Technical Data Vivaro
List of contents
1
Design of the Vivaro Range ................................................................................................
1
2
Chassis number and identification plate ........................................................................
2
3
Body frame plans and sectional drawings of the Vivaro ..............................................
Van ......................................................................................................................................
Body sections ......................................................................................................................
Installation of windows or sheet-metal panels in the vehicle sides ................................
Floor group – main sections ..............................................................................................
Position of crossmembers ..................................................................................................
Partition between cab and load compartment ..............................................................
Lashing points ....................................................................................................................
Load compartment sections ..............................................................................................
Accessibility via rear doors/tailgate ..................................................................................
Accessibility via the side sliding door................................................................................
Platform chassis ..................................................................................................................
Body connection – Position of the fastening points ........................................................
Body connection – Side sill closing panel ........................................................................
Body connection – Floor group..........................................................................................
Rear wheel housing ............................................................................................................
Electric ....................................................................................................................................
Wiring and positioning of connections ............................................................................
Circuit diagrams ..................................................................................................................
Relay/fuse box Vivaro ........................................................................................................
Fuse and relay boxes ..........................................................................................................
Relais in driver cabine ........................................................................................................
Main Fuses in engine compartment..................................................................................
Relais in Engine compartment ..........................................................................................
Supplementary information ................................................................................................
Ground clearance................................................................................................................
Centre of gravity ................................................................................................................
Tyres and turning-circle diameter......................................................................................
Seat belt anchorage points................................................................................................
Seat mountings ..................................................................................................................
Position of R points ............................................................................................................
Fuel supply system ..............................................................................................................
Position of brake system ....................................................................................................
Location of the spare wheel ..............................................................................................
Parking brake system..........................................................................................................
Modification of the exhaust system ..................................................................................
Engine cooling ....................................................................................................................
Alternator/110 A alternator ................................................................................................
125 A alternator ..................................................................................................................
Options and Accessories ......................................................................................................
Power take-off ....................................................................................................................
Additional Air Condition for engine versions F4R and F9Q ............................................
Auxiliary heater ..................................................................................................................
Roof rack..............................................................................................................................
Trailer hitch ..........................................................................................................................
5
5
6
7
8
8
10
13
15
16
21
22
22
25
29
32
33
33
33
34
35
36
37
38
40
40
42
45
46
47
48
50
55
57
58
59
61
65
66
67
67
68
70
71
73
4
5
6
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 transverse
engine. 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 permissible
weights), two different wheel bases and four different engines. Three turbocharged diesel (F9Q eco, F9Q
and G9U) and one petrol engine (F4R) are available.
H1 = Normal roof
H2 = high roof
TPW = Total Permissible Weight
–1–
Technical Data Vivaro
2
Chassis number and identification plate
The chassis number can be viewed by levering up one of the two flaps located above the right-hand
cab 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: Manufacturer
Line 2: Approval number
Line 3: Chassis number
Line 4: Total permissible weight
Line 5: Perm. gross towing weight
Line 6: Max. perm. front axle load
Line 7: Max. perm. rear axle load
Colour code
Country-specific information (if avail.)
Equipment Level
National approval numbers
Only for Van and Platform Chassis
Belgium
Czechoslovakia
Germany
Spain
France
Italy
Poland
–3–
Technical Data Vivaro
Weights and dimensions
TOTAL PERMISSIBLE WEIGHT
CURB WEIGHT
PERMISSIBLE
COMBINATION WEIGHT
PV 0.00 t PTAC 0.00 t
PTRA 0.00 t
Lon 0.00 m Lar 0.00 m
S 0.00 m2
VEHICLE LENGTH
VEHICLE WIDTH
BOTTOM SURFACE
Chassis number
CHASSIS NUMBER
WOL
WOL
REPLACEMENT CHASSIS NUMBER
–4–
Technical Data Vivaro
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 between
unladen and laden conditions.
Van
• Superstructure
The main sections for the Vivaro are indicated in the diagram overleaf.
–5–
SECTION 1
SCALE 1:4
SECTION 2
SCALE 1:4
SECTION 13
SCALE 1:20
SECTION 3
SCALE 1:8
SECTION 10
SCALE 1:20
SECTION 11
SCALE 1:20
–6–
SECTION 12
SCALE 1:20
SECTION 9
SCALE 1:20
SECTION 5
SCALE 1:20
SECTION 6
SCALE 1:20
SECTION 4
SCALE 1:20
SECTION 8
SCALE 1:20
SECTION 7
SCALE 1:20
Technical Data Vivaro
Body sections
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.
Section
PANEL VAN
ROOF STRUT
50 mm
UPPER REINFORCEMENT
GLASS OR SHEET METAL INSERT
GLAZED VAN
UPPER REINFORCEMENT
50 mm
STRUT
SIDE PANEL
SLIDING WINDOW
LOWER REINFORCEMENT
50 mm
200 mm
–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 and
crossmembers for vans, combis and buses are illustrated (L1, L2, RHD and LHD).
L1 Van (LHD and RHD)
3788
3487
816
3187
2955
2911
570
2790
2392
543
2067
1743
905
516
634
634
75
25
516
145
211
FRONT AXLE
489
1269
1354
1455
1954
2411
2611
L1 Combi and bus (LHD)
FRONT AXLE
250
196
For further details, see drawing of L1 Van.
1840
ONLY APPLIES TO VEHICLES WITH SLIDING DOOR ON RIGHT
2165
2644
2969
–8–
Technical Data Vivaro
L2 Van (LHD and RHD)
For further details, see drawing of L1 Van.
4188
3887
3587
3355
3311
3187
FRONT AXLE
ONLY APPLIES TO VEHICLES WITH SLIDING DOOR
ON LEFT OR NO SLIDING DOOR
ONLY APPLIES TO VEHICLES WITH SLIDING DOOR
ON RIGHT OR NO SLIDING DOOR
2354
2811
3011
L2 Combi and bus (LHD)
FRONT AXLE
250
196
For further details, see drawing of L1 Van.
1840
2165
2644
2969
–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 show
the ideal installation position taking account the driver’s seat suspension, cab ergonomics and the
pallet 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
50
FRONT ACCESS LIMIT
50
849,4
50
1262,7
50
1171,1
%
50
FULL PARTITION
DOOR APERTURE WITH SEAL
Separation grille
50
FRONT ACCESS LIMIT
50
839,4
50
1262,7
50
1171,1
%
50
SEPARATION GRILLE
DOOR APERTURE WITH SEAL
– 11 –
Technical Data Vivaro
• Loading a europallet
Full partition
84
FRONT ACCESS LIMIT
50
80
800
1283
1000
%
70
50
145
FULL PARTITION
DOOR APERTURE WITH SEAL
Separation grille
84
FRONT ACCESS LIMIT
50
70
800
1283
1000
%
70
50
145
SEPARATION GRILLE
DOOR APERTURE WITH SEAL
– 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.
Diameter 9,2 mm
– 13 –
Technical Data Vivaro
Position of lashing points
70
36
40
FRONT AXLE
L1 Van
276
Z0
1435
2633
3679
L2 Van
– 14 –
Technical Data Vivaro
• 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
SECTION A-A
Y0
1672
Y 400
Y 200
Y 600
1673
800
A
Z 1600
827
Z 1400
834
Z 1200
802
Z 1000
890
803
A
Y 800
Z 800
Z 600
633
833
Z 400
285
Z 200
Z0
– 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
Y-800
Y-400
Y0
Y400
Z1600
Z 1651
1314
Z1200
1390
Z800
1268
Z400
Z 285
Z0
– 16 –
Y800
Technical Data Vivaro
• Accessibility via rear doors
1678
172° opening angle, applies to L1H1
678
1642
34
870
721
870
39
– 17 –
Technical Data Vivaro
• Accessibility via the rear doors
1255
1686
250° opening angle, applies to L2 without sliding doors
1641
1233
678
870
870
721
– 18 –
Technical Data Vivaro
• Accessibility via the rear doors
– 19 –
1641
1401
678
870
870
721
1685
1440
233° opening angle, applies to L2 with sliding doors
Technical Data Vivaro
min. 405,5
(laden)
max. 2042,6 (unladen)
• Accessibility via the rear doors
• Accessibility via the tailgate, applies to L1
– 20 –
2027 / 2128
(laden / unladen)
1846 / 1959
1767 / 1854
1141
Technical Data Vivaro
• Accessibility via the side sliding door
For further details, see:
– partition wall
– insulation of the side sliding door
max. 1078 mm
min. 1003 mm
– 21 –
Technical Data Vivaro
• Platform chassis
Vivaro platform chassis are fitted with a connection flange with six fastening points. The seat belt
anchor 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.
A
A
B
B
C
C
– 22 –
Technical Data Vivaro
Section A-A
(Body fastening points)
PARTITION
Section B-B
PARTITION
– 23 –
Technical Data Vivaro
Section C-C
PARTITION
– 24 –
Technical Data Vivaro
• 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
--- -- --- -- --- ______________
Van
Platform chassis
100
Section B-B
--- -- --- -- --- ______________
Van
Platform chassis
100
– 26 –
Technical Data Vivaro
Section C-C
324.7
196.3
--- -- --- -- --- ______________
Van
Platform chassis
100
Section D-D
--- -- --- -- --- ______________
Van
Platform chassis
– 27 –
Technical Data Vivaro
Section E-E
On the rear of the B pillar
Maximum
overall width
Floor panel
Lower pillar lining
Sill closing panel
sill end piece
Area which must be closed
for acoustic reasons.
sill beam
Section F-F
Horizontal cut at B pillar
Side window glazing bar
sill end piece
Lower pillar
lining
Front door
frame
Lower door end panel
Side
mounting
Area which must
be closed for acoustic
reasons.
Maximum overall width
– 28 –
Technical Data Vivaro
• Body connection – Floor group
BODY KAROSSERIE
ACCESS
ZUGANG
The following illustration shows sections and fastening points for the floor group. The lower rear panel
for various vehicle versions is also illustrated.
The lower rear panel performs an important load-bearing function. For modifications to the lower rear
panel, please consult the Vivaro conversion recommendations manual under “Modifying the rear
overhang”.
D
D
A
B
C
A
B
C
– 29 –
Technical Data Vivaro
Section A-A
CUTTING
AREA
SCHNITTBEREICH
100
Section B-B
CUTTING
AREA
SCHNITTBEREICH
171
130
100
– 30 –
Technical Data Vivaro
Section C-C
100
100
Section D-D
150
100
50 mm
– 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 the
new 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.
1
2
Rear wheel housing section
VAN SIDE PANEL
FLANGE (3 mm)
– 32 –
WHEEL HOUSING COVER
Technical Data Vivaro
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 platform
chassis.
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 instrument
panel) 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
Fuse assignment
1 Not used
2
3
4
5
6
7
8
9
10
Radio
Not used
Not used
Not used
Not used
AC, rear
Not used
Fog lamps
Central locking
11 Interior illumination
12 Diagnostic plug,
immobiliser
13 Rear screen heating
14 Rear screen
wiper/washer system
15 Screen wipers
16 Brake light
17 ABS
18 Not used
19 Window winders
20 Window winders
21 Seat heating
22 Not used
23 Not used
27 High beam, left
24 Radio
25 Heating
High beam, right
Low beam, left
Low beam, right
Tail lamp, left
Tail lamp, right
Rear fog lamp
Horn
Mirror heating
Windscreen heating
control
37 Not used
38 Not used
26 Accessories
39 Not used
– 34 –
28
29
30
31
32
33
34
35
36
Technical Data Vivaro
• 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
• 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
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
• 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 relay
4 Fuel pump/diesel pre-heating relay.
5 Relay for fan unit, second speed level
(Diesel parking heater)
6 Coupling relay: AC compressor
7 1 add-on heater (thermo-plunger) relay
8 2 or 3 add-on heater (thermo-plungers)/
parking heater (petrol) relay
9 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.
Bundled (multiplex) network
1 Instruments – dashboard/
instrument panel
2 Airbag computer
3 CPU cab
4 Connection for diagnostics plug
5 Fuel injection computer
The Vivaro multiplex network enables the 4 computers (CPU cab, fuel injection, airbag and instrument
panel) 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
• 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
MULDE SPARE WHEEL WELL
MUFFLER
ANGLE OF INCLINATION 24°
24°
21°
171
165
ENGINE SUPPORT
173
TPW only
L2 version
SPARE WHEEL WELL
MUFFLER
ANGLE OF INCLINATION 15°
20°
22°
ENGINE SUPPORT
– 40 –
183
165
179
TPW only
Technical Data Vivaro
Platform chassis version
SPARE WHEEL WELL
MUFFLER
ANGLE OF INCLINATION 14°
18°
20°
– 41 –
184
160
ENGINE SUPPORT
178
TPW only
Technical Data Vivaro
• Centre of gravity
The specified centres of gravity relate to the unladen vehicle, ready to drive.
L1 Van
1198,8
366,2
5 mm LEFT OF LONGITUDINAL AXIS
L2 Van
1333,3
370,7
5 mm LEFT OF LONGITUDINAL AXIS
– 42 –
Technical Data Vivaro
L1 Combi and bus
1345,2
BUS
1336,5
391,5
393.2
BUS
7.6 mm LEFT OF LONGITUDINAL AXIS
BUS
11.2 mm LEFT OF THE VEHICLE’S LONGITUDINAL AXIS
L2 Combi
COMBI (6-SEATER)
394,6
KOMBI (8/9-SEATER)
8.6 mm LEFT OF LONGITUDINAL AXIS
KOMBI (6-SITZER)
386.3
1418,1
COMBI (8/9-SEATER)
KOMBI (6-SEATER)
1467,2
11.2 mm LEFT OF LONGITUDINAL AXIS
KOMBI 8/9-SITZER
– 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
TPW
2,7 t
2,9 t
Option
Tyre size
195 / 65 R16
205 / 65 R16
215 / 65 R16
Rolling circumference
2000 mm
2042 mm
2085 mm
Rims
6J16
6J16
6J16
Speed index
R
R
R
Load index
100/98R
107/105R
106/104R
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 extended
wheel base.
TURNING CIRCLE
WHEEL BASE (MM)
BETWEEN WALLS
BETWEEN PAVEMENTS
– 45 –
Technical Data Vivaro
• Seat belt anchorage points
Seat belt anchorage points for L1 vans, combis and buses
3300
2720
FRONT AXLE
1450
50
1311
195
474
294
1245
1219
%
276
379
Z0
1425
2708
3519
Seat belt anchorage points for L2 vans and combis
3300
2720
FRONT AXLE
1450
50
1311
474
294
219
1245
1219
%
1425
2708
3077
– 46 –
276
379
Z0
Technical Data Vivaro
• Seat mountings:
Seat mounting points for vans and combis
X1840
Y516
X1319
Y329
X1319
Y516
X1840
Y250
X2164,8
Y516
X2164,8
Y250
X2644
Y516
X2644
Y250
X905
Y616
X2968,8
Y516
X1319
Y0
X905
Y0
X2968,8
Y250
LONGITUDINAL AXIS
X905
Y-254
X2968,8
Y-250
X2968,8
Y-516
X905
Y-616
X1319
Y-254
X1319
Y-516
X1840
Y-250
X2164,8
Y-516
X2164,8
Y-250
X2644
Y-516
X2644
Y-250
X1840
Y-516
Seat mounting points for buses
X1840
Y516
X1319
Y254
X1319
Y516
X1840
Y250
X2164,8
Y516
X2164,8
Y250
X2644
Y516
X2644
Y250
X905
Y616
X2968,8
Y516
X905
Y254
X2968,8
Y250
LONGITUDINAL AXIS
X905
Y-254
X2968,8
Y-250
X2968,8
Y-516
X905
Y-616
X1319
Y-254
X1319
Y-516
X1840
Y-250
X2164,8
Y-516
X1840
Y-516
– 47 –
X2164,8
Y-250
X2644
Y-516
X2644
Y-250
Technical Data Vivaro
• Position of R points
R points for combis and buses
(LHD)
50
Z0
– 48 –
276
454
416
379
%
Technical Data Vivaro
R points for combis
(LHD)
500
123
523
1147
500
435
LONGITUDINAL AXIS
FRONT AXLE
1077
2053
2857
R points for buses
356
435
(LHD)
435
383
LONGITUDINAL AXIS
FRONT AXLE
1077
2053
2857
– 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 changes
are absolutely necessary, the result must comply with all applicable regulations and allow unimpaired
filling.
• Add-on heater
The add-on heater can be ordered ex works. When retrofitting, the feed line must be replaced by part
number 91166223. These modifications ensure sufficient fuel supply to the engine, regardless of tank
level and vehicle dynamics.
Note:
The fuel lines are made from PA11/PA12.
Position of fuel supply system
(Petrol version)
FRONT AXLE
LONGITUDINAL AXIS
– 50 –
Technical Data Vivaro
Position of the fuel supply system
(Diesel version)
FRONT AXLE
LONGITUDINAL AXIS
Section A-A
89
Tank filler pipe (according to SAE J 1140)
B
BODY MAXIMUM
290
B
100 mm
– 51 –
Technical Data Vivaro
Section B-B
Tank filler pipe (according to SAE J 1140)
80
100 mm
90
BODY MAXIMUM
150
– 52 –
Technical Data Vivaro
• Fuel tank versions
Fuel tank (petrol) without add-on heater
Feed hose, Sleeve, seal
Tank
Line with solenoid valve
Supply unit
Engine feed line
Charcoal canister
Clamp
Filter
Ground cable
Fuel tank (petrol) with add-on heater
Feed hose, Sleeve, seal
Supply unit
Tank
Line with solenoid valve
Engine feed line
Feed hose,
Add-on heater
Clamp
Charcoal canister
Filter
– 53 –
Ground cable
Technical Data Vivaro
• Fuel tank versions
Fuel tank (diesel) without add-on heater
Feed hose, Sleeve, seal
Filter
Supply unit
Tank
Feed line
Return line
Clamp
Fuel tank (diesel) with add-on heater
Feed hose, Sleeve, seal
Supply unit
Tank
Feed line,
Add-on heater
Filter
Feed line
Return line
Clamp
– 54 –
Technical Data Vivaro
• Position of brake system
The position of the brake system is shown in the following illustrations. Two different brake servos units
are used, depending on the engine and vehicle version. One is a 10 inch brake servo for LHD vehicles
with F9Q engine, the other is a 9/10 inch brake servo for versions with F4R or G9U engines and for all
RHD vehicles.
Note: For safety reasons, all vehicles with extended wheel base must be equipped with an ABS
brake system.
LONGITUDINAL AXIS
FRONT AXLE
10-inch brake servo (without ABS)
LONGITUDINAL AXIS
FRONT AXLE
10-inch brake servo (with ABS)
– 55 –
Technical Data Vivaro
LONGITUDINAL AXIS
FRONT AXLE
9/10-inch brake servo (without ABS)
LONGITUDINAL AXIS
FRONT AXLE
9/10-inch brake servo (with ABS)
– 56 –
Technical Data Vivaro
• Location of the spare wheel
LONGITUDINAL AXIS
FRONT AXLE
X 3431
Y-127
Z 140
– 57 –
Technical Data Vivaro
• Parking brake system
LONGITUDINAL AXIS
FRONT AXLE
LHD
LONGITUDINAL AXIS
FRONT AXLE
RHD
– 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
FRONT AXLE
LONGITUDINAL AXIS
F9Q engine
FRONT AXLE
LONGITUDINAL AXIS
– 59 –
Technical Data Vivaro
G9U engine
FRONT AXLE
LONGITUDINAL AXIS
– 60 –
RADIATOR
RADIATOR FEED HOSE
HOSE CLAMP |A 32
COOLANT COMPENSATION TANK
HOSE CLAMP |A 12
RADIATOR OUTLET HOSE
HOSE CLAMP |A 18
HOSE CLAMP |A 12
DEGASSING HOSE
– 61 –
HOSE CLAMP |A 32
HOSE CLAMP |A 16
HOSE CLAMP |A 20
HEAT EXCHANGER FEED HOSE
HOSE CLAMP |A 20
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
RADIATOR
HOSE CLAMP |A 32
RADIATOR FEED HOSE
COOLANT COMPENSATION TANK
HOSE CLAMP |A 12
RADIATOR OUTLET HOSE
– 62 –
HOSE CLAMP |A 16
HEATER OUTLET HOSE
AUX. ON HEATER FEED HOSE
HOSE CLAMP |A 20
HEAT EXCHANGER FEED HOSE
HOSE CLAMP |A 24
HOSE CLAMP |A 32
HOSE CLAMP |A 20
HOSE CLAMP |A 12
DEGASSING HOSE
HOSE CLAMP |A 18
Technical Data Vivaro
F9Q engine coolant circuit
Technical Data Vivaro
G9U engine coolant circuit
Spring clamping ring, diameter 12
Inlet pipe, Compensation tank
Spring clamping ring, diameter 18
4-auxiliary heater
Inlet pipe, heater
Outlet pipe, Compensation tank
Compensation tank
Spring clamping ring, Spring clamping ring,
diameter 12
diameter 20
Inlet pipe,
heater
Spring clamping ring,
diameter 18
Radiator inlet pipe
Outlet pipe,
heater
Non-AC radiator
Alumeca
Water outlet
module
Spring clamping ring,
diameter 20
Spring clamping ring, diameter 20
Spring clamping ring, diameter 32
Radiator outlet pipe
Spring clamping ring,
diameter 32
G9U engine AC circuit
Low-pressure pipe, evaporator
coolant collector,
Low-pressure pipe, receiver drier, compressor
Condenser
Receiver drier,
assembled
High-pressure pipe, condenser
Evaporator
High-pressure pipe
Condenser compressor
Compressor
– 63 –
Technical Data Vivaro
Additional heating circuit for G9U engine
clamp
radiator inlet pipe
radiator outlet pipe
clamp
clamp
radiator
under body ridgid pipes
clamp
add.
Heating
return pipe
heater unit
• AC circuit
F4R and F9Q engines
RECEIVER DRIER – COMPRESSOR LOW PRESSURE HOSE
EVAPORATOR – RECEIVER DRIER LOW PRESSURE HOSE
COMPRESSOR – CONDENSER HIGH PRESSURE HOSE
RECEIVER DRIER
CONDENSER – EVAPORATOR HIGH PRESSURE HOSE
COMPRESSOR
CONDENSER
– 64 –
Technical Data Vivaro
Alternator
Depending on the version and connections, the X83 vehicles can be equipped with one of the two
following 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
Output curve
– 65 –
Technical Data Vivaro
125 A alternator
MINIMUM OUTPUT AT 13.5 VOLT (INSTANTANEOUS VALUE); AFTER WARM-UP PERIOD FOR Ω HOUR
AT 3000 RPM AT 13.5 V
Output curve
– 66 –
Technical Data Vivaro
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
Drive belt
pulley
Note: The output and torques which can be reached are considerably in excess of the specified
values. 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
• 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 van
with an additional AC unit it must be retrofitted using combi components.
Procedure:
1
2
3
4
Use original condenser
Use evaporator and condenser lines.
Cut holes in floor panel (see illustration overleaf).
Attach AC to rear panel inner lining (use existing bores)
(Note: Care is required with part numbers for intermediate pipe for L1 / L2 versions)
CONDENSER
EVAPROATOR – RECIVER DRIER LOW PRESSURE PIPE
TUBE
CONDENSOR – EVAPORATOR DRIER HIGH-PRESSURE PIPE
UNIT
INTERMEDIATE LINE
HIGH PRESSURE LINE
LOW PRESSURE LINE
– 68 –
Technical Data Vivaro
• Cutouts for additional AC lines, right side of vehicle, behind the rear wheel housing.
68,5
35,5
75
67,3
35,5
1 TO 7,2
4R = 5
1 BO 7,2 x 14,2
49
– 69 –
Technical Data Vivaro
• Auxiliary heater
An auxiliary heater is available as an option for the combi and bus versions. In order to equip the van
version 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, replace
thermostat 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 fuel
supply system.
(Note: For details of electrical connections, see section on “Electrics”)
Overall view
HEAT EXCHANGER OUTLET HOSE
VERSION WITH AUXILIARY HEATER
RADIATOR OUTLET HOSE
VERSION WITH AUXILIARY HEATER
UNDERBODY LINE
5 KW HEATER UNIT
– 70 –
Technical Data Vivaro
• Roof rack
Vivaro vehicles are fitted with roof rack fastening points, which constitute the only permissible fastening
points. The maximum permissible roof load is 200 kg for all vehicle versions. All the fastening points
must be used. If a shorter roof rack is used, the maximum permitted roof load is reduced by 25 kg for
each 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 therefore
not advisable.
The roof would otherwise need to be fitted with suitable fastenings in order to avoid damage caused
by vibration and wind pressure.
L1H1 van
2865
2079
1218
1451
FRONT AXLE
3345
A
– 71 –
A
Technical Data Vivaro
L2H1 van
3745
2079
1218
1451
FRONT AXLE
2865
A
Section A-A
(applies to versions L1 and L2)
|A 8,2
88
– 72 –
A
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 signal
lamps, 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 area
will result in damages of the underbody structure.
• Trailer hitch fastening points
REAR SIDE MEMBER
REINFORCEMENT
3 M10 NUTS
LINK ELEMENT
DISTANCE FROM VEHICLE CENTRE
– 73 –
Technical Data Vivaro
• Trailer hitch fastening points
Return to
main menu
– 74 –