged The clearance of the wheels may no longer be guaranteed Brakes or suspension components may no longer function correctly The upfitter must ensure that the following require ments are fulfilled There must be sufficient space between the tire and the fender or wheel well even wit...

Page 65: ...uction process and are not suit able for securing equipment 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 bows Modification of vehicles with window airbag is not permissible in the roof area of the B pillar Partitions may be totally or partially removed see chapter 7 2 2 Partition e Page 67 The...

Page 66: ...s In positions where safety equipment is located see chapter 7 4 2 Safety equipment e Page 74 Drilling in the longitudinal member web is only possi ble in accordance with the following illustration and if spacer bushings welded to the longitudinal member are used Drilling work on the longitudinal frame members 1 Chassis frame 2 Spacer bushings a Distance of at least 20 of the frame height b Distan...

Page 67: ...argo 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 9 7 2 Crosswind Assist e Page 112 for modifications on the projected lateral face A certificate of non objection is required from the department responsible see chapter 1 6 Contact e Page 9 Note Upon complet...

Page 68: ...h 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 ...

Page 69: ...equired The bows must be secured to the sidewalls in such a way that a non positive connection is guaranteed bend resistant connection of bows and roof panel The maximum roof load must be observed The maximum permissible location of the center of gravity must not be exceeded e Page 47 When mounting a carrier system directly to the rivet nuts only mounting consoles approved by Daimler AG or mountin...

Page 70: ...hatch Note Retrofitting of a pop up roof or roof hatch is only permissible with an upfitter impact study UIS from the department responsible see chapter 1 6 Con tact e Page 9 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 see ...

Page 71: ...d engine limp home mode For connections supplying fuel to an auxiliary heater the procedure for type approval must be followed H H Environmental note Modifications carried out incorrectly to the fuel system may have a detrimental effect on the envi ronment 7 3 2 Exhaust system On no account may any modifications be made to the exhaust system The following minimum clearances from plastic lines elec...

Page 72: ...d by attaching spoilers below the bumper additional hub caps or brake disk covers etc a 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 tire damage For this reason modifications which impair the flow of cooling air to the brake system are only permis s...

Page 73: ...d to the restraint systems no longer functioning correctly A restraint system can fail or unintentionally activate This can lead to personal injury Modifications to restraint systems are therefore not permitted a 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 ...

Page 74: ... seat belt anchor age points Airbags and emergency tensioning retractor units All airbag units are labeled with the word Airbag The driver airbag on the padded boss is recogniz able by the inscribed word Airbag The front passenger airbag can also be recognized by the word Airbag inscribed on the dashboard paneling The window airbags are identified by the Airbag inscription on the side of the headl...

Page 75: ...dard equipment 2 Front passenger airbag 3 A D window airbag Airbag deployment areas example 1 Window airbag 2 Driver airbag standard equipment 3 Front passenger airbag 4 Thorax airbag Difference between A B and A D window airbags 1 Deployment and coverage areas of A B window airbags 2 Deployment and coverage areas of A D window airbags Note The preceding illustrations of the airbag deployment area...

Page 76: ...wise 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 in the footwell center console behind the trim 1 Airbag control unit with integrated ESP turn rate sensor Arrow Direction of travel A removed airbag control unit is susc...

Page 77: ...ted 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 cle...

Page 78: ...tting torches by smelting or if primed parts are disposed of on open fires or smoldering 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 cont...

Page 79: ... available ex factory is not permitted When seat belts and seats including seat bases are reinstalled the specified screws bolts must be tight ened to the specified torque a 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 airbags Otherwise thorax airbags may not be able to...

Page 80: ...vy duty insulating foil may be provided in the area of the wheel wells Note Insulating foils have limited temperature resistance They should therefore not be installed in the immedi ate vicinity of the engine or exhaust system 1 Carpet rubberized 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 ...

Page 81: ...the bulkhead and the vehicle interior must be carefully sealed with flexible 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 7 4 5 Ventilation The p...

Page 82: ...t 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 heater Exhaust pipes of the auxiliar...

Page 83: ...ust be designed as per 7 2 6 Modifications to the roof structure e Page 69 7 6 2 Roof racks Make sure that the load is distributed evenly across the entire roof area Installation of a stabilizer bar on the front axle is recommended Support feet must be spaced at regular inter vals The load per support foot may not exceed 25 kg 55 lbs With shorter roof racks the load must be reduced proportionally ...

Page 84: ...ail sys tem 500 1 124 Code V42 Tie down rails sidewall to belt rail 100 225 see chapter 5 4 3 Threshold values for fastening points e Page 52 The maximum tensile force of the properly retrofitted genuine Mercedes Benz Tie down rails sidewall to belt rail retrofit code V42 is as for special equipment code V42 see table above 100 daN Tie down rails sidewall to belt rail code V42 are only available a...

Page 85: ...tion with shelving or workshop installa tions The wiring harness routing for the interior illumi nation or for the trailer hitch in the roof or in the D pillar may not be impaired The electrical limits specifications maximum connected loads see e g chapter 9 5 4 Interior lamps e Page 108 voltage 12 V electrical power 80 W rated fuse values with respect to the installation of lamps LEDs must be obs...

Page 86: ...ownward out of the vehicle 6 Shim plate Corrosion protection measures To ensure compliance with the anti corrosion warranty of the vehicle manufacturer upfitters must observe important corrosion protection measures after drilling through the body Whenever an assembly hole is made in the vehicle body one or more elements of the existing protection system is are irreparably damaged The upfitter maki...

Page 87: ... to combine the two aforementioned fastening types We recommend anti slip pressure resistant oil water acid resistant floors for shelving or workshop installations The quality of the mounting floor should be at least equal to the wooden floor supplied ex factory Bolting to the floor There are various methods for bolting the shelving to the floor depending on the requirements Bolting it to a specia...

Page 88: ... on the size weight of the installa tion Tie down rails sidewall to belt rail code V42 are only available ex factory for the Metris cargo van and only as special equipment or they must be retrofitted to the cargo van by the upfitter It is the responsibility of the upfitter to provide a substitute of equal quality when installing shelving or a workshop installation as a retrofit All of the holes pr...

Page 89: ...e see table above under Load rails ex factory must be clearly indicated in the area of the tie down rails e g using adhesive labels and must also be indicated in the operator s manual in the vehicle Connection to vehicle sidewall by threaded connec tion Tie down rail sidewall to belt rail Permissible rated tensile force 100 daN 225 lbf The stated values only apply if the following conditions are m...

Page 90: ...ould only be attached at the intended points on the bodyshell rear longitudinal member Technically there is no problem retrofitting a trailer hitch when a preinstallation code E57 is already fitted If a trailer control unit was not pre installed at the fac tory it must be installed and connected in addition to the retrofitted wiring harness In addition variant cod ing of the electronic ignition lo...

Page 91: ...tings cell phone holders bottle holders etc See the illustrations of the airbag deployment areas for more information e Page 75 8 1 2 Retrofitting additional seats Retrofitting seats is not permitted for certification reasons a a WARNING It is not permitted to modify the driver and front pas senger seats or to mount seats on the wheel wells In the event of an accident the seats could become detach...

Page 92: ...ide airbags Otherwise tho rax side airbags 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 Center 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 M...

Page 93: ...ign of bodies 8 2 Refrigerated vehicles temperature controlled vehicles Refer also to the following chapters 7 2 6 Modifications to the roof structure e Page 69 7 4 4 Reducing interior noise e Page 80 9 4 4 Connecting additional electrical consumers e Page 104 These requirements and notes are also applicable for vehicles used to transport loads under constant condi tions within the load compartmen...

Page 94: ...s Permissible center of gravity position and axle loads Particular attention must be paid to the following sec tions of the Body Equipment Guideline 4 3 Dimensions and weights e Page 34 7 Modifications to the basic vehicle e Page 61 7 2 4 Fenders and wheel wells e Page 68 9 Electrical system e Page 97 9 7 Driver assistance systems e Page 110 The interior equipment must be designed in such a way th...

Page 95: ...rve the revision notes compared to 09 18 2015 Only print out complete sections of the current version 95 8 4 Retrofitting a pop up roof 8 Design of bodies 8 4 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 ...

Page 96: ...ons and weights e Page 34 7 Modifications to the basic vehicle e Page 61 7 3 3 Engine cooling e Page 72 9 2 Electromagnetic compatibility EMC e Page 98 9 4 4 Connecting additional electrical consumers e Page 104 Recommended special equipment codes for conversion to a government vehicle Code ED5 PSM parameterizable special module Code EK1 Electronic terminal strip for connecting electrical or elect...

Page 97: ...rticular when working on safety related sys tems service by a qualified specialist workshop is indispensable Note When connecting additional electrical consumers e Page 104 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 po...

Page 98: ...ctri 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 compatib...

Page 99: ...ch i i Additional information Additional information on special equipment can be obtained from any Mercedes Benz Service Center from the relevant department e Page 9 or under 4 10 Special equipment e Page 46 9 3 3 Additional battery Note Batteries with capacities of more than 100 Ah may not be directly connected to the on board electri cal system as this can cause damage to the basic vehicle A pos...

Page 100: ...ading aids or electrical equipment in motor homes refrigerator 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 an automatic start stop system Location of additional battery 1 Additional battery Arrow Direction of travel Other additional batteries Note If the vehicle is already equipped with an additional battery n...

Page 101: ...ion of backup battery 1 Backup battery Arrow Direction of travel 9 3 5 Emergency battery On 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 9 3 6 Battery maintenance and storage Batteries must be regular...

Page 102: ...st be dimensioned in accor dance with the current level drawn and protected with fuses see 5 5 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 wiring duct must not be damaged or re routed when carrying out modifications in the area of the transmission tunnel The wiri...

Page 103: ... components and conse quently to accidents or damage to the vehicle The ring shaped MOST network of the Metris uses a fiber 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...

Page 104: ...l 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 5 5 1 Electric wiring fuses e Page 53 Electrical lines must be routed correctly see 9 4 1 Electrical lines fuses e Page 102 There must be no ...

Page 105: ...the cockpit on the right hand side in the direction of travel and has three connections 1 Terminal strip Arrow Direction of travel Position plug pin Terminal designa tion Fuse number Fuse rating A S9 7 15 F320 15 S4 30 F321 25 S9 9 61 F319 15 9 4 6 Retrofitting an alternator When retrofitting additional electrical consumers the increased current requirement can be met by using a more powerful alte...

Page 106: ...es must be routed correctly e Page 102 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 72 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 assemblie...

Page 107: ...mps 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 center 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 Center using XENTRY Kit Headlamp basic setti...

Page 108: ...ps with the exception of the cen ter high mounted brake lamp turn signals licence plate illumination side markers and clearance lamps This will not have any negative effect on lamp monitoring 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 upfitter 9 5 4 Interior lamps All interior lamps can be replaced by other body manu facture...

Page 109: ...if they are connected to an exterior antenna 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 9 6 2 Antenna connection and cable routing radio frequency Co...

Page 110: ...read depths etc under 4 6 Tires e Page 37 and 7 2 4 Fenders and wheel wells e Page 68 In wintry driving conditions always use winter tires M S tires and if necessary snow chains Only in this way will the driving safety systems described in this section work as effectively as possible i i Additional information Further information on equipping the vehicle with driver assistance systems and their po...

Page 111: ... bracket and its installa tion 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 i...

Page 112: ... impact study UIS should be requested e Page 9 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 i i Additional information Additional information is available from the relevant department...

Page 113: ...on and thickness paints or film coatings can cause dampening 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 front end of the vehicle is damaged please have the settings and function of the radar sensor checked at a qualified spe...

Page 114: ...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 Modifications to outside mirrors Blind Spot Assist can be deactivated using a button on the operating panel a a WARNING Depending on the version and thickness paints or film coatings can cause dampening of radar waves This cou...

Page 115: ...ons be made to the position of the camera or the surrounding area e g changing the standard windshield Otherwise the camera may not be able to function properly The camera must be readjusted after any modifications to the vehicle which alter the vehicle inclination e g replacement of a suspension strut Have the re adjust ment carried out without delay at a qualified specialist workshop possessing ...

Page 116: ...e made to the position of the rain sensor Headlamp Assist system or the surrounding area e g changing the standard windshield Otherwise the rain sensor Headlamp Assist system may no longer function correctly 9 7 7 Tire pressure monitoring a 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 tire pressure m...

Page 117: ...thout impairing sensor operation is 120 µm This also includes repeated paint applications 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 ...

Page 118: ... into the liftgate above the license plate molding 1 License plate molding a 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 result in a lack of compliance with the legal requirements of FMVSS 111 and or CMVSS 111 cau...

Page 119: ...n read the mes sages on the CAN bus and for example make them available as switching 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 121 The electronics installed by the upfitter then have access to the necessary signals i i Additional information For further information on the topic of CAN bus syst...

Page 120: ...Chassis CAN information E Wheel speed E Vehicle 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 installation E Sliding roof E Transmission Output to body CAN Light control E Parking lights E Standing lights E Turn signals E High beams Alarm functions E Alarm ...

Page 121: ...table 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 9 8 3 ABH CAN A second CAN bus is available on the PSM The upfitter CAN ABH CAN High speed CAN Class C Extended CAN identifier 29 bit E Baud rate...

Page 122: ... 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 stabilizing the on board electrical system voltage This includes an additional backup battery and a modified fuse box To avoid dropping below the defined charge capacity of the battery the system is automatically deactivated ...

Page 123: ...the procedures described under 10 1 1 Determination of the center of gravity in the x direction e Page 123 and 10 1 2 Determination of the center of gravity in the z direction e Page 125 must be followed and services of qualified persons must be used so as to achieve realistic and useful results 10 1 1 Determination of the center of gravity in the x direction CoG coordinates in x direction front r...

Page 124: ...on of the center 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 of empty vehicle specification or weighing of the chassis in question GHA Rear axle load of empty vehicle specification or weighing of the chassis in question Dimensions lV Distance of overall center of gravity of empty vehicle from front axle lH Distance of overal...

Page 125: ... 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 23 62 in 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 vehi...

Page 126: ...the front axle VA by the value h at least 600 mm 23 62 in 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 measure ments 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 deter...

Page 127: ...at 5 rstat Loaded tire radius QVA Front axle load with vehicle raised at rear QHA Rear axle load with vehicle raised at front hS Height of center of gravity above road surface ha Height of center of gravity above wheel center h Height by which the vehicle was raised SG Overall vehicle center of gravity 1 Weighing device i i Additional information The wheelbase I is defined by the vehicle model des...

Page 128: ...mplete sections of the current version 128 10 1 Center of gravity 10 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 center of gravity must not exceed the limits specified under 5 1 2 Maximum permissible positions of center of gravity e Page 47 ...

Page 129: ...ces 102 Electrical system 97 Electric wiring fuses 53 Electronic Stability Program ESP 110 EMC 98 Emergency tensioning retractors 74 Emission and safety information 16 Engine air intake 72 Engine peripherals 71 Exhaust system 71 F Fenders 68 Flaps 67 Fuel system 71 Fuses 53 G Gas shielded plug welding 40 Gross axle weight rating GAWR 48 H Handover 45 I Interior 73 91 L Labels 28 Lighting 107 Limit...

Page 130: ... Springs 61 Steerability 47 Storage in enclosed premises 44 Suspension threshold values 48 T Technical threshold values for planning 47 Threshold values for additional assemblies 54 Threshold values for electrics electronics 53 Threshold values of basic vehicle 47 Threshold values of body 51 Tire pressure monitoring 116 Traceability 22 Trademarks 23 Trailer hitch 90 U Underfloor paneling 68 Upfitt...

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