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 .............................................. 5Van ...................................................................................................................................... 5Body sections ...................................................................................................................... 6Installation of windows or sheet-metal panels in the vehicle sides................................ 7Floor group – main sections .............................................................................................. 8Position of crossmembers .................................................................................................. 8Partition between cab and load compartment .............................................................. 10Lashing points .................................................................................................................... 13Load compartment sections .............................................................................................. 15Accessibility via rear doors/tailgate .................................................................................. 16Accessibility via the side sliding door................................................................................ 21Platform chassis .................................................................................................................. 22Body connection – Position of the fastening points ........................................................ 22Body connection – Side sill closing panel ........................................................................ 25Body connection – Floor group.......................................................................................... 29Rear wheel housing ............................................................................................................ 32

4 Electric .................................................................................................................................... 33Wiring and positioning of connections ............................................................................ 33Circuit diagrams .................................................................................................................. 33Relay/fuse box Vivaro ........................................................................................................ 34Fuse and relay boxes.......................................................................................................... 35Relais in driver cabine ........................................................................................................ 36Main Fuses in engine compartment.................................................................................. 37Relais in Engine compartment .......................................................................................... 38

5 Supplementary information ................................................................................................ 40Ground clearance................................................................................................................ 40Centre of gravity ................................................................................................................ 42Tyres and turning-circle diameter...................................................................................... 45Seat belt anchorage points................................................................................................ 46Seat mountings .................................................................................................................. 47Position of R points ............................................................................................................ 48Fuel supply system.............................................................................................................. 50Position of brake system .................................................................................................... 55Location of the spare wheel .............................................................................................. 57Parking brake system.......................................................................................................... 58Modification of the exhaust system .................................................................................. 59Engine cooling .................................................................................................................... 61Alternator/110 A alternator ................................................................................................ 65125 A alternator .................................................................................................................. 66

6 Options and Accessories ...................................................................................................... 67Power take-off .................................................................................................................... 67Additional Air Condition for engine versions F4R and F9Q ............................................ 68Auxiliary heater .................................................................................................................. 70Roof rack.............................................................................................................................. 71Trailer hitch .......................................................................................................................... 73

Technical Data Vivaro

1 Design of the Vivaro Range

• Overview

The Vivaro range is based on a front-wheel drive platform with a self-supporting body and a transverseengine. The main versions include vans, platform vans and vehicles for passenger transport (minibuses,etc.). Depending on the format, vehicles are available in a choice of two different TPWs (total permissibleweights), two different wheel bases and four different engines. Three turbocharged diesel (F9Q eco, F9Qand G9U) and one petrol engine (F4R) are available.

– 1 –

Technical Data Vivaro

H1 = Normal roofH2 = high roofTPW = Total Permissible Weight

2 Chassis number and identification plate

The chassis number can be viewed by levering up one of the two flaps located above the right-handcab foot board using a suitable tool (e. g. a screwdriver).

The identification plate is located on the right-hand cab door frame.

Data interpretation details are outlined on the following pages.

– 2 –

Technical Data Vivaro

Identification plate

Line 1: ManufacturerLine 2: Approval numberLine 3: Chassis numberLine 4: Total permissible weightLine 5: Perm. gross towing weightLine 6: Max. perm. front axle loadLine 7: Max. perm. rear axle loadColour codeCountry-specific information (if avail.)

– 3 –

Technical Data Vivaro

National approval numbersOnly for Van and Platform Chassis

BelgiumCzechoslovakiaGermanySpainFranceItalyPoland

Equipment Level

Technical Data Vivaro

– 4 –

CHASSIS NUMBER

REPLACEMENT CHASSIS NUMBER

WOLWOL

Chassis number

CURB WEIGHT

PERMISSIBLECOMBINATION WEIGHT

VEHICLE LENGTH

BOTTOM SURFACEVEHICLE WIDTH

TOTAL PERMISSIBLE WEIGHT

PV 0.00 t PTAC 0.00 tPTRA 0.00 t

Lon 0.00 m Lar 0.00 mS 0.00 m2

Weights and dimensions

3 Body frame plans and sectional drawings of the Vivaro

• Reference system and interpretation of dimensions

In general, the dimensions are expressed as absolute values (distance between two points) and the positions as relative values (determination of position within the reference system). The origin of the reference system is the centre of the front axle, as shown in the diagram below. The position of the front axle is constant with a deviation of ± 1 mm along the X-axis betweenunladen and laden conditions.

Van

• Superstructure

The main sections for the Vivaro are indicated in the diagram overleaf.

– 5 –

Technical Data Vivaro

Body sections

SECT

ION

1SC

ALE

1:4

SECT

ION

2SC

ALE

1:4

SECT

ION

3SC

ALE

1:8

SECT

ION

5SC

ALE

1:20

SECT

ION

4SC

ALE

1:20

SECT

ION

6SC

ALE

1:20

SECT

ION

7SC

ALE

1:20

SECT

ION

8SC

ALE

1:20

SECT

ION

9SC

ALE

1:20

SECT

ION

10

SCAL

E 1:

20

SECT

ION

11

SCAL

E 1:

20SE

CTIO

N 1

2SC

ALE

1:20

SECT

ION

13

SCAL

E 1:

20

– 6 –

Technical Data Vivaro

• Installation of windows or sheet-metal panels in the vehicle sides

It is recommended that a glazed version of the Vivaro is used as the basis for conversion. If this is not possible, the following method is recommended:– Cut out the panel along the contours– Attach the panel and reinforcement with water-tight rivets (distance between rivets: 120 mm)– Bond in standard windows (use special seal provided).

• Rear doors

The procedure is the same as for side panels.

SectionPANEL VAN

50 mm

SLIDING WINDOW

50 mm

GLAZED VAN

50 mm

SIDE PANEL

GLASS OR SHEET METAL INSERT

UPPER REINFORCEMENT

LOWER REINFORCEMENT

STRUT

ROOF STRUT

200 mm

UPPER REINFORCEMENT

– 7 –

Technical Data Vivaro

• Floor group – main sections

See also platform chassis

• Position of crossmembers

The following drawings are plan views (without floor panel). The positions of the side members andcrossmembers for vans, combis and buses are illustrated (L1, L2, RHD and LHD).

L1 Van (LHD and RHD)

L1 Combi and bus (LHD)

For further details, see drawing of L1 Van.

ONLY APPLIES TO VEHICLES WITH SLIDING DOOR ON RIGHT

FRO

NT

AXLE

2969

2644

2165

1840

196

250

2392

2790

2911

2955

3187

1954

3487

570

816

543

25

75

1354

1455

634

2411

2611

1269

516

516 63

4

3788

FRO

NT

AXLE

489

211

905

1743

2067

2392

2790

145

– 8 –

Technical Data Vivaro

L2 Van (LHD and RHD)

For further details, see drawing of L1 Van.

L2 Combi and bus (LHD)

For further details, see drawing of L1 Van.

FRO

NT

AXLE

2165

2644

2969

1840

250

196

3311

3355

3187

3587

2811

3011

4188

FRO

NT

AXLE

3887

ONLY APPLIES TO VEHICLES WITH SLIDING DOOR ON RIGHT OR NO SLIDING DOOR

ONLY APPLIES TO VEHICLES WITH SLIDING DOOR ON LEFT OR NO SLIDING DOOR

2354

– 9 –

Technical Data Vivaro

• Partition between cab and load compartment

Vans and platform chassis can be supplied with a partition (as standard in some models).

The following partitions are available:

– One third separation grille on right or left side, depending on whether the vehicle is RHD or LHD(not available for platform chassis)

– Sheet metal partition with window

– Sheet metal partition without window

The partitions are attached with bolts and rivets, but are not completely sealed.

Vehicle converters installing partitions should refer to diagrams on the following pages, which showthe ideal installation position taking account the driver’s seat suspension, cab ergonomics and thepallet loading through the side door (pallet dimensions 800 mm x 1000 mm x 1000 mm).

– 10 –

Technical Data Vivaro

• Access to load compartment via side sliding door

Full partition

Separation grille

50%

849,450

1262

,7

50

5011

71,1

50

DOOR APERTURE WITH SEAL

FULL PARTITION

FRONT ACCESS LIMIT

50%

FRONT ACCESS LIMIT

SEPARATION GRILLE

DOOR APERTURE WITH SEAL

5011

71,1

50

50 50839,4

1262

,7

– 11 –

Technical Data Vivaro

• Loading a europallet

Full partition

Separation grille

50%

1283

800 7070

8410

0050

DOOR APERTURE WITH SEAL

SEPARATION GRILLE

FRONT ACCESS LIMIT

145

50%

FRONT ACCESS LIMIT

FULL PARTITION

DOOR APERTURE WITH SEAL

5010

0084

70

1283

80 800

145

– 12 –

Technical Data Vivaro

• Lashing points

The L1 van features six lashing points, the L2 van features eight.All the rings are attached to the sheet metal panel and conform to DIN 75410. The specification for the fastening bolts is M8 x 26.5.

– 13 –

Technical Data Vivaro

Diameter 9,2 mm

Position of lashing points

L1 Van

L2 Van

FRON

T AX

LE

Z0

276

40

36 70

2633

3679

1435

– 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

Y 0 Y 200 Y 400 Y 600 Y 800

Z 1600

Z 1400

Z 1200

Z 1000

Z 800

Z 600

Z 400

Z 0

Z 200

285

SECTION A-A

16731672800

803

890

802

834

827

633

833

A

A

– 15 –

Technical Data Vivaro

• Accessibility via rear doors/tailgate

Access to the load compartment via the rear door frame fulfils the EN 1789 for ambulance vehicles.The overall dimensions include details of gap dimensions and installation position (version with 250°opening angle) at various levels.Note: The height of the floor ribbing is 10 mm

– 16 –

Technical Data Vivaro

Y-400Y-800 Y800Y400Y0

Z1600

Z0

Z1200

Z800

Z400

Z 1651

1390

1314

1268

Z 285

1678

870

1642

721

678

34

39

870

• Accessibility via rear doors

172° opening angle, applies to L1H1

– 17 –

Technical Data Vivaro

1233

1641

870

1686

870

1255

678

721

• Accessibility via the rear doors

250° opening angle, applies to L2 without sliding doors

– 18 –

Technical Data Vivaro

870

1401

1641

870

1685

1440

678

721

• Accessibility via the rear doors

233° opening angle, applies to L2 with sliding doors

– 19 –

Technical Data Vivaro

• Accessibility via the rear doors

• Accessibility via the tailgate, applies to L1

(la

den /

unlad

en)

1846

/ 195

9

1141

1767

/ 185

4

2027

/ 21

28m

ax. 2

042,6

(un

laden

)

min.

405,5

(lad

en)

– 20 –

Technical Data Vivaro

• Accessibility via the side sliding door

For further details, see:

– partition wall

– insulation of the side sliding door

– 21 –

Technical Data Vivaro

min. 1003 mm

max

. 107

8 mm

• Platform chassis

Vivaro platform chassis are fitted with a connection flange with six fastening points. The seat beltanchor points are certified as such.

• Body connection – Position of fastening points

The position of the fastening points is shown below.

Note: For reasons of structural rigidity, the new body must be fastened to all fastening points. It is not sufficient to fasten them to the floor only.

– 22 –

Technical Data Vivaro

A

A

BB

CC

Section A-A

(Body fastening points)

Section B-B

PARTITION

– 23 –

Technical Data Vivaro

PARTITION

Section C-C

– 24 –

Technical Data Vivaro

PARTITION

• Body connection – side sill closing panel

The following illustrations show the sections of the side sill closing panel for platform chassis and vans. It is advisable to select a geometrical inertia which corresponds to that of the van.

– 25 –

Technical Data Vivaro

Section A-A

Section B-B

100

100

– 26 –

Technical Data Vivaro

--- -- --- -- --- - Van______________ Platform chassis

--- -- --- -- --- - Van______________ Platform chassis

100

196.3

324.7

Section C-C

Section D-D

– 27 –

Technical Data Vivaro

--- -- --- -- --- - Van______________ Platform chassis

--- -- --- -- --- - Van______________ Platform chassis

– 28 –

Technical Data Vivaro

Lower pillar lining

Sill closing panel

Area which must be closed for acoustic reasons.

Side window glazing bar

Front door frame Sidemounting

Maximum overall width

Area which must be closed for acousticreasons.

Lower door end panel

Lower pillar

lining

sill end piece

Maximumoverall width

sill beam

sill end piece

Floor panel

Section E-E

On the rear of the B pillar

Section F-F

Horizontal cut at B pillar

• Body connection – Floor group

The following illustration shows sections and fastening points for the floor group. The lower rear panelfor various vehicle versions is also illustrated.The lower rear panel performs an important load-bearing function. For modifications to the lower rearpanel, please consult the Vivaro conversion recommendations manual under “Modifying the rearoverhang”.

– 29 –

Technical Data Vivaro

A

A

B

B

C

C

ZUGA

NG

KARO

SSER

IE

DD

BO

DY

AC

CES

S

171

130SCHNITTBEREICH

100

100

SCHNITTBEREICH

Section A-A

Section B-B

– 30 –

Technical Data Vivaro

CUTTING AREA

CUTTING AREA

50 mm

100

150

100

100

Section C-C

Section D-D

– 31 –

Technical Data Vivaro

• Rear wheel housing

Use standard fastenings 1 and 2 of the rear wheel housing cover to fasten the protective plate to thenew body.The protective plate must be tensioned along the Y axis between the wheel housing cover and body,in order to ensure sufficient stability and water-tightness.For details, please consult the drawings below.

Rear wheel housing section

VAN SIDE PANEL

WHEEL HOUSING COVER FLANGE (3 mm)

2

1

– 32 –

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 platformchassis.The relay/fuse box in the engine compartment has the following vacant slots:

– Position X, main fuse reserved for possible future applications

– Two vacant relay sockets

The relay/fuse box in the passenger compartment (accessible via the driver’s side flap in the instrumentpanel) has the vacant sockets: 1, 3, 4, 5, 6, 8, 18, 22, 23, 37, 38 and 39. The use of these vacant slots in production at a later date cannot be ruled out.

• Circuit diagrams

This section contains the following electrical diagrams:

– Fuse boxes and relay units

– Relais and fuses in driver cabine

– Main fuse in Engine compartment

– Relais in Engine compartment

– Wiring for Van and tailgate

– 33 –

Technical Data Vivaro

• Relay/fuse box Vivaro

– 34 –

Technical Data Vivaro

1 Not used

2 Radio3 Not used4 Not used5 Not used6 Not used7 AC, rear8 Not used9 Fog lamps

10 Central locking

11 Interior illumination12 Diagnostic plug,

immobiliser13 Rear screen heating

14 Rear screenwiper/washer system

15 Screen wipers16 Brake light17 ABS18 Not used19 Window winders20 Window winders21 Seat heating22 Not used23 Not used

24 Radio25 Heating

26 Accessories

27 High beam, left

28 High beam, right29 Low beam, left30 Low beam, right31 Tail lamp, left32 Tail lamp, right33 Rear fog lamp34 Horn35 Mirror heating36 Windscreen heating

control37 Not used38 Not used

39 Not used

Fuse assignment

• Fuse and relay boxes

In the cab

– One relay box behind the cigarette lighter.

– One fuse box on the left-hand side of the instrument panel.

– One main fuse for the power supply, located on the side of the battery.

– 35 –

Technical Data Vivaro

Note: The relay for the electronic thermostat is installed on the left-hand side of the air mixer and distributor.

• In the engine compartment

One fuse box is located on the left-hand side of the engine compartment.

– 36 –

Technical Data Vivaro

• Relais in driver cabine

A Relay for the rear screen heating

B Time-out for rear screen wipers

C Relay for the rear screen wipers

D Relay + after-contact

E AC tripping relay

F Relay for the heatable windscreen

G Relay for the fog lamps

H “Headlight” relay for low beam

H “Headlight” relay for parking lights

J “Headlight” main relay

K Relay for the electronic thermostat

• Main Fuses in engine compartment

– 37 –

Technical Data Vivaro

• Relais in Engine compartment

1 2 or 3 add-on heater (auxiliary heater)/parking heater (diesel) relay

2 Relay for fuel injection computer (diesel)/ injection interrupt (petrol)

3 Diesel pump relay4 Fuel pump/diesel pre-heating relay.5 Relay for fan unit, second speed level

(Diesel parking heater)6 Coupling relay: AC compressor7 1 add-on heater (thermo-plunger) relay8 2 or 3 add-on heater (thermo-plungers)/

parking heater (petrol) relay9 Fan unit (diesel)/Relay for second speed level

with AC (diesel)/first speed level with AC (petrol)10 Fan unit (petrol)/Relay for first speed level of the

fan with AC (diesel)/second speed level with AC (petrol).

11 Not used.12 Relay for heatable windscreen.13 Relay for heatable windscreen.

Diesel vehicles equipped with cab/parking heater.

Note: In the diesel version the vehicle is either equipped with an auxiliary heater or with a parking heater.

The Vivaro multiplex network enables the 4 computers (CPU cab, fuel injection, airbag and instrumentpanel) to exchange data.

The network is connected with the connection for the diagnostics plug and uses the CAN (Controller Area Network) protocol

– 38 –

Technical Data Vivaro

Bundled (multiplex) network

1 Instruments – dashboard/instrument panel

2 Airbag computer

3 CPU cab

4 Connection for diagnostics plug

5 Fuel injection computer

• Wiring harnesses

– 39 –

Technical Data Vivaro

5 Supplementary information

• Ground clearance

The specified ground clearance given for the van, combi and platform chassis relate to vehicles at total permissible weight.

L1 version

L2 version18

3

179

165

SPARE WHEEL WELL

ENGINE SUPPORT

MUFFLER

20° 22°

ANGLE OF INCLINATION 15°

TPW only

TPW only 24° 21°

165 173

ANGLE OF INCLINATION 24°

MULDE SPARE WHEEL WELLMUFFLER

ENGINE SUPPORT

171

– 40 –

Technical Data Vivaro

Platform chassis version

18° 20°

ANGLE OF INCLINATION 14°

184

178

160

TPW only

SPARE WHEEL WELL

ENGINE SUPPORT

MUFFLER

– 41 –

Technical Data Vivaro

• Centre of gravity

The specified centres of gravity relate to the unladen vehicle, ready to drive.

L1 Van

L2 Van

1333,3

370,

7

5 mm LEFT OF LONGITUDINAL AXIS

1198,8

366,

2

5 mm LEFT OF LONGITUDINAL AXIS

– 42 –

Technical Data Vivaro

L1 Combi and bus

L2 Combi

11.2 mm LEFT OF LONGITUDINAL AXIS

386.

3

394,

6

KOMBI (6-SITZER)8.6 mm LEFT OF LONGITUDINAL AXIS

1467,2 COMBI (8/9-SEATER)

1418,1 COMBI (6-SEATER)

KOMB

I (8/9

-SEA

TER)

KOMBI 8/9-SITZER

KOMB

I (6-SE

ATER

)

1336,5

391,5

11.2 mm LEFT OF THE VEHICLE’S LONGITUDINAL AXIS

393.

2BU

S

1345,2 BUS

BUS7.6 mm LEFT OF LONGITUDINAL AXIS

– 43 –

Technical Data Vivaro

Platform chassis

1044,4

284,

4

18.4 mm LEFT OF LONGITUDINAL AXIS

– 44 –

Technical Data Vivaro

• Tyres and turning circle diameter

The rebound clearance envelope of the rear wheels is specified as a section with dimensions.The section is shown with an asymmetrical rebound clearance and fully compressed stops.It is recommended that a clearance of 10 mm should be added for each body position.

• Turning circle diameter

The specified turning circle diameters relate to wheel bases L1 and L2 and vehicles with extendedwheel base.

– 45 –

Technical Data Vivaro

TPW Tyre size Rolling circumference Rims Speed index Load index2,7 t 195 / 65 R16 2000 mm 6J16 R 100/98R2,9 t 205 / 65 R16 2042 mm 6J16 R 107/105R

Option 215 / 65 R16 2085 mm 6J16 R 106/104R

TURNING CIRCLE

BETWEEN WALLS

BETWEEN PAVEMENTS

WHEEL BASE (MM)

• Seat belt anchorage points

Seat belt anchorage points for L1 vans, combis and buses

Seat belt anchorage points for L2 vans and combis

50%

379

276

Z0

1219

294

1311

1245

474 21

9

1450

2720

3300

1425

2708

3077

FRON

T AX

LE

50%

FRON

T AX

LE

3519

2708

1425

3300

2720

1450

195

474

1245 13

11

294

1219

Z0

276379

– 46 –

Technical Data Vivaro

• Seat mountings:

Seat mounting points for vans and combis

Seat mounting points for buses

LONGITUDINAL AXIS

X905Y-616

X905Y-254

X905Y254

X905Y616

X1319Y516

X1319Y254

X1319Y-254

X1319Y-516

X1840Y-250

X2164,8Y-250

X1840Y-516

X2164,8Y-516

X2968,8Y-250

X2968,8Y-516

X2644Y-250

X2644Y-516

X2968,8Y250

X2968,8Y516

X2644Y516

X1840Y516

X1840Y250

X2164,8Y250

X2164,8Y516

X2644Y250

X1319Y0

LONGITUDINAL AXIS

X905Y-616

X905Y-254

X905Y0

X905Y616

X1319Y516

X1319Y329

X1319Y-254

X1319Y-516

X1840Y-250

X2164,8Y-250

X1840Y-516

X2164,8Y-516

X2968,8Y-250

X2968,8Y-516

X2644Y-250

X2644Y-516

X2968,8Y250

X2968,8Y516

X2644Y516

X1840Y516

X1840Y250

X2164,8Y250

X2164,8Y516

X2644Y250

– 47 –

Technical Data Vivaro

50%

45441

6

Z0

276

379

• Position of R points

R points for combis and buses

(LHD)

– 48 –

Technical Data Vivaro

R points for combis

(LHD)

R points for buses

(LHD)

LONGITUDINAL AXIS

FRON

T AX

LE

1077

2053

2857

435

435

383

356

LONGITUDINAL AXIS

FRON

T AX

LE

1147

1077

2053

2857

435

523

123

500

500

– 49 –

Technical Data Vivaro

• Fuel supply system

The fuel supply system is identical for all versions, regardless of whether they are LHD or RHD. The fuel tank filler pipe (passenger vehicle model, according to SAE J 1140) is described overleaf. Any changes to the fuel lines or the fuel tank require re-certification. The fuel tank has a capacity of 90 litres.

• Changing position of the filler pipe

This modification is not recommended as the routing of the tank filler pipe is very complex. If changesare absolutely necessary, the result must comply with all applicable regulations and allow unimpairedfilling.

• Add-on heater

The add-on heater can be ordered ex works. When retrofitting, the feed line must be replaced by partnumber 91166223. These modifications ensure sufficient fuel supply to the engine, regardless of tanklevel and vehicle dynamics.

Note: The fuel lines are made from PA11/PA12.

Position of fuel supply system

(Petrol version)

FRON

T AX

LE

LONGITUDINAL AXIS

– 50 –

Technical Data Vivaro

Technical Data Vivaro

100 mm

BODY

MAX

IMUM

290

89

BB

FRON

T AX

LE

LONGITUDINAL AXIS

– 51 –

Position of the fuel supply system

(Diesel version)

Section A-A

Tank filler pipe (according to SAE J 1140)

Section B-B

Tank filler pipe (according to SAE J 1140)

100 mm

150

90

80

BODY MAXIMUM

– 52 –

Technical Data Vivaro

• Fuel tank versions

– 53 –

Technical Data Vivaro

Fuel tank (petrol) without add-on heater

Line with solenoid valve

Engine feed line

Supply unit

Feed hose, Sleeve, seal

Charcoal canister

Filter

Tank

Clamp

Ground cable

Fuel tank (petrol) with add-on heater

Line with solenoid valve

Engine feed line

Supply unit

Feed hose, Sleeve, seal

Charcoal canister

Filter

Tank

Clamp

Ground cable

Feed hose,Add-on heater

• Fuel tank versions

– 54 –

Technical Data Vivaro

Fuel tank (diesel) without add-on heater

Feed line

Supply unit

Return line

Filter Tank

Clamp

Feed hose, Sleeve, seal

Fuel tank (diesel) with add-on heater

Feed line,Add-on heater

Supply unit

Return line

Filter

Tank

Clamp

Feed hose, Sleeve, seal

Feed line

• Position of brake system

The position of the brake system is shown in the following illustrations. Two different brake servos unitsare used, depending on the engine and vehicle version. One is a 10 inch brake servo for LHD vehicleswith F9Q engine, the other is a 9/10 inch brake servo for versions with F4R or G9U engines and for allRHD vehicles.

Note: For safety reasons, all vehicles with extended wheel base must be equipped with an ABSbrake system.

10-inch brake servo (without ABS)

10-inch brake servo (with ABS)

LONGITUDINAL AXIS

FRON

T AX

LEFR

ONT

AXLE

LONGITUDINAL AXIS

– 55 –

Technical Data Vivaro

9/10-inch brake servo (without ABS)

9/10-inch brake servo (with ABS)

LONGITUDINAL AXIS

FRON

T AX

LE

LONGITUDINAL AXIS

FRON

T AX

LE

– 56 –

Technical Data Vivaro

• Location of the spare wheel

– 57 –

Technical Data Vivaro

LONGITUDINAL AXIS

FRON

T AX

LE

X 3431Y-127Z 140

• Parking brake system

LHD

RHD

LONGITUDINAL AXIS

FRON

T AX

LE

LONGITUDINAL AXIS

FRON

T AX

LE

– 58 –

Technical Data Vivaro

• Modification of the exhaust system

The exhaust pipe must be extended in length in the central section (diameter 50/47 mm).The extension must be made from stainless steel, in accordance with the warranty against corrosion.

F4R engine

F9Q engine

LONGITUDINAL AXIS

FRON

T AX

LE

LONGITUDINAL AXIS

FRON

T AX

LE

– 59 –

Technical Data Vivaro

G9U engine

LONGITUDINAL AXIS

FRON

T AX

LE

– 60 –

Technical Data Vivaro

• Engine cooling

The illustrations below show the coolant circuits for the engine versions F4R, F9Q and G9U as well as the A/C circuits for the engine versions F4R and F9Q.

F4R engine coolant circuit

HO

SE C

LAM

P |A

16

RADI

ATO

R

RADI

ATO

R FE

ED H

OSE

HEA

T EX

CHAN

GER

FEED

HO

SE

DEG

ASSI

NG

HOSE

HO

SE C

LAM

P |A

18

HO

SE C

LAM

P |A

20

COO

LAN

T CO

MPE

NSA

TIO

N T

ANK

HO

SE C

LAM

P |A

20

HOSE

CLA

MP

|A 1

2

HO

SE C

LAM

P |A

12

HO

SE C

LAM

P |A

32

HOSE

CLA

MP

|A 3

2

RADI

ATO

R O

UTLE

T HO

SE

– 61 –

Technical Data Vivaro

F9Q engine coolant circuit

RADI

ATO

R O

UTLE

T HO

SE

HOSE

CLA

MP

|A 3

2

HO

SE C

LAM

P |A

32

HO

SE C

LAM

P |A

12

HOSE

CLA

MP

|A 1

2

HO

SE C

LAM

P |A

20

COO

LAN

T CO

MPE

NSA

TIO

N T

ANK

HO

SE C

LAM

P |A

20

HO

SE C

LAM

P |A

18

DE

GASS

ING

HOSE

HEA

T EX

CHAN

GER

FEED

HO

SE

RADI

ATO

R FE

ED H

OSE

AUX

. ON

HEA

TER

FEED

HO

SE

RADI

ATO

R

HEA

TER

OUT

LET

HOSE

HO

SE C

LAM

P |A

24

HO

SE C

LAM

P |A

16

– 62 –

Technical Data Vivaro

– 63 –

Technical Data Vivaro

Non-AC radiatorAlumeca

G9U engine coolant circuit

G9U engine AC circuit

Radiator outlet pipe

Spring clamping ring, diameter 18

Spring clamping ring,diameter 18

Spring clamping ring, diameter 12

Spring clamping ring,diameter 12

Inlet pipe, heater4-auxiliary heater

Inlet pipe,heater

Outlet pipe, Compensation tank

Outlet pipe, heater

Spring clamping ring, diameter 20

Spring clamping ring, diameter 20

Spring clamping ring, diameter 20

Inlet pipe, Compensation tank

Compensation tank

Spring clamping ring, diameter 32

Spring clamping ring, diameter 32

Water outletmodule

Radiator inlet pipe

Condenser

High-pressure pipeCondenser compressor

Low-pressure pipe, evaporatorcoolant collector,

High-pressure pipe, condenserEvaporator

Receiver drier,assembled

Compressor

Low-pressure pipe, receiver drier, compressor

• AC circuit

F4R and F9Q engines

CONDENSER

COMPRESSOR

RECEIVER DRIER

CONDENSER – EVAPORATOR HIGH PRESSURE HOSE

EVAPORATOR – RECEIVER DRIER LOW PRESSURE HOSERECEIVER DRIER – COMPRESSOR LOW PRESSURE HOSE

COMPRESSOR – CONDENSER HIGH PRESSURE HOSE

– 64 –

Technical Data Vivaro

Additional heating circuit for G9U engine

radiator outlet pipe

radiator inlet pipe clamp

clamp

clampunder body ridgid pipes

clamp

radiator

heater unit

add. Heating

return pipe

Alternator

Depending on the version and connections, the X83 vehicles can be equipped with one of the twofollowing generators:

– 110 A alternator (F4R engine)– 125 A alternator (F4R, F9Q and G9U engines)

110 A alternator

MINIMUM OUTPUT AT 13.5 VOLT (INSTANTANEOUS VALUE) AFTER WARM-UP FOR Ω HOUR AT 3000 RPM AT 13.5 V

– 65 –

Technical Data Vivaro

Output curve

125 A alternator

MINIMUM OUTPUT AT 13.5 VOLT (INSTANTANEOUS VALUE); AFTER WARM-UP PERIOD FOR Ω HOURAT 3000 RPM AT 13.5 V

– 66 –

Technical Data Vivaro

Output curve

6 Options and Accessories

• Power take-off

The vehicle can be ordered with an optional power take-off in the form of a belt-driven pulley. A drive belt with the following specification is employed:

– Number of ribs: 6– Width (mm): 21.36 ± 0.5

– Length: 1795 ± 0,5

– Service life: 120,000 km (for standard compression characteristics)– Static tension of the belt in operation: 250 N per strand at 20 °C

Pulley and drive belt

Note: The output and torques which can be reached are considerably in excess of the specifiedvalues. Systematic calculations are necessary to determine the following values relating to the drive belt and pulley:

– Tension

– Service life

Contact the belt manufacturer in order to determine these values.

– 67 –

Technical Data Vivaro

Drive belt

pulley

• Additional Air Condition for engine versions F4R and F9Q

(only in conjunction with AC and power take-off).

An additional AC is available as an option for the combi and bus versions. In order to equip the vanwith an additional AC unit it must be retrofitted using combi components.

Procedure:

1 Use original condenser2 Use evaporator and condenser lines.3 Cut holes in floor panel (see illustration overleaf).4 Attach AC to rear panel inner lining (use existing bores)

(Note: Care is required with part numbers for intermediate pipe for L1 / L2 versions)

– 68 –

Technical Data Vivaro

TUBE

UNIT

LOW PRESSURE LINE

HIGH PRESSURE LINE

INTERMEDIATE LINE

CONDENSOR – EVAPORATOR DRIER HIGH-PRESSURE PIPE

EVAPROATOR – RECIVER DRIER LOW PRESSURE PIPE

CONDENSER

• Cutouts for additional AC lines, right side of vehicle, behind the rear wheel housing.

– 69 –

Technical Data Vivaro

4R = 5

1 TO 7,2

1 BO 7,2 x 14,249

75

67,3

35,5 35,5

68,5

• Auxiliary heater

An auxiliary heater is available as an option for the combi and bus versions. In order to equip the vanversion with an auxiliary heater, combi parts must be used.

Procedure:

1 For F4R engine, replace radiator outlet line with part number 91166712; for F9Q engine, replacethermostat outlet line with part number 91166712.

2 Replace the original heating radiator feed line with part number 91166713.

3 Connect heater unit to the new pipes in the engine compartment (route fixed lines under body,part number 91166732).

4 Install auxiliary heater unit (part number 91167501). For details of the tank filler pipe, see fuelsupply system.

(Note: For details of electrical connections, see section on “Electrics”)

Overall view

RADIATOR OUTLET HOSEVERSION WITH AUXILIARY HEATER

UNDERBODY LINE

HEAT EXCHANGER OUTLET HOSEVERSION WITH AUXILIARY HEATER

5 KW HEATER UNIT

– 70 –

Technical Data Vivaro

A A

FRO

NT A

XLE

1218

2079

2865

3345

1451

• Roof rack

Vivaro vehicles are fitted with roof rack fastening points, which constitute the only permissible fasteningpoints. The maximum permissible roof load is 200 kg for all vehicle versions. All the fastening pointsmust be used. If a shorter roof rack is used, the maximum permitted roof load is reduced by 25 kg foreach fastening point not used.It is recommend to use original parts (roof rack). If other manufacturers’ products are used, the attaching points must be identical to the original parts.The centre of gravity of the roof load must not be higher than 100 mm above the roof rack, i.e. approx. 200 mm above the van roof.

• Wind deflector

Important: Vivaro vehicles are not designed to be fitted with a roof spoiler, this option is thereforenot advisable.The roof would otherwise need to be fitted with suitable fastenings in order to avoid damage causedby vibration and wind pressure.

L1H1 van

– 71 –

Technical Data Vivaro

L2H1 van

Section A-A

(applies to versions L1 and L2)

88

|A 8,2

1451

3745

A A

FRO

NT A

XLE

1218

2079

2865

– 72 –

Technical Data Vivaro

• Trailer hitch

The maximum permissible trailer weight is 2000 kg (braked) and 750 kg (unbraked).The van and combi versions can be ordered with a pre-installed trailer hitch. All versions (including platform chassis) can be retrofitted with a trailer hitch.The maximum permissible tongue load is 80 kg. A telltale lamp indicating faulty trailer turn signallamps, is located on the instrument panel.

• Liftgate

The fastening holes for the trailer hitch can also be used as additional fastening points for a liftgate.These must not, however, be used as the only fastening points, as the forces exposured in this areawill result in damages of the underbody structure.

• Trailer hitch fastening points

– 73 –

Technical Data Vivaro

REAR SIDE MEMBER

REINFORCEMENT

3 M10 NUTS

LINK ELEMENT

DISTANCE FROM VEHICLE CENTRE

• Trailer hitch fastening points

– 74 –

Technical Data Vivaro

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