Conversion Guideline

Opel Movano [ X62 ]

Part 3 - Chapter 53-79 and 142-148

Edition: September 2014

GME Engineering
Special Vehicle Development / Light Commercial Vehicles
Rüsselsheim / Germany
OPEL MOVANO (X62)
CONTENTS

Conversion Guideline - Part 3

CHAPTER DESCRIPTION: PAGE

53 FOLDING PARKING BRAKE 3
56 ROOF RACKS AND ROOF BARS 4
57.1 * TRAILER HITCH 7
57.2 INTEGRATED STEP IN REAR BUMPER 15
58 TACHOGRAPH 17
59 SUNROOF AND EMERGENCY EXIT 18
60 REAR AND FRONT SUSPENSION 20
63.1 POWER TAKE-OFF, FRONT WHEEL DRIVE 24
63.2 POWER TAKE-OFF, REAR WHEEL DRIVE 28
63.3 POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE 32
65 PREPARING FOR COLD COUNTRIES 37
67 FUEL SUPPLY SYSTEM 38
68 EXHAUST SYSTEM 43
69 BRAKE SYSTEM 47
78 TRANSLATION OF THE FUEL TANK FILLER PIPE 54
79 MAXIMUM AUTHORIZED LOAD PER AXLE 56

142 AERIAL WORK PLATFORM (CHERRY PICKER) ON PANEL VAN 57

143 PROHIBITED CONVERSION TYPES 58
146 LIFT TAILGATE 59
148 DETERMINING THE CENTRE OF GRAVITY 60

* = This chapter is new or was modified after the last edition of September 2014.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines).
OPEL MOVANO (X62)
53 – FOLDING PARKING BRAKE

The platform cab and chassis cab versions specific to campervans may be fitted with a folding parking
brake as an option.
The parking brake on all vehicles can be replaced by a folding model. The folding parking brake reference
for ordering from the Opel dealer network is 8200727562. Upon replacement, the main cable must also be
changed.

FOLDING PARKING BRAKE

1: Parking brake 2: Main cable (under body)

Operating the folding parking brake:

- To engage: pull the lever up and then release. It goes back down into horizontal position.
- To release: while holding down the push button, pull the lever up before returning it to a horizontal
position.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 3
OPEL MOVANO (X62)
56 – ROOF RACKS AND ROOF BARS

Fixing points for roof rack systems

Movano vehicles are prepared for the fitting of a roof rack, except on models with an H3 high roof. The use
of roof rack fixing points requires an inside connection and reinforcement plate between the roof and roof
strut reinforcement.
For safety reasons and to avoid damage to the roof, the vehicle approved roof rack system is
recommended. Follow the installation instructions and remove the roof rack when not in use. Driving with a
roof load increases the sensitivity of the vehicle to cross-winds and has a detrimental effect on vehicle
handling due to the vehicle's higher centre of gravity. Distribute the load evenly and secure it properly with
retaining straps. Adjust the tyre pressure and vehicle speed according to the load conditions.
N.B: For passenger transport vehicles fitted with emergency exits in the roof, it is forbidden to block or
even partially obstruct these openings when installing roof racks or roof bars.
The following specified fixing points must be used.

L1H1 / L1H2 1- 2 3- 4 5- 6

L2H2

1- 2 3- 4 5- 6 7- 8

L1H1 L1H2 L2H2

X Y (+/-) Z X Y (+/-) Z X Y (+/-) Z
1 1557 1557 1557
2 1617.5 1617.5 1617.5
3 2397 2397 2480
4 2458 2458 2540
660.5 1979 600 2177 600 2177
5 3635.5 3635.5 3330
6 3696 3696 3390
7 -- -- 4135.5
8 -- -- 4196
N.B: The values are in mm and start from the axis of the front axle for the dimensions along X.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status January 2012 4
OPEL MOVANO (X62)
56 – ROOF RACKS AND ROOF BARS

1- 2 3- 4 5- 6 7- 8 9-10
L3H2

L4H2

1- 2 3- 4 5- 6 7- 8 9-10 11-12

L3H2 L4H2
X Y (+/-) Z X Y (+/-) Z
1 1557 1557
2 1617.5 1617.5
3 2480 2480
4 2540. 2540
5 3330 3330
6 3390 3390
600 2177 600 2177
7 3938 3938
8 3999 3999
9 4785.5 4785.5
10 4846 4846
11 -- 5435.5
12 -- 5496
N.B: The values are in mm and start from the axis of the front axle for the dimensions along X.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status January 2012 5
OPEL MOVANO (X62)
56 – ROOF RACKS AND ROOF BARS

Roof bars

MAX. PERMISSIBLE LOAD

MAX. NUMBER MASS OF ONE
VEHICLE TYPE LENGTH * ON THE ROOF
OF BARS BAR *
(All fixing points must be used)

L1H1 approx. 1650 mm approx. 2.4 kg

3 150 kg
L1H2
L2H2 4
approx. 1530 mm approx. 2.3 kg
L3H2 5 200 kg
L4H2 6

*= Weight and length may vary depending on version.

ATENTION:
- The maximum permissible mass per bar on the roof is 50kg.
- The maximum permissible mass on the roof is 150kg for a
Van L1H1 and L1H2.
- The maximum permissible mass on the roof is 200kg for a
Van L2H2, L3H2 and L4H2.
- The H3-roof is made of plastic. This roof is not intended for
attaching a roof rack
Example of roof bars
Roof rack

MAX. PERMISSIBLE LOAD ON

NUMBER OF MASS OF
VEHICLE TYPE THE ROOF
MOUNTINGS THE ROOF RACK *
(All fixing points must be used)

L1H1 approx. 22,7 kg

2x3 200 kg
L1H2 approx. 22,0 kg
L2H2 2x4 approx. 30,5 kg
L3H2 2x5 approx. 34,5 kg 200 kg
L4H2 2x6 approx. 43,0 kg

*= Weight may vary depending on version.

Example of roof rack

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status January 2012 6
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

A trailer hitch is available as an option for the panel van, combi models und chassis cabs; a tow bar can also
be obtained as an accessory from your Opel dealer (all models, including chassis cab).

The fitted tow bar must comply with European standard 94/20.
The permissible maximum towable, unless otherwise noted:
of a braked trailer is 2500 kg, vehicles with a GVW of 3500kg and single wheels only.
The maximum nose weight is 100kg (vertical force
allowable on the ball/towing system).
of a braked trailer is 3000 kg, vehicles with a GWV of 4500kg, RWD and twin wheels only.
The maximum nose weight is 120kg (vertical force
allowable on the ball/towing system).
of a braked trailer is 3500 kg, chassis cab with a GWV of 3500kg, RWD and twin wheels
only. The maximum nose weight is 140kg (vertical force
allowable on the ball/towing system).
of an unbraked trailer is 750kg

The permissible trailer loads are specified in the vehicle documents. In general, they are valid
for gradients up to max. 12 %.
GVW = gross vehicle weight; RWD = rear wheel drive

Mounting points and fabrication tolerances are given as follows; it is essential that all these mounting
points are used.

Note:

Vehicles from MY2015 are usually equipped with a trailer stability function ( = TSF ).
This system helps improve vehicle stability when it is towing a trailer or caravan. The system
detects the oscillation being a trailer and rear brake works by alternating left / right to cancel
the oscillations.
The TSF-function is deactivated in vehicles without tow bar. When retrofitting a trailer hitch, this
function can be activated by your Opel/ Vauxhall-Service. With the diagnostic tool [GDS2] under
the option item "Trailer Brake Control" it is possible to activate this function.
In the case of a change in the rear overhang, reinforcing brackets must be added if a trailer hitch is
fitted. These reinforcing brackets will ensure the soundness of the vehicle's side member when
towing.
It may be necessary to check compliance with the regulations.
The wiring diagram for this trailer hitch is given in chapter 132.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 7
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

1. Trailer hitch on panel vans

1 4

3 5

6
View from the bottom assembly, left side.

1: Rear left suspension

2: SCREW: HM12X175-55
3: Rear section of the rear left sidemember
4: Rear crossmember and skirt
5: trailer hitch
6: support trailer hitch

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 8
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

1.1. Front wheel drive version (Towing weight 2,5 t)

2
1
3

1: trailer hitch
2: support left side
3: support right side

1.2. Single wheel rear drive version (Towing weight 2,5 t)

outside

2
1
3

1: trailer hitch
2: support left side
3: support right side

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 9
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

1.3. Twin wheel rear drive version (Towing weight 3 t and 3,5 t)

inside

2
1
3

1: trailer hitch
2: support left side
3: support right side

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 10
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

2. Tow bars on chassis cabs and chassis double cabs

1
2

4 5

View from the bottom assembly, left side.

1: Rear left suspension

2: Rear section of the rear left sidemember
3: Extreme rear crossmember
4: Support trailer hitch
5: Trailer hitch

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 11
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

2.1. Front wheel drive version single wheel (Towing weight 2,5 t)

S1 single wheel
S2 single wheel

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 12
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

2.2. Twin wheel rear drive version twin wheels (Towing weight 3 t and 3,5 t)

S1 twin wheels
S2 twin wheels

S1 twin wheels < S1 single wheel

S2 twin wheels < S2 single wheel

Note:
The short overhang chassis cab version is not compatible with the coupling devices described
above.
It may be necessary to check compliance with the regulations.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 13
OPEL MOVANO (X62)
57.1 – TRAILER HITCH

3. Dimensions trailer hitch ball

trailer hitch ball type approved at
2.5t for vehicles with a maximum permissible laden mass of 3.5t GVW.
3.0t and 3,5t for vehicles with a maximum permissible laden mass of 3,5 and 4.5t GVW
(Only for RWD with twin wheels).

3.1. Version 2,5 t

oder oder

3.2. Version 3 t and 3,5 t

min = minimum

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2014 14
OPEL MOVANO (X62)
57.2 – INTEGRATED STEP IN REAR BUMPER

Integrated step in rear bumper for panel vans are available as an option or in after-sales.
They are compatible with tow bars.
Parts A, B and C must be installed for versions without tow bars.

1.1. Front wheel drive version

1.2. Rrear drive version

B - Single wheel C - Twin wheel

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status Mai 2011 15
OPEL MOVANO (X62)
57.2 – INTEGRATED STEP IN REAR BUMPER

Van
overall length in mm
Vehicle without with
wheelbase drive
length integrated step integrated step

L1 3182 FWD 5048 5095

L2 3682 FWD 5548 5595

4332 FWD 6198 6245

L3
3682 RWD 6198 6311

L4 4332 RWD 6848 6961

Example for integrated step in rear bumper for rear wheel drive version (the rear parking
distance sensors are available as an option)

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status Mai 2011 16
OPEL MOVANO (X62)
58 – DIGITAL TACHOGRAPH

Depending on the type of vehicle and the country where it is sold, the vehicle may be fitted with a digital
tachograph as standard.
It is also possible, on a vehicle not fitted with a tachograph as standard and depending on what the vehicle
will be used for, to order the tachograph as an option.
This is particularly the case in Europe for goods vehicles with a gross train weight of more than 3.5 t. It is
therefore highly recommended to offer the chronotacygraph option for vehicles ordered with the trailer
coupling option.
If the customer is exempt from the use of a tachograph , it is prudent to get him to mention this on the order
stating that he is lawfully exempt from tachograph use.
A vehicle fitted with a digital tachygraph (standard or optional) is also fitted with an CAN BUS- Interface
module (refer to chapter105- CAN BUS- INTERFACE MODULE) for reduncancy of vehicle speed information.

N.B.:
Fitting after manufacture is not possible.

TACHOGRAPH POSITION IN THE ROOF CONSOLE

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status October 2012 17
OPEL MOVANO (X62)
59 – SUNROOF AND EMERGENCY EXIT

The roofs of some bodywork versions are marked out for cutting out and installing a sunroof and/or an
emergency exit.

SUNROOF
(Panel vans L1H1)

(L2H2 Chassis double cab)

SUNROOF AND EMERGENCY EXIT

(Panel vans L2H2, L3H2 and L4H2)

Sunroof Emergency Exit

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 18
OPEL MOVANO (X62)
59 – SUNROOF AND EMERGENCY EXIT

DIMENSIONS

396
(Sunroof cut-out)

816
27

(Emergency exit cut-out) 522

756
33

N.B: For passenger transport vehicles fitted

with emergency exits in the roof, it is
forbidden to block or even partially
obstruct these openings when installing
roof racks or roof bars.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 19
OPEL MOVANO (X62)
60 – REAR AND FRONT SUSPENSION

1. Rear suspension
The vehicle’s rear suspension is created by leaf springs coupled to hydraulic shock absorbers. All rear
wheel drive vehicles and some front wheel drive versions also have an anti-roll bar.
The definition of the leaf springs varies depending on the type of vehicle and the gross vehicle weight
(GVW).
Regardless of the suspension type, it is prohibited to add an additional air cushion in the bump stop
area and between the side members.
A host structure, sized to withstand the cushion / body interface forces, must be used.
Regardless of the vehicle, do not touch the original bump stops, which are suspension parts with two
functions:
- bump stop
- suspension function

2 1 3 2

1: Bump stop of the vehicle

2: air bellows
3: frame longitudinal member

N.B.:
The polyurethane bump stops are in constant contact with the axle and therefore contribute to the
stiffness of the rear suspension.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2013 20
OPEL MOVANO (X62)
60 – REAR AND FRONT SUSPENSION

2. Front wheel drive vehicles

All front wheel drive vehicles are fitted with one single steel leaf spring.

2.1. Rear axle for panel van and chassis cabs

The rate of the single spring, flanged in the centre and with no articulation, is 71.7 N/mm

2.2. Rear axle for camper vans (with normal and widened tracks)
Special campervan versions with widened tracks for which the rate is 100.9 N/mm.

Note: The widened track is strictly reserved for camper vans. It is prohibited to fit this axle to any
other conversion.

2.3. Rear Axle with Pneumatic suspension

It is available for panel vans and chassis

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2013 21
OPEL MOVANO (X62)
60 – REAR AND FRONT SUSPENSION

3. Rear wheel drive vehicles

3.1. Rear axle with single wheels

All single wheel rear drive vehicles are fitted with two steel leaf springs.
The rate of the single spring flanged in the centre and with no articulation, is 89.08 N/mm for a
deflection of 0 to 80 mm and 121.14 N/mm for a deflection of 80 to 180 mm. The origin of the travel
corresponds to the spring in free state.

3.2. Rear axle with twin wheels

All twin wheel rear drive vehicles are fitted with three steel leaf springs.
The rate of the single spring flanged in the centre and with no articulation, is 72.25 N/mm for a
deflection of 0 to 100 mm and 166.22 N/mm for a deflection of 100 to 200 mm. The origin of the
travel corresponds to the spring in free state.

4. Front suspension
The front suspension is a McPherson strut type suspension.
All rear wheel drive vehicles and some front wheel drive versions also have an anti-roll bar.
The coil spring rate is 56 N/mm.
FRONT AXLE

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2013 22
OPEL MOVANO (X62)
60 – REAR AND FRONT SUSPENSION

5. If the anti-roll bar is absent

5.1. Front axle

MOVANO [X62] WITHOUT ANTI-ROLL BAR ON REAR AXLE

Front wheel Rear wheel Wheelbase Roof Twin- GVW
ESP
drive drive [mm] height wheels [kg]

PANEL VAN X 3182 H1, H2 No 2800

PANEL VAN X 3182 2800

5.2. Rear axle

MOVANO [X62] WITHOUT ANTI-ROLL BAR ON REAR AXLE

Front wheel Rear wheel Wheelbase Roof Twin- GVW
ESP
drive drive [mm] height wheels [kg]

2800
PANEL VAN X 3182 H1 No 3300
3500
PANEL VAN X 3682 H2, H3 No X 3500
PANEL VAN X 3182 H2 No
PANEL VAN X 3682 H2 No 3300
COMBI X 3682 H2 No 3300
COMBI X 3182 H1 No X 2800

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2013 23
OPEL MOVANO (X62)
63.1 – POWER TAKE-OFF, FRONT WHEEL DRIVE

1. Option V66
Power take-off is available as an option on front wheel drive versions. The option consists mainly of a free
pulley attached to a support in place of the air-conditioning compressor and an automatic idler pulley.
Power take-off on rear wheel drive see also chapter 63.2 and 63.3
The power take-off option is incompatible with the robotized gearbox.
The power take-off option is incompatible with air conditioning.
If a piece of equipment is not installed in place of the free pulley immediately, the free pulley can be left as
it is. Its operation has been validated for normal use of the vehicle with no change to the belt changing
frequencies.

N.B.:
It is not possible to fit power take-off to the vehicle at a later stage. However, a space is provided at the
top of the engine to fit an additional piece of equipment driven by a second belt.

FREE PULLEY

5 1

3
1: Alternator
2: Accessory belt
3: Free pulley
4: Crankshaft damper pulley
5: Water pump
6: Power-assisted steering pump

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 24
OPEL MOVANO (X62)
63.1 – POWER TAKE-OFF, FRONT WHEEL DRIVE

Care must be taken to comply with the following points for assembly minimizing the impact on engine
reliability.
- The weight of the equipment to be fitted in place of the free pulley must not exceed 7.5 kg.
- The equipment must use the existing fastening points on the accessory support.
- The pitch diameter of the equipment’s drive pulley must be the same as that of the original pulley.
The pitch diameter of the engine’s free pulley is between 119.88 mm and 120.68 mm.
- The position of the equipment’s drive pulley must match the spatial coordinates of the free pulley.
- The alignment of the belt’s grooves must be the same as they were to start with.
- The maximum power absorbed by the equipment replacing the engine’s free pulley should not
exceed 6 kW.
- Characteristics of the original belt:
Type Poly-V to 7 V, width: 21.36 0.5 mm, length: 1,970 4 mm

These criteria allow the use of the original accessory belt. The belt replacement frequency must be re-
assessed according to the vehicle's use cycle and may differ from that stated in the vehicle maintenance
log book.

Driving a piece of equipment may call for the use of the accelerated idle.

2. After-sales assembly
This allows equipment to be fitted to a vehicle with air conditioning or to a vehicle without the power take-
off option.
An additional pulley (Kat.-No. 44 21 741) can be fitted to the crankshaft damper pulley to operate an
additional belt. Assembly of the additional crankshaft damper pulley means the original strut needs to be
removed and a new fastening screw used (Kat.-No. 44 31 161). The tightening torque is 50 Nm, plus angular
tightening of 85 6°.
The additional belt can vary from 5 to 7 V and may be elastic for which a dynamic tensioner need not be
used. Check that the additional belt is correctly lined up. The changing frequency for the additional belt
should be assessed and the user notified.
A space at the top of the engine is provided for fitting additional equipment. The fastenings for the
additional equipment support should take into account its weight. The maximum power absorbed by the
additional equipment should not exceed 6 kW.

This type of assembly is incompatible with the robotised gearbox.

Driving a piece of equipment may call for the use of the accelerated idle.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 25
OPEL MOVANO (X62)
63.1 – POWER TAKE-OFF, FRONT WHEEL DRIVE

ADDITIONAL CRANKSHAFT DAMPER PULLEY ASSEMBLY

8 1

3
5
4

1: Alternator
2: Accessory belt
3: Air-conditioning compressor
4: Strut (to be removed)
5: Additional crankshaft damper pulley
6: Mounting bolt
7: Crankshaft damper pulley
8: Water pump
9: Power-assisted steering pump

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 26
OPEL MOVANO (X62)
63.1 – POWER TAKE-OFF, FRONT WHEEL DRIVE

ASSEMBLY EXAMPLE

4
2

1 : Additional equipment
2 : Additional belt
3 : Additional crankshaft damper pulley
4: Idler roller
5 : Additional equipment support

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 27
OPEL MOVANO (X62)
63.2 – POWER TAKE-OFF, REAR WHEEL DRIVE

1. Option V66
Power take-off is available as an option on rear wheel drive versions. The option is comprised only of an
additional pulley attached to the crankshaft pulley. Power take-off on front wheel drive see also chapter
63.1 and 63.2.
The power take-off option is incompatible with the robotised gearbox.
Assembly of the additional crankshaft pulley is independent of the equipment fitted to the accessory face.
The additional crankshaft pulley may be left as it is without any particular effect.

ASSEMBLY EXAMPLE

3
6

4
5

1: Crankshaft pulley 2: Additional crankshaft pulley

3: Mounting bolt 4: Additional belt
5: Cooling compressor 6: Support

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 28
OPEL MOVANO (X62)
63.2 – POWER TAKE-OFF, REAR WHEEL DRIVE

Care must be taken to comply with the following points for assembly minimising the impact on engine
reliability.
- The weight of the equipment must not exceed 7.5 kg.
- The equipment must use the existing mounting points on the engine block.
- The equipment pulley and the additional crankshaft pulley must be aligned.
- The maximum power absorbed by the equipment should not exceed 6 kW.
- The additional belt can vary from 5 to 7 V and may be elastic for which a dynamic tensioner need
not be used.
- Check that the additional belt is correctly lined up.
- The changing frequency for the additional belt should be assessed and the user notified.

With this type of assembly, the whole equipment and support should be tested for vibratory resistance and
the additional belt for slippage, jump and longevity.

Driving a piece of equipment may call for the use of the accelerated idle.

N.B.: There is no free pulley on rear wheel drive versions.

DETAIL OF THE ADDITIONAL CRANKSHAFT PULLEY

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 29
OPEL MOVANO (X62)
63.2 – POWER TAKE-OFF, REAR WHEEL DRIVE

POSITION OF THE ADDITIONAL CRANKSHAFT PULLEY

IN RELATION TO THE SUPPORT’S MOUNTING POINTS

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 30
OPEL MOVANO (X62)
63.2 – POWER TAKE-OFF, REAR WHEEL DRIVE

N.B.:
The three holes are threaded to a depth of 19 mm; M8 x 1.25 tapping

2. After-sales assembly
The additional crankshaft pulley (Kat.-No. 44 21 741) can be fitted post-process. Assembly of the additional
crankshaft pulley means the original strut needs to be removed and a new mounting bolt used (Kat.-No.
44 31 161). The tightening torque is 50 Nm, plus angular tightening of 85 6°.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2011 31
OPEL MOVANO (X62)
63.3 – POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE

1. Power take-off (PTO) on gearbox option is available on rear wheel drive vehicles only.
The option consists of the power take-off, assembled on the gearbox, an activation button on the
instrument panel and an ECU.
The power take-off on gearbox option is incompatible with the robotized gearbox.

POWER TAKE-OFF ON GEARBOX

Power take-off (PTO) for M9T engines is a production option which must be specified by the converter
when the vehicle is ordered.

2. Power take-off production option assembly

PTO requires a ZF4*001 type gearbox and cannot be ordered with a robotized gearbox (Easytronic).

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2012 32
OPEL MOVANO (X62)
63.3 – POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE

3. Power take-off/Unit interface

1: Power take-off on ZF4 gearbox

2: Kit to mount a unit to the power take-off.

A
B

2 E
1

3.1. Assembly flowchart D

Clean mating surface (1)
Screw the studs (A) to the power take-off Tighten to a torque of 20 ± 3 N.m
Put the sleeve into place (B)
Put into place the joint (C), unit (pump, etc.), washers (D) and nuts (E) M10x150
Tighten the nuts (E) Torque of 50 ± 8 N.m

3.2. Mechanical properties

Maximum resulting torque 150 N.m between 1,000 and 2,000 rpm
PTO weight 7,4 kg
Drive/Engine rotation speed ratio 1.091
Max. permissible power at idle 22 kW

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2012 33
OPEL MOVANO (X62)
63.3 – POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE

4. Positioning of the PTO on vehicle (±2mm).

Distance Description (mm)

D PTO mounting face / front axle 369,5
E PTO mounting face / partition wall of the Panel van 1482
F PTO mounting face / rear panel of the Chassis Cab 1615
G PTO mounting face / rear panel of the Chassis Crew Cab 2366

Part Description Part Description

1 left front side member 5 partition wall of the Panel van
2 motor 6 rear panel of the Chassis Cab
3 gearbox 7 rear panel of the Chassis Crew Cab
4 Power take-off

1 2 3 4 5 6 7

D E
F

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2012 34
OPEL MOVANO (X62)
63.3 – POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE

Distance Description (mm)

A Middle axle shaft PTO / vehicle longitudinal axis (X- axis) 176
B Middle axle shaft PTO / left front side members 285,5
C Middle axle shaft PTO / left front side members 61,5

Part Description
1 left front side member
3 gearbox
4 Power take-off

C
B

PTO mounting face

Middle axle shaft PTO

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2012 35
OPEL MOVANO (X62)
63.3 – POWER TAKE-OFF ON GEARBOX, REAR WHEEL DRIVE

5. Position from the PTO and its control unit

2 3 1

Part Description

1 Power take-off

2 control unit (ECU) of Power take-off

engine interconnections unit (= BIM can be found to the left of the
3
engine compartment)

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status August 2012 36
OPEL MOVANO (X62)
65 – PREPARING FOR COLD REGIONS

The vehicle is adapted to extreme cold configuration by modifying or adding the following elements:
- Coolant
- Windscreen wash
- Addition of protective parts

Engine coolant
Drain the circuit and refill with a mixture of 5.5 litres of coolant and 5.5 litres of demineralised water.

Windscreen wash
Vehicles manufactured between April 1 and July 31 are delivered with a screen wash composed of
20% washer liquid and 80% demineralised water.
Outside of these dates, the vehicles are delivered in extreme cold (-20°C) configuration (45%
Antifreeze & clear view liquid and 55% demineralised water).

Front brake disc protection

Front brake disc protection must be added for extreme cold vehicles:
Front left:
Front right:
The addition of disc protection also protects the steering ball joint cover.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status November 2009 37
OPEL MOVANO (X62)
67 – FUEL SUPPLY SYSTEM

1. Fuel tank capacity

The mass production vehicle is delivered with an 80 litre fuel tank. A fuel tank with a capacity of 100
litres is available as an option. From the outside, the two tanks are identical. It is not possible to
modify the capacity of the fuel tank.
Any modification to the fuel tank will require the converter to apply for a new type approval.

Precaution
If disassembling and re-assembling the fuel tank, it is essential to maintain the assembly order of the
fuel tank straps on the front zone.
The vertical strap must be positioned above the strap that holds the fuel tank in place.

Retaining straps
Vertical strap

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status December 2010 38
OPEL MOVANO (X62)
67 – FUEL SUPPLY SYSTEM

100 and 80 litre fuel tank - REAR WHEEL DRIVE - Left-hand drive

4 2
6

5 1

100 and 80 litre fuel tank - REAR WHEEL DRIVE - Right-hand drive
2
6

5 1
4

1: Filler pipe 2: Tank

3: Engine supply pipe 4: Diesel filter
5: Vapour absorber pipe 6: Intake assembly

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status December 2010 39
OPEL MOVANO (X62)
67 – FUEL SUPPLY SYSTEM

100 and 80 litre fuel tank - FRONT WHEEL DRIVE - Left-hand drive

4 2
6

5 1

100 and 80 litre fuel tank - FRONT WHEEL DRIVE - Right-hand drive
2
6

4 5 1

1: Filler pipe 2: Tank

3: Engine supply pipe 4: Diesel filter
5: Vapour absorber pipe 6: Intake assembly

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status December 2010 40
OPEL MOVANO (X62)
67 – FUEL SUPPLY SYSTEM

2. Precautions for assembly and disassembly

2-1 Fuel tank

If disassembling and re-assembling the fuel tank, it is essential to maintain the assembly order of
the fuel tank straps on the front zone.
The vertical strap (1) must be positioned above the strap (2) that holds the fuel tank in place.

3 1 2

1: Vertical strap
1 2 2: Front support strap
3: Rear support strap

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status December 2010 41
OPEL MOVANO (X62)
67 – FUEL SUPPLY SYSTEM

2-2 Regulatory tank guard

This protective guard around the tank is subject to Regulation ECE 34 and
concerns the fire resistance of the fuel circuit.
Any modification or removal of this guard must comply with this directive.

For information:
On all the CHASSIS CAB vehicles (except the double cab), carry-over of the fuel tank guard element.
This measure is identical for TRACTION HEADS when the standard fuel tank is carried over onto a specific
chassis developed by a coach-builder.

Fuel tank guard

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status December 2010 42
OPEL MOVANO (X62)
68 – EXHAUST SYSTEM

Modification of the exhaust pipe:

The exhaust lines for the MOVANO versions are designed for output below the vehicle.
The architecture of the MOVANO has been designed to maintain the vehicle's ground clearance and
to direct the exhaust gases downwards.
Any modification may result in alteration of the vehicle's type approval (engine power, noise or
exhaust emissions). The body builder is entirely responsible for carrying out this type approval.

A B

A= Rear attachment of the silencers

B= Front attachment of the silencers
C= Connection clamp

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status March 2010 43
OPEL MOVANO (X62)
68 – EXHAUST SYSTEM

On the A and B attachments:

- Respect the parallelism between the 2 hooks (body and line), see reference D.
- Check that the internal clearances of the 2 flexible exhaust mounts are indeed identical, see
reference E.

Exhaust clamp:

The exhaust clamp must be changed for a new one.

Depending on the tooling used for tightening the connection clamp, apply the following procedure:
- with an automatic screw driving machine (plant type and not impact type tooling) tighten to 21 Nm
- during manual tightening, it must be carried out as linear as possible, without sudden pickup.
Tightening stops when the X clearance between the clamp ends is between 3.6 mm and 6.3 mm
(which correspond to a torque of approximately 18 Nm).

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status March 2010 44
OPEL MOVANO (X62)
68 – EXHAUST SYSTEM

EXHAUST LINE ENGINE M9T 74 / 92 / 110 KW Euro 4

Front and rear wheel drive version.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status March 2010 45
OPEL MOVANO (X62)
68 – EXHAUST SYSTEM

EXHAUST LINE ENGINE M9T 74 / 92 / 110 KW Euro 5

Front and rear wheel drive version.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status March 2010 46
OPEL MOVANO (X62)
69 – BRAKE SYSTEM

Irrespective of the version, there is only one power brake system of 10 inches. The power brake system is
located on the left for left-hand drive vehicles and on the right for right-hand drive vehicles.
ESP is available as an option on front wheel drive versions.

For more information, see also Chapter 114

- A sufficient distance must be maintained between brake lines and heat sources, sharp-edged or
moving parts.
- If the routing of the brake hoses, lines and cables has to be altered, avoid routing across sharp
edges and through narrow cavities or near moving components
- No other lines may be attached to brake hoses.
- The brake cables must be routed without kinks.
- Cover plastic lines, brake hoses and brake cables before carrying out any welding, drilling and
grinding work or before working with cutting discs. If necessary, the plastic lines, brake hoses and
brake cables should be removed.

N.B:
On no account should modifications be made to brake callipers, discs, sensors etc. Any
modifications to brake components may result in these systems not functioning correctly and
ultimately failing.
The ESP option is not compatible with large-scale bodywork modifications and prohibits any
major modifications to the vehicle's load distributions or centre of gravity.
Work carried out incorrectly on the brake hoses, lines and cables may impair their function. This
may lead to the failure of components or parts relevant to safety.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 47
OPEL MOVANO (X62)
69 – BRAKE SYSTEM

LEFT-HAND FRONT WHEEL DRIVE / ABS / ESP*

1

4
2
7*

5
3

RIGHT-HAND FRONT WHEEL DRIVE / ABS / ESP*

7*
1

2 5
3

1: Master cylinder and ESP/Emergency brake assist booster M/CYL 10/10 27-0
2: Left power brake system pipe
3: Primary master cylinder rigid tube - ABS
4: Secondary master cylinder rigid tube - ABS
6
5: ABS / ASR / ESP* Hydraulic Block
6: ABS / ASR / ESP*Hydraulic block support
7: ESP - sensor *

*= Vehicles with ESP only

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 48
OPEL MOVANO (X62)
69 – BRAKE SYSTEM

Engine cover – All types version

1: FR RH WHEEL ABS BRAKE RIGID TUBE

2: FR LH WHEEL ABS BRAKE RIGID TUBE
3: RR LH SENSOR ABS BRAKE RIGID TUBE
RR RH SENSOR ABS BRAKE RIGID TUBE
4: BRAKE RETAINER 2
1

4
3
4

Under-body circuit – Wheelbase 1, front wheel drive panel van version

2
1

5
1. RR LH SENSOR ABS BRAKE RIGID TUBE
RR RH SENSOR ABS BRAKE RIGID TUBE
3
2. RR LH INTM BRAKE RIGID TUBE
RR RH INTM BRAKE RIGID TUBE
3. RR LH WHEEL SENSOR BRAKE RIGID TUBE
4. RR RH WHEEL SENSOR BRAKE RIGID TUBE
5. BRAKE RETAINER

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 49
OPEL MOVANO (X62)
69 – BRAKE SYSTEM

Under-body circuit – Wheelbase 2, front wheel drive panel van version

1 2 5

1. RR LH SENSOR ABS BRAKE RIGID TUBE 5

4
3
RR RH SENSOR ABS BRAKE RIGID TUBE
2. RR LH INTM BRAKE RIGID TUBE
RR RH INTM BRAKE RIGID TUBE
3. RR LH WHEEL SENSOR BRAKE RIGID TUBE
4. RR RH WHEEL SENSOR BRAKE RIGID TUBE
5. BRAKE RETAINER

Under-body circuit – Wheelbase 3, front wheel drive panel van version

1. RR LH SENSOR ABS BRAKE RIGID TUBE

RR RH SENSOR ABS BRAKE RIGID TUBE
2. RR LH INTM BRAKE RIGID TUBE
RR RH INTM BRAKE RIGID TUBE
3. RR LH WHEEL SENSOR BRAKE RIGID TUBE
4. RR RH WHEEL SENSOR BRAKE RIGID TUBE
5. BRAKE RETAINER

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 50
OPEL MOVANO (X62)
69 – BRAKE SYSTEM

Under-body circuit – Wheelbase 2, front wheel drive chassis cab version

4
2 5
1

3 5
1. RR LH SENSOR ABS BRAKE RIGID TUBE
RR RH SENSOR ABS BRAKE RIGID TUBE
2. RR LH INTM BRAKE RIGID TUBE
RR RH INTM BRAKE RIGID TUBE
3. RR LH WHEEL SENSOR BRAKE RIGID TUBE
4. RR RH WHEEL SENSOR BRAKE RIGID TUBE
5. BRAKE RETAINER

Under-body circuit – Wheelbase 3, front wheel drive chassis cab version

4
2
1 5

5
3

1. RR LH SENSOR ABS BRAKE RIGID TUBE

RR RH SENSOR ABS BRAKE RIGID TUBE
2. RR LH INTM BRAKE RIGID TUBE
RR RH INTM BRAKE RIGID TUBE
3. RR LH WHEEL SENSOR BRAKE RIGID TUBE
4. RR RH WHEEL SENSOR BRAKE RIGID TUBE
5. BRAKE RETAINER

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 51
OPEL MOVANO (X62)
69 – BRAKE SYSTEM

Front left-hand wheel sensor calliper – All types version

3
1: FRONT WHEEL SPEED SENSOR
2: FR BRAKE HOSE
3: FR RH BRAKE DISC DIAM 48/48 DSQ 302x28

Front right-hand wheel sensor calliper – All types version

3 2

1: FRONT WHEEL SPEED SENSOR

2: FR BRAKE HOSE
3: FR RH BRAKE DISC DIAM 48/48 DSQ 302x28

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 52
OPEL MOVANO (X62)
69 – BRAKE SYSTEM

Rear left-hand wheel sensor calliper – All types version

1: RR LH BRAKE DISC DIAM 48 DSQ 305/12

2: RR WHEEL SPEED SENSOR
3: HOSE SUPPORT LUG
4: RR BRAKE HOSE

Rear right hand wheel sensor calliper – All types version

1: RR LH BRAKE DISC DIAM 48 DSQ 305/12

2: RR WHEEL SPEED SENSOR
3: HOSE SUPPORT LUG
4: RR BRAKE HOSE

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 53
OPEL MOVANO (X62)
78 – TRANSLATION OF THE FUEL TANK FILLER PIPE

Some conversions require translation of the fuel tank filler pipe.

The following recommendations can be used to offset, by up to 150 mm, the position of the filler pipe along
the Y axis. However, the position along the X and Z axes cannot be modified.
To carry out the translation, the standard connecting sleeve between the tank and the filler pipe needs to
be replaced with a special sleeve.

EXAMPLE OF SLEEVE

388 MAX

188

L A

39 110
39
39 39
39

2
43.8
A
A-A 4

1: Fuel tank side 2: Filler pipe side

L: From 0 to 150 mm

The sleeve material must be compatible with its use.

The sleeve must be held in place on the filler pipe and on the fuel tank by elastic reserve clamps.
Assembly must comply with legislation in force, in particular Directive 70/221/EEC and Directive 2000/8/EC
for Europe: For two minutes, the fuel system (tank, pipe, sleeve) fixed as on the vehicle, must be exposed to
flame. There must be no leakage of fuel. Three tests must be carried out on three different tanks half filled
with fuel. It may be possible to thermally protect the filler sleeve to avoid the need for the flame test.
When fitted, the sleeve must not be twisted or trapped in such a way that might hinder filling.
The filler pipe must be held in place and the place where it passes through the floor must be sealed.
For translations of more than 60 mm, the body needs to be cut. After cutting, the filings or shavings must be
vacuumed and a corrosion inhibitor used; please refer to the “Specific Corrosion Guidelines”.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 54
OPEL MOVANO (X62)
78 – TRANSLATION OF THE FUEL TANK FILLER PIPE

STANDARD ASSEMBLY

TRANSLATION OF THE FILLER PIPE

3 4

1: Fuel tank 2: Filler pipe

3: Sleeve 4: Area of body to be modified

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2009 55
OPEL MOVANO (X62)
79 – MAXIMUM AUTHORIZED LOAD PER AXLE

The maximum authorized load per axle depends on the version and the gross vehicle weight (GVW).

The values are given in the table.

GVW Front axle Rear axle

(kg) (kg) (kg)

Front wheel drive 2800 1550 1650

Front wheel drive 3300 1650 1900

Front wheel drive 3500 1850 2100

Single wheel rear drive 3500 1850 2300

Twin wheel rear drive 3500 1850 2800

Twin wheel rear drive 4500 1850 3200

After vehicle conversion, the weight per axle must be lower than the maximum authorised loads and the
vehicle weight must be lower than the maximum authorised laden weight.

N.B.:
The maximum authorised loads per axle and the gross vehicle weight are shown on the
manufacturer’s plate.

In order to ensure the directional stability and traction of the vehicle, Opel/Vauxhall recommends a weight
ratio (minimum weight on front axle) / (total converted vehicle weight when laden) in excess of:
- 30% for rear-wheel drive vehicles
- 40% for front-wheel drive vehicles
These conditions can be more restrictive than the maximum regulatory technical axle values in the table
above.
For more information on the compliance with the Centre of Gravity position, refer to the chapter 148 -
Determining the Centre of Gravity and chapter 40 - Limit of conversions with ESP.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2012 56
OPEL MOVANO (X62)
142 – CHERRY PICKER ON PANEL VAN

With two side stabiliser jacks

During a platform conversion, the panel van vehicle may have to be fitted with two side stabiliser jacks.
The stabiliser jacks must under no circumstances be able to lift the vehicle with the wheels in suspended
position. During the stabilization and horizontal adjustment phase, the relief for the suspension system
must be limited to the minimum.

For platform conversions on FWD and RWD Chassis Cabs and Chassis Double Cabs, see Chapter 143-
prohibited conversion types-X62.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status April 2010 57
OPEL MOVANO (X62)
143 – PROHIBITED CONVERSION TYPES

The following conversions are not allowed:

1. Cherry picker conversion on FWD and RWD Chassis Cabs and Chassis Double Cabs
For conversion on panel vans, see chapter 142 - Cherry picker -X62.

2. Transformation allowing the lifting of vehicle (Unballasting of axles)

For the adaptation of type : stabilizers and jacks.

3. TRACTOR conversion on the entire range

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2010 58
OPEL MOVANO (X62)
146 – LIFT TAILGATE

The Movano can be fitted with a lift tailgate.

Fitting a tailgate precludes the fitting of a Opel/Vauxhall towing system. When installing a new coupling,
it is necessary to plan for a validation, in compliance with regulatory requirements.

Permitted masses

The maximum load + tailgate mass can vary between the vehicles in the range.
The maximum lifting capacity of the tailgate must not exceed 500kg.
It depends on the type of vehicle and the type of tailgate bearing structure.
In all cases, and particularly in the case of vehicles without an additional chassis, the loading gate
mounting system must include a structure that allows forces to be distributed over the vehicle’s chassis.

Lift tailgate maximum

Lift tailgate maximum lifting capacity
lifting capacity +
Tailgate mass

Panel Van 500 kg 700 kg

Max. load to be determined by the coachbuilder

ChassisCab according to the type of mounting.
Mounting on a built-on structure is advised.

Max. load to be determined by the coachbuilder

according to the type of mounting.
Platform Cab
The absence of an upper structure (rear ring) limits the
maximum permissible load on the tailgate

NB:
The converter shall be solely responsible for any changes made.
For all versions, the converter shall ensure that the lifting tailgate does not adversely
affect the integrity or reliability of the basic vehicle.

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status September 2010 59
OPEL MOVANO (X62)
148 – DETERMINING THE CENTRE OF GRAVITY

The vehicle's centre of gravity after conversion can be determined:

- by measurement
- by calculation.

1. DETERMINING THE CENTRE OF GRAVITY POSITION BY MEASUREMENT

1.1. X and Y position

The x and y position of the centre of gravity is determined by measuring the mass on each
wheel and calculating the barycentre.

Gv1 Gh1

Rsc

Xv1 Xh1

ES1

S = centre of gravity
E = Wheelbase
v = Front axle
h = Rear axle
H = Height of centre of gravity
Rsc = Loaded radius of the tyre, axle not raised (in m)

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2010 60
OPEL MOVANO (X62)
148 – DETERMINING THE CENTRE OF GRAVITY

1.2. Z position
The Z position of the centre of gravity is determined by measuring the variation in mass on one axle. The
vehicle is weighed horizontally, and then inclined at an angle .

H = Height of the centre of gravity in relation to the floor (in m)

Rsc = Loaded radius of the tyre, axle not raised (in m)

E = Wheelbase (in m)
M = Radial force variation measured on the axle (in kg)
Mtot = Total vehicle mass (in kg)
= Vehicle lift angle (in rad)

Gv2 S

Gh2

XV2 Xh2

ES2

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2010 61
OPEL MOVANO (X62)
148 – DETERMINING THE CENTRE OF GRAVITY

The measurement requires the following precautions to be taken:

- no moving fluids => tank completely empty or completely full
- Tyres overinflated to the maximum permitted level (to minimise loaded radius variations)
- Front and rear suspensions locked
- the brakes (service and handbrake) MUST NOT be applied
- in order to obtain a reliable measurement, the vehicle must be lifted at an angle of at least 20°
- either the front or rear axle may be lifted

2. DETERMINING THE CENTRE OF GRAVITY POSITION BY CALCULATION

The converted vehicle's centre of gravity is determined by calculating the barycentre between the centre
of gravity positions of the basic and converted vehicles.
Comments on the information in the table below:
- The centre of gravity position is given in the vehicle reference guide and in relation to the floor
where the Z dimension is concerned (indicated as ‘Z (mm)/floor' in the table)
- The positions are given for the extremes (vehicle with no options and with all options).

It will be necessary to interpolate for an intermediate vehicle.

Glossary:
- TRS: front-wheel drive vehicle
- PRS: rear-wheel drive vehicle with single-wheel
- PRJ: rear-wheel drive vehicle with twin-wheel
- E1-3: wheelbase (from 1 to 3)
E1 = 3182 mm
E2 = 3682 mm
E3 = 4332 mm
- P1-2: rear overhang (1 and 2)
P1* = short
P2* = long
- H1-3: roof height* (from 1 to 3)
- D1-2: Motor (1 - 2)
- EURO 5: emissions compliance
- t: Tons (Weight for GVW 2,8 / 3,3 / 3,5 / 4,5)

= For the corresponding values, refer to the Chapter 7

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2010 62
OPEL MOVANO (X62)
148 – DETERMINING THE CENTRE OF GRAVITY

MIN. UNLADEN MAX. UNLADEN

PANEL VAN (no options) (all options)
Z (mm) / Z (mm) /
Vehicle variant X (mm) Y (mm) X (mm) Y (mm)
floor floor
PRS-E2P2H2 EURO5 D1/D2 3,5t 1690 -26 858 1793 -30 850
PRS-E2P2H3 EURO5 D1/D2 3,5t 1702 -26 881 1802 -30 867
PRJ-E2P2H2 EURO5 D1/D2 4,5t 1750 -25 831 1840 -28 830
PRJ-E2P2H3 EURO5 D1/D2 4,5t 1758 -24 852 1846 -28 847
PRJ-E3P2H2 EURO5 D1/D2 4,5t 2045 -18 843 2123 -23 840
PRJ-E3P2H3 EURO5 D1/D2 4,5t 2056 -18 867 2132 -23 858
TRS-E1P1H1 EURO5 D1/D2 2,8t 1183 -29 806 1296 -17 802
TRS-E1P1H1 EURO5 D1/D2 3,3t 1179 -29 805 1293 -17 801
TRS-E1P1H1 EURO5 D1/D2 3,5t 1183 -29 809 1296 -17 805
TRS-E1P1H2 EURO5 D1/D2 2,8t 1194 -29 833 1307 -17 826
TRS-E1P1H2 EURO5 D1/D2 3,3t 1191 -29 831 1304 -17 825
TRS-E1P1H2 EURO5 D1/D2 3,5t 1195 -29 835 1307 -17 829
TRS-E2P1H3 EURO5 D1/D2 3,3t 1370 -31 854 1447 -21 829
TRS-E2P1H3 EURO5 D1/D2 3,5t 1374 -30 858 1451 -21 833
TRS-E3P1H2 EURO5 D1/D2 3,5t 1633 -30 766 1732 -35 842
TRS-E3P1H3 EURO5 D1/D2 3,5t 1651 -29 877 1744 -35 853
TRS-E2P1H2 EURO5 D1/D2 3,3t 1355 -31 832 1469 -35 823
TRS-E2P1H2 EURO5 D1/D2 3,5t 1359 -31 836 1472 -35 827

MIN. UNLADEN MAX. UNLADEN

PLATFORM CAB (no options) (all options)
Z (mm) / Z (mm) /
Vehicle variant X (mm) Y (mm) X (mm) Y (mm)
floor floor
TRS-E2P1H1 EURO5 D1/D2 3,5t 954 -35 702 981 -44 697
TRS-E2P1H2 EURO5 D1/D2 3,5t 954 -35 712 980 -44 706
TRS-E3P1H1 EURO5 D1/D2 3,5t 1103 -35 697 1129 -44 693
TRS-E3P1H2 EURO5 D1/D2 3,5t 1101 -34 706 1127 -44 701
TRS-E1P1H1 EURO5 D2 3,5t 861 -35 705 886 -34 700

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2010 63
OPEL MOVANO (X62)
148 – DETERMINING THE CENTRE OF GRAVITY

CHASSIS CAB MIN. UNLADEN MAX. UNLADEN

(no options) (all options)
Z (mm) / Z (mm) /
Vehicle variant X (mm) Y (mm) X (mm) Y (mm)
floor floor
PRJ-E2P2 EURO5 D1/D2 4,5t 1439 -25 697 1440 -33 699
PRJ-E3P2 EURO5 D1/D2 4,5t 1620 -18 695 1617 -26 696
PRJ-E2P1 prime EURO5 D1/D2 4,5t 1395 -26 700 1436 -33 698
PRS-E2P1 EURO5 D1/D2 3,5t 1312 -29 717 1318 -36 716
PRS-E3P1 EURO5 D1/D2 3,5t 1507 -25 718 1508 -33 717
TRS-E2P1 EURO5 D1/D2 3,5t 1044 -33 707 1101 -42 700
TRS-E3P1 EURO5 D1/D2 3,5t 1179 -30 709 1242 -38 701

CHASSIS CREW CAB MIN. UNLADEN MAX. UNLADEN

(no options) (all options)
Z (mm) / Z (mm) /
Vehicle variant X (mm) Y (mm) X (mm) Y (mm)
floor floor
PRJ-E2P2 EURO5 D1/D2 4,5t 1485 -24 734 1484 -31 732
PRJ-E3P2 EURO5 D1/D2 4,5t 1658 -17 736 1653 -24 735
PRS-E2P1 EURO5 D1/D2 3,5t 1409 -24 765 1409 -31 762
PRS-E3P1 EURO5 D1/D2 3,5t 1520 -26 756 1520 -34 753
TRS-E2P1 EURO5 D1/D2 3,5t 1178 -27 759 1220 -35 748
TRS-E3P1 EURO5 D1/D2 3,5t 1227 -31 750 1280 -38 741

N.B.:
The floor specified in the tables is an unladen floor in running condition.
X, Y and Z refer to the fixed reference system in the vehicle, see Chapter 6
Other important measurements are in the Conversion Guideline, Part 1, Chapter 7

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of
up-to-date data on body guidelines (online body guidelines). Data status June 2010 64