2007-08_abr_lt_en

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Body builder guidelines 2007

Body builder guidelines LT

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The body builder guidelines define the requirements for custom body builders and equipment fitters designing andmounting bodies or performing conversions to base vehicles of the Volkswagen Commercial Vehicles brand.

The body builder guidelines must be strictly adhered to when performing any modifications to the vehicle.

Ensure that no modification adversely affects the functional reliability and safety of the running gear, the body or theelectric system. Modifications must only be performed by qualified specialists and in accordance with the generallyacknowledged rules of the automotive industry.

Prerequisites for modifications to used vehicles: The vehicle must be in a good overall condition, i.e. structural parts suchas longitudinal and cross members, pillars etc. must not be corroded to such an extent that structural stability might beadversely affected.

Vehicles whose modifications might affect the validity of general certificate of roadworthiness must be presented to an

authorised testing centre for approval. It is recommended to clarify in advance with the relevant authority whether approvalis required.

When inquiring about planned modifications, please enclose two sets of design drawings of the complete scope of themodification, including weights, centre of gravity and dimensions, which also clearly show how the body is attached to thechassis. Please use the online contact form:http://www.vwn-aufbaurichtlinien.de/de/kontaktformular

Please also provide information about the intended operating conditions of the vehicle. If bodies, installations or conversions comply with the present guidelines, no additional approval by Volkswagen AG is required for the presentationof the vehicle at the relevant authority examining roadworthiness.

The work safety regulations of the trade association and the EU machine directive apply.

When making modifications to vehicles, all corresponding and applicable legal regulations, rules, laws and directives mustbe observed.

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 bodyguidelines). Data status March 2009

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Extended storage times cannot always be avoided. The following measures are recommended to ensure that vehiclequality is not affected by long-term storage:

At vehicle delivery:

Fill tank•

Do not park the vehicle under trees, poles; etc.•

Open all ventilation flaps, set blower to maximum speed•

Disconnect battery(ies)•

Remove dirt, snow and moisture from vehicle (footwell)•

Close windows, doors, front lid, rear lid and sunroof •

Put manual gearbox into 1st gear or lever of automatic gearbox into park position. Do not engange reverse gear.Do not apply the parking brake.

•

Remove the windscreen wiper bags and prop up the wiper arm using a foam pad, remove any loose protective

film. ("Aero wipers": remove and store in suitable location inside vehicle).

•

Check tyre pressures; increase to 4.5 bar for commercial vehicles, if required.•

Check vehicles weekly for contamination by aggressive media (e.g. bird droppings, industrial dusts) and clean, if required.

Check battery open-circuit voltage every three months. Open-circuit voltage means the voltage of the disconnectedbattery after a minimum storage period of 12 hours. Recharge battery in due time before it reaches an open-circuit voltageof 12.4 volt ('magic eye' changes from green to black). Batteries with an open-circuit voltage of less than 11.6 volt are instate of exhaustive discharge and should be disposed of soon.

Batteries must be recharged only with current-controlled and voltage-limited chargers. A maximum charging voltage of 14.4 volt must not be exceeded.

It is recommended to check the tyre inflation pressure every three months and to increase it to 4.5 bars for commercial

vehicles, if required.

Reconnect battery negative lead(s) before recommissioning the vehicle.


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Fitters of accessories and body builders must ensure that they comply with all applicable environmental rules andregulations, especially EU directive 2000/53/EC concerning end-of-life vehicles and EU directive 2003/11/EC relating torestrictions on the marketing and use of certain dangerous substances and preparations.

The vehicle owner must keep all assembly documentation concerning the modification and hand them over together withthe vehicle to the dismantler. This ensures that modified vehicles are processed in compliance with environmental rulesand regulations at the end of their lifecycle.


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Maintenance instructions or service schedules outlining inspection and servicing work should be provided for themodifications performed by the body builder or accessories fitter. These instructions or schedules must include themaintenance and inspection intervals as well as the required operating fluids and materials and the spare parts. Parts andcomponents with a limited service life which must be checked in regular intervals to ensure service reliability and timelyreplacement must be explicitly stated.

This should be supported by a repair manual including tightening torques, settings and tolerances as well as other relevant specifications. Special tools, including their source of supply, must also be stated.

The manual must also state which type of work must be performed only by the body builders and accessories fitters or their authorised workshops.

If the body builders or accessory fitter's scope of supply includes electric, electronic or mechatronic, hydraulic or pneumatic systems, circuit diagrams and diagnosis routines or similar documentation facilitating a systematic search for

faults must be provided.


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Body builders must ensure that the fitted components, conversions, bodies and modifications comply with applicable legalrules and regulations as well as all regulations regarding work safety and accident prevention. All safety rules and theinformation material provided by accident insurance providers must be observed.

All technically feasible measures must be taken to prevent unsafe operation.

Country-specific laws, directives and approval regulations must be observed.

The body builder or device or equipment manufacturer is responsible for the compliance with these laws, rules andregulations.

For further information about commercial freight traffic in the Federal Republic of Germany please contact:

Berufsgenossenschaft für Fahrzeughaltung

Fachausschuss "Verkehr"Sachgebiet "Fahrzeuge"

Ottenser Hauptstraße 5422765 Hamburg, Germany

Homepage: www.bg-verkehr.deE-Mail: [email protected]

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 bodyguidelines). Data status September 2010

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http://www.bg-verkehr.de/

http://www.bg-verkehr.de/

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Extras: The standard vehicle can be prepared ex-works for the desired attachment. Please, check the attachment-relevantextras before ordering the vehicle. Ordering options and prices are included in the sales documents.

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Exhaust gas pipe, lateral•

End cross-member (omitted at chassis)•

Increase of axle load, front (LT 35)•

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Reductions of total weight•

Absorption of external noise•

Exterior mirror (bracket)•

Battery power / 2nd battery•

Flashing indicators, lateral (for wide attachments)•

Damping for high attachments•

Differential lock•

Rpm governor •

Tachograph•

Generator power / 2nd generator •

Rear axle gear ratio•

Coolant compressor •

Auxiliary drive of standard transmission•

Spare-wheel support•

SBBR line (700 mm reserve)•

SBBR lamp preparation•

Stabilizers•

Connection socket 12 V in the seat box•

Telephone/D-Netz [mobile phone network] preparation•

Underrun protection•

Wheel chocks•

Periphery lamps•

Fastening lugs box-type delivery van/station wagon•

VW emblem, rear doors (steering)•

Warning lamp, triangle and first-aid kit•

Heat isolation•

Cowl•

Auxiliary heating•

Auxiliary instruments (switches for electronic installations)•


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standard designfavourable traction with full payload•

service-friendly•

low air resistance•

good entrance and passing-through possibility•

•

high load-carrying capacity of the chassis•

highly chargeable torsion-resistant cap-profile frame•

even upper belt•

attachment fixing already installed•

appropriate wheel bases•

selectable rear axle gear ratio for individual operating conditions•

efficient engine offer - environmentally friendly and consumption-oriented•

high trailing load•

easy to write on, large-surface side walls at box-type delivery van•

full standing height in high-space box-type delivery vans (high roof made of steel)•

Volkswagen quality•


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The weights and axle loads (permissible/empty) for the LT attachment variants - box-type delivery van, chassis withcab/double cab, can be downloaded in the download area, together with the appropriate drawings. For the chassis withcowl (without roof and back wall), the weight has to be reduced by approx. 50 kg compared to the chassis with cab.

Note:

To ensure a sufficient manoeuvrability of the vehicle, the minimum front axle load must amount to 25% of the total weight.In the case of vehicles with loading tailboard, the minimum front axle load must amount to 30% of the total weight.

The indicated unloaded-state weights refer to the standard vehicle equipment (including driver, spare wheel, tool and filledfuel tank). Weight tolerances of +5% are permitted according to STVZO [German traffic regulations] and are to be takeninto consideration, where appropriate.

If extras are installed, the permitted unloaded weight increases. If required, the final unloaded vehicle weight is to bedetermined using a scale.

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 bodyguidelines). Data status August 2007

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The weights must never exceed the

permissible total weight•

permissible front axle load•

permissible rear axle load.•

When projecting attachments, it has to be ensured that a single-sided weight distribution is avoided - in particular if fixedattachments are to be installed. If it is not possible to adhere to this recommendation, the single-sided load may only resultin a maximum difference between the wheel loads of 8%.

Note:

Observe the tyre load-carrying capacity!

Example:

Permitted axle load 2.000 kg

theoretical wheel load left/right 1.000/1.000 kg

4% of this wheel load 40 kg

Permitted wheel load distribution left/right 1.040 kg/960 kg


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The chassis dimensions are shown in the drawings. The drawings are available in the "Download" section. They can bedownloaded and used for planning/constructing.

When you are using tyre sizes which are differing from the standard equipment, the vehicle and chassis heights(measured from ground level) may change. In this case, it is necessary to consider these deviations during projecting.

Important note:

The minimum distance between cab and attachment must be at least 50 mm.•

The rear overhang of the attachments may under no circumstances exceed the default values indicated in thefollowing table.

•

The distance between the rear edge of the attachment and the rear edge of the end cross-member/underrunprotection must not exceed 400 mm.

•

[Translate to English:] Aufbauaußenlängen und Fahrzeugüberhänge für Fahrgestelle mit Fahrerhaus/Doppelkabine(Doka):

Modell Karosserie Radstand(mm)

max.Fahrzeug-überhang mitÜberhangver-längerung/spezif.Unterfahr-schutz (mm)

EmpfohlenerFahrzeugüberhangohneÜberhangver-längerung (mm)

Empfohlene AufbauaußenlängeohneÜberhangver-längerung (mm)

LT 28 Fahrerhaus/-Fahrerhaus/Doka

3.0003.550

1.500/-1.775/-

1.340/-1.340/1.410

2.980/-3.530/2.800

LT 35 Fahrerhaus/-Fahrerhaus/DokaFahrerhaus/Doka

3.0003.5504.025

1.500/-1.775/-2.060

1.340/-1.340/1.4101.620/1.490

2.980/-3.530/2.8004.290/3.350

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LT 46 Fahrerhaus/-Fahrerhaus/Doka

3.5504.025

1.775/-2.060

1.690/1.4801.940/1.840

3.880/2.8704.600/3.700

Bei Fahrgestellen mit Doka sind größere Fahrzeugüberhänge (als empfohlen) nur nach Rücksprache mit derVolkswagen AG zulässig. Auch bei den empfohlenen Aufbaulängen ist durch eine Lastverteilungsrechnung dieEinhaltung der Mindest-Vorderachslast und der zulässigen Achslasten zu überprüfen.


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Numerous guidelines are to be adhered to, when chassis is to be transported on their own axles:

Wheel cover •

Ballast weight for braking•

Lateral starting protection•

Lighting equipment•

These parts are neither developed nor on-stock, thus making the transport on own axle unnecessarily expensive. For thisreason, the self-pickup of chassis is no longer possible. It is recommended to deliver the chassis by rail or truck.


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For attaching a loading tailboard, it is required to consider the following instructions:

The permitted rear-axle load must not be exceeded.•

Consider minimum front-axle load (i. e. 30% of the total vehicle weight).•

Check the stability.•

Calculate the load distribution including all extras.•

If required, shorten attachment length and rear overhang.•

Guide subframe as far as possible to the front and realise a force-locked connection with the chassis frame.•

Standard box-type delivery vans require no subframe.•

A stabilizer bar is necessary for the front and rear axle.•

If possible, use only hydraulic supporting devices. Do not lift the vehicle with the supporting device (chassis maybe damaged)

•

Load distance max. 500 mm•

Security

The regulations for the prevention of industrial accidents and the EC Machinery Directive are to be adhered to.Check for underrun protection and lighting devices.

•

The standard vehicle can be provided ex-works with the required extras item 1.3).•

Vehicles with double cab may only be provided with a loading tailboard in special cases. The mounting is only permittedwith the permission of Volkswagen AG.

Maximum load-carrying capacity and profiledimensions:

Models Wheelbase(mm)

Liftingpower

to n KN

Minimumdimensions

Subframeside rail*

LT 28-chassis 3.0003.550

55

80 x 45 x 380 x 45 x 3

LT 35-chassis 3.0003.5504.025

555

80 x 45 x 380 x 45 x 3120 x 50 x 4

LT 46-chassis 3.5504.025

7,57,5

120 x 50 x 4140 x 60 x 5

LT 28-box-typedelivery van

3.0003.550

33

--


3.0004.5503.025

333

---


3.5504.025

33

--

The specified minimum dimensions refer to normal operating conditions and applications without overhang extension.

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For example, when working with a lifting hoist, the entire vehicle may be lifted on 4 hydraulic pillars -the wheels lose allcontact with the ground. Due to the heavy weight of the front of the vehicle, this causes impermissibly high tension in thelongitudinal frame members in the area of the front support.

A reinforcement of the chassis frame is essential for such applications. To this end, fit a mounting frame through the rear wall of the cab under the base of the seats and secure this with an additional console and a bolt connection. A suggestionas to how this can be implemented can be given on request by the responsible department.

An additonal battery as per PR-No. 8FV (location underbase of co-driver's seat) is not possible with this configuration andalso for the LT 46.


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When laying out the loading crane attachments, it is required to observe - apart from the necessary stability - theconnection between loading crane and chassis (item 3.4).

Loading crane and vehicle attachment are to be arranged in such a way, that the permitted axle loads are kept in everyloading state.

Loading crane attachment behind the driver™s cab

Maximum crane-load moment: 25 KNm•

Moments of resistance for mounting-frame side rails: Wx = 45cm3 (45cm3 (profile dimensions according todiagram under item 3.3)

•

Determine the flatbed length depending on the loading-crane attachment.•

Due to the load distribution, it may be necessary to lengthen the chassis.•

A permission is required for deviating crane attachments.•

The necessary supporting devices should be hydraulically actuated.•

Do not lift the vehicle with the supporting device (chassis may be damaged)•

Crane attachments and supporting devices must neither impair other equipment, modules, units, etc., nor theassociated functions.

•

Loading crane attachments must meet the requirements of the regulations for the prevention of industrialaccidents and the EC Machinery Directive.

•

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 bodyguidelines). Data status December 2007

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According to article §51b. of the German motor vehicle traffic regulations (STVZO), vehicles with a width of more than2,100 mm must be provided with parking lamps when they are to be used in the Federal Republic of Germany.

As standard, all chassis and chassis with flatbed attachment are not provided with parking lamps (standard vehicle width1,922 mm and 1,990 mm).

In the LT delivery program, the tipper with single and double cab as well as the LT46 Pick up with single and double cabexceeds the pre-set vehicle width (standard width: 2,120 mm). At these vehicles, parking lamps are assembled in front onthe side on the cab roof. In addition, the outside chambers of the 6-chamber lamps at the vehicle rear are designed asparking lamps (series equipment: PR-No. 6S1).When ordering a chassis that is to be used for an attachment with a width of more than 2,100 mm, it is required to order also back and front parking lamps (PR-No. 6S1).

If the intended vehicle width exceeds 2,100 mm and if the rear parking lamps are to be mounted by the attachmentmanufacturer, it is only possible to order parking lamps that are to be mounted on the roof in front (PR-No. 6S3) (SBBRlamps can be left out at PR-No. 8SZ; preparation SBBR lamp).


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According to article §51a. of the German motor vehicle traffic regulations (STVZO), vehicles with a length of more than 6m must be provided with yellow side marker lamps and lateral reflectors.

In the LT delivery program, only the chassis with long wheel base exceeds the pre-set vehicle length.

If required, all standard vehicles are to be provided with reflecting side marker lamps.

All chassis with long wheel base are prepared ex-works for side marker lamps (wiring harness). The attachmentmanufacturer is responsible for installing side marker lamps.


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According to article §54 of the German motor vehicle traffic regulations (STVZO), multitrack vehicles must be provided atthe long sides with additional flashing indicators to be mounted in the first third of the front section.

If the permitted total weight is more than 3.5 t, the light intensity of these flashing indicators must lie between 50 cd (min.)and 200 cd (max.). All vehicles with a permitted total weight of less than 3.5 t are to be provided with small lateral flashingindicators (5W). All vehicles with a total weight of more than 3.5 t are to be provided with large lateralflashing indicators (21W).

Minimum visual angle ranges are pre-defined for mounting of lateral flashing indicators. As a result, it is mandatory tomount various flashing indicators, depending on the attachment width: Small lateral flashing indicators

Width up to 2,100 mm•

Large lateral flashing indicators

Width between 2,101 and 2,200 mm•

Large lateral flashing indicators with adapter

Width between 2,201 and 2,500 mm•

Due to the confinements imposed by vehicle length (cf., item 3.13), permitted total weight and attachment width, therequired combinations of flashing indicators/marker lamps are already pre-defined for standard vehicles. Only attachmentwidths of more than 2,200 mm require large lateral flashing indicators with adapter (can be ordered, PR-No. 8F8).

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 2007

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According to EU Directive 76/756 EEC and article §54 of the German motor vehicle trafficregulations (STVZO), motor cars that are to be used in the Federal Republic of Germany mustbe provided with mirrors. These mirrors must be designed and installed in such a way to permitthe driver to look backwards and sideways - also if a trailer is hooked up to the vehicle - so thathe or she is capable of observing the traffic.

As standard, all LT-model are equipped with an interior mirror and a exterior mirror - for a max.attachment width of up to 2,150 mm.

For attachment widths between 2,150 mm and 2,400 mm, exterior bracket mirrors are available(normal/large bow).

Availability of LT exterior mirrors

(see also Sales Manual):

Standard mirror (serial) - attachment widths up to 2,150 mm•

Bracket exterior mirror, normal (standard dump truck and LT 46 chassis) - attachmentwidths between 2,151 mm and 2,300 mm

•

Bracket exterior mirror, large - attachment widths between 2,301 mm and 2.400 mm•


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The attachment manufacturer has to ensure that

it is possible to mount the largest permissible tyre size,•

the distance between tyres and mudguard or wheel housing is sufficient, even with mounted snow chains or antiskid protection chains and with full single-sided or two-sided compression. Consider the dimensions that arespecified in the chassis drawings.

•

LT wheels/tyres/allocation

Disk wheel Tyre

LT 28 5 1/2 J x 15 H2

(press-in depth

83 mm)

195/70 R15 C 104/102 R

(Special equipment) 6 J x 15 H2 225/70 R15 C 112/110 R

LT 35 6 J x 15 H2 225/70 R15 C 112/110 R

Twin tyres at the back

LT 46 5 1/2 J x 15 H2(press-in depth

115 mm)

195/70 R15 C 104/102 R


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The standard spare-wheel positions, depending on car-body design and motorization and according to the followingoverview/assignment matrix, are shown in the box-type delivery van and chassis drawings.

Assignment - LT spare wheel/spare wheel support

Car-body design Model Engine PR-Nr.1BO 1B1 1B2 1B5 1B9

Box-type delivery van LT 28/35/46 Diesel o x - o -

Chassis with cab LT 28/35 Diesel o o x - oLT 46 Diesel o x - - -

Chassis with double cab LT 28/35 Diesel o o x - oLT 46 Diesel o x - - -

x = Standard production typeo = Special equipmentPR-No. 1B0 = Without spare wheel support (enforces "Without spare wheel (PR-No. 1G0)")

PR-No. 1B1 = Normal spare wheel support - behind the rear axle, below the frame

PR-No. 1B2 = Spare wheel support for double cab and driver™s cab - on the right side rail

PR-No. 1B5 = Spare wheel support in the interior - behind the wheel housing

PR-No. 1B9 = Spare wheel support for double cab and driver's cab - provisionally attached on the right side rail. Theattachment manufacturer is responsible for the final attachment according to official regulations (easy access, simpleoperation, dual protection against losing) ("1B9" enforces: "Without flatbed bottom frame (PR-No. 5HA/5HJ)")

In case of deviations from the ex-works spare-wheel attachments (this does not apply to fastenings at the

attachment), it is required to ask the responsible department for a permission


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According to EU Directive 70/221 EEC and article §32 b. of the German motor vehicle trafficregulations (STVZO), motor cars at which the distance between rear limitation and rear axle ismore than 1,000 mm and which have, in unloaded condition, a headroom of more than 700mm (applying either to the total width of the rear chassis or the main car-body parts) abovelane, must be provided with an underrun protection.

At all LT vehicles, the main car-body parts lie less than 700 mm above lane. For this reason,standard vehicles require no underrun protection. As standard, all LT 46 chassis models(with/without flatbed) are equipped with a rear underrun protection.

The maximum distance between the rear edge of the attachment and the main car-body parts(at the chassis, this applies to the bulb retainers) is 400 mm. If 400 mm are exceeded, theattachment manufacturer is obliged to construct and install an underrun protectioncorresponding to the relevant EU Directives.

For this purpose, it is recommended to use the screw connections at the frame that areprovided for the trailer coupling.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 bodyguidelines). Data status August 2007

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According to EU Directive 89/297 EEC and article §32 c. of the German motor vehicle trafficregulations (STVZO), motor cars whose permitted total weight exceeds 3.5 t and whose maincar-body parts have a headroom of more than 500 mm above lane, must be provided withlateral protectors, if these vehicles are to be used in the Federal Republic of Germany.Excluded from this regulation are tractive units, driven machines and special vehicles whoseoperational purpose cannot be fulfilled by the lateral protectors.

As standard, all LT 46 flatbed models are provided with lateral protectors. At the LT chassis(cab/double cab without flatbed), no lateral protectors are mounted. The lateral protectors mustbe constructed and installed by the attachment manufacturer relating to the attachmentsaccording to the relevant EU directive.

If lateral protectors are to be installed subsequently, the following instructions apply:

Component parts, such as battery box, air receivers, petrol tanks, lamps, reflectors,spare wheels and tool boxes, may be installed if the prescribed distance dimensionsare kept. Brake, air or hydraulic lines and other parts must not be attached to thelateral protector.

•

Function and accessibility of all equipment, modules, units, etc. of the vehicle mustnot be impaired.

•



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There are clear instructions available for handling vehicles with longer service lives (see manual Service Technology,volume: Inspection and Maintenance, item 3.2.4, Storage of Brand-New Vehicles). These instructions are defined by thecustomer service and are to be adhered to. Observe the following note when handling the tachograph: If the acceptancestamp is older than six months, the tachograph should be re-submitted to an acceptance test.


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General information

The attachment of the trailer coupling must correspond to the specific directives of the relevant country. In theFederal Republic of Germany, standard DIN 74 050 has to be complied with.

•

Consider free-space dimensions*. In the Federal Republic of Germany, standard DIN 74.058 has to be compliedwith.

•

If deviations from the German regulations for the prevention of industrial accidents (UVV) are necessary, it isrequired in the Federal Republic of Germany to request an import certificate ["Unbedenklichkeitsbescheinigung"]from: Berufsgenossenschaft für Fahrzeughaltung [German Trade Co-operative Association for Matters Associated with Car Owning], 22757 Hamburg (phone +49 [0] 40/38 10 91).

•

If trailer couplings are to be installed subsequently, only products which have been approved by us and originalVolkswagen end cross-members may be used. Attachment points are available at our end cross-member and/or side rail.

•

The size of the trailer coupling is defined according to the D-value.•

The size of the trailer coupling is defined according to the D-value

D = control-shaft value

mk = permitted total weight of the tractor (motor car) in t

mA = permitted total weight of the trailer in t

g = 9,80665 m/s2

The permitted trailing load can be taken from the valid sales documents or the guide "Trailer Operation". In order to permit the trailers being exchanged in transborder traffic, the distancedimension, x, must not exceed 300 mm.

* If the trailer is extremely low lying or if a special attachment is extremely overhanging, it maybe prohibited to use a trailer coupling.

Mouth clutch (can be ordered ex works under PR-No.1D5)

Max. distance between the middle of clutch bolt of the trailer coupling and attachmentend: 420 mm. Keep clearances.

•

In special cases, it is permitted to exceed the distance dimension of 420 mm: Max.distance 650 mm for vehicles with tiltable attachments or rear attachments. Max.distance 1,320 mm, if the headroom between lane and the lower attachment edge isat 1,150 mm. A suitable remote control for the clutch must be available. The safeactuation of the clutch must not be impaired.

•

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Spherical coupler (can be ordered ex works under PR-No.1D1)

Keep clearances.•

The installation is only permitted at approved trailing supports.•

It is not permitted to perform the installation only at the underrun protection. Modifications of the underrunprotection must be arranged with the responsible testing and research laboratory (in Germany: TÜV).

•


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An operating permit is available for the brake system of the vehicles. This licensing becomes invalid if the brake system ismodified. Therefore, modifications of the brake system are illegal.

If it cannot be avoided to perform works on the brake system, e. g. changing the wheel base, the following instructions areto be considered:

Replace hydraulic brake lines completely.•

Dimensions of roller laminated tube: 4.75 x 0.7; plastic lines/tubes are not permitted.•

Mould lines only with a bending fixture•

Bend radius = 17.5 mm•

Clean the interior of lines.•

Keep safety clearance to heat sources, pointed, sharp or moving parts•

Attachment with plastic loops, max. distance 500 mm•

Let the ALB controller be re-adjusted by a VW dealer if the weight has changed.•

After finishing works, check whether the brake system is perfectly functioning.

Retarder

If a retarder is to be subsequently installed at the transmission or in the drive-shaft strand, it is required to ask theresponsible department for a permission. Approvals are not generally given but are basically limited to specificvehicle designs and wheel bases.

•

The mounting drawings must include the following information:

Position of the retarder in the vehicle•

Drive-shaft angle•

Length of the drive shafts•

Due to the additional weight of the retarder, the distribution of weight and adherence of the permitted axle loadshas to be checked. Check location of the centre of mass of the attachment. Adjust it, if required.

•

Mounting is only permitted at vehicles with sufficiently dimensioned electrical installation (generators andbatteries with sufficient capacity). Ensure a sufficient ground connection of the retarder.

•

Ensure sufficient freedom of operation.•

In the drive-shaft strand, attach the retarder only at the bar of the chassis frame using brackets with silent blocks.•

Protect lines against heat by using an appropriate insulation. The permitted maximum temperature for polyamidelines is 80°C.

•


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Power output of the engine via v-belts At the engine, the output can be decreased by max. 10 kW via v-belts, if the available flange points are being used.

Versions available ex works:

Power steering pump/steering booster pump, standard•

optional:

2. Generator, 90 A (PR-No. 8HB)•

Refrigerant compressor (PR-No. 2AB), operative compressor installed in the vehicle, Sanden SD7 H 15(non-controlled)

•

Hydraulic pump as enclosed package (PR-No. 2BD) preparation for installation•

At backfitting of a refrigerant compressor it is important to order the preparation refrigerant compressor (PR-No. 2AC).Otherwise you have to assemble the original parts. Differing parts can cause damages (for example, fracture of theclamping element).

Auxiliary drive of standard transmission Actuation is realised via the countershaft of the transmission

Versions available ex works:

Module PR-Number

ZSBTransmission without auxiliary drive, standard 0R0

ZSBTransmission with auxiliary driveCountershaft without flange

0R1

ZSBTransmission with auxiliary driveCountershaft with flange

0R3

ZSBTransmission with auxiliary driveSwitch lock for transmissionCountershaft without flange

0R6

ZSBTransmission with auxiliary driveSwitch lock for transmissionCountershaft with flange

0R7

Power take-offs are not available for 2,5l diesel TDI(61kW).

The electronical engine speed govemor (PR-No. 6Y3, 6Y6) is only available for power take-offs (PR-No. 0R6, 0R7).

Notes:

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The design of the auxiliary drive and the selection of the gear ratio depend on the power and speed (revolutionsper minute) of the modules to be actuated.

•

Transmission-dependent auxiliary drives may only be switched on/off with the vehicle standing still.•

Information on max. transmissible torques (Nm) of the individual auxiliary drives can be taken as guide values for shock-free and non-oscillating operation. According to DIN 922, the above specifications are based on afatigue-limited gearing layout and a calculated service life of 500 hours. Additionally occurring inertia forces at themodules to be actuated are not considered.

•

The gear ratio of the auxiliary drive has to be selected in such a way, that the minimum speed (engine), i. e.between 1,000 rpm and 1,200 rpm, is not exceeded if the auxiliary drive is loaded. The output decrease shouldlie within the range of the maximum engine torque.

•

Exposed drive shafts, fan rotors or belt pulleys must be covered.•

It is not permitted to attach belts or chain drives to the drive shaft or flange of the auxiliary drive. However, if exceptions from the above specifications cannot be avoided, the appropriate drawings and data must besubmitted for approval.

•

Dimensions - clutch flange - Auxiliary drive

aø b ø c ø

dø e ø f ø

Number of holes

90 74,5 47e8 6 2.1 8,0B12 6

Technical data/information - auxiliary drive

Max. torque decrease for shock-free and non-oscillating operation: Md = 200 Nm•

Continuous power at engine speed 2,500 rpm: Nmax = 20 kW

(max. 40 kW, for short time: approx. 3 minutes)

•

Continuous power with engine cooling system with heavy-duty fan and radiator (PR-No. 8Z2): Nmax = 30 kW(max. 40 kW, for short time: approx. 3 minutes)

•

Drive speed at auxiliary driveMNA = 0,775 x nMot

•

I II III IV V VI VII A1 B1 C1

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2,5 lTDI2,8 lTDI

G 28-5 0R3/0R70R1/0R6

0,7750,775

20/250020/2500

200200

aa

639745

131127

100,6100,6

Additional information on table "Auxiliary drives":

I

II Transmission

III Designation of auxiliary drive

IV Drive speed (rpm)at auxiliary drive nNA = iNA x nMotor

V Continuous power at auxiliary drive

VI Max. torque decrease atauxiliary drive in Nm

VII Direction of rotation seen in driving directiona) anti-clockwise

A1 Distance between rear edge of clutch flange and middle of front axle

B1 Distance between middle of clutch flange and top edge of chassis frame

C1 Distance between middle of clutch flange and middle of transmission flange


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Usually the flatbed must be raised according to the required subframe height. Since the standard flatbed version affectedhere is provided with very high, u-shaped cross-members, it is possible to perform the following procedure:

The cross-members of the standard flatbed are cut out in the areas the chassis side-rails in such a way, that it is possibleto fit in precisely the continuous subframes and to connect them to the cross-members by means of welding. (Position of subframes exactly above the standard side rails, see illustration below.) Dimensions of subframes and attachment of theloading tailboard to be performed according to our construction guideline.

The attachment of the standard flatbed, which is modified as described, can be performed without changing the chassis,however, appropriately longer screws are to be used. The spacing between flatbed cross-member and chassis brackets isto be levelled out with shims (bushings).


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General Information:

For a perfect connection between chassis and attachment, for all attachments a subframe or a floor panelassembly (taking over the function of the subframe) is required (except for self-supporting attachments andsubframes as a base group).

•

The subframe side rails should lie flatly and following the chassis profile on the upper belts of the chassis frame.•

The following applies to LT 46 models (twin tyres):In the area of the rear axle, the chassis-frame side rails are inwardly offset. The subframe side rails need notfollow this offset but can be executed continuously straight. Wooden fillets between chassis-frame side rail andsubframe side rail are not permitted. A bracket attachment, via subframe cross members, is required in the area

of the rear axle.

•

Subframe cross members are to be arranged above the chassis-frame cross members.•

For the side rails, use bevelled u-beams or standard u-beams that are generally used for the construction of vehicles (no rolled steel sections). Box sections are also permitted.

•

The side rails dimensions result from the moment of resistance (Wx) required for attachment and chassis. Seediagram 3.3.2. The specified moments of resistance and section/beam dimensions refer to frame side rails thatare evenly loaded on both sides.

•

If several attachments are to be assembled on a chassis (e. g. flatbed and loading tailboard), the greater value of thespecified moments of resistance must be taken as a basis for defining the subframe.

Subframe as base group:

A subframe with continuously running side rails is not required if the base group of the attachment can take over thefunction of the subframe.

Subframe for reinforcing the side bars in the front-end area of the vehicle: For example, when lifting platforms areoperated, the entire vehicle may be lifted by 4 hydraulic supports, so that the wheels no longer touch the ground. Due tothe high weight of the front end of the vehicle, inadmissibly high tensions appear in the chassis side rails in the area of thefront support. For this reason, it is mandatory to reinforce the chassis frame if this application is planned. This requires to

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lead the subframe through the back of the cab to a location under the seat box. It has to be attached with a supplementarybracket and a bolted connection. An execution recommendation can be requested at Volkswagen AG, department NV-VS.

This subframe execution does not permit to install an additional battery (PR-Nr.8FR).

Material Qualities for Prescribed Steel Subframes:The subframe with bracket attachment (force-locking) is to be implemented as St 12.03 or St 37-2.

Material Tensile strengthN/mm2 Yield pointN/mm2

St 12.03 >360 210

St 37-2 >360 235

Subframes that are made of high-strength steel must at least correspond to the stiffness of steel subframes. The attachment must be realised with force-locking capability.

Flatbed truck attachments, aluminium type

Adhere to the instructions of the aluminium manufacturers•

Side rails, plank floor, floor mats and carrying hook conveyors must form aself-supporting unit.

•

The profile transition at the front ends of the side rails should be gradually realised.

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I Box section

II U-beams

1 Chassis frame2 Subframe3 Standard fixing bracket4 Console

If it is required to implement very high side rails or if low total heights of the chassis are to be implemented, theu-beam - at locked-force connections - must meet the following specifications:

It must be closed as a box•

It must be nested into each other •

It must be nested•

As a result, the moment of resistance and the torsional stiffness are increased. Make sure that the transition betweenclosed side rail and open u-beam is properly executed.

Profile dimensionsThe profile dimensions for subframe side rails (open profile), subframes and chassis frames should approximately havethe same material thickness and flange width.

Profile height (in mm)

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Determine the mounting method depending on the chassis type, attachment and according to the operation purpose of thevehicle. Attach the subframe on the fixing brackets (which are available as standard) of the chassis frame. Use shackleattachments if additional attachment points are required. Define the number of attachments in such a way that is itensured that the braking and lateral forces are properly absorbed.

The correct attachment is decisive for:

Road behaviour and the operational safety of the vehicle.•

Operational life of chassis frame and attachment.•

If locked-force connection are used, the side rails must be attached length and crosswise.

If pre-assembled subframes are used, constructional tolerances of the chassis frame width (max. + 6/-3 mm) are to beconsidered. Compensate for manufacturing related frame bending (max. 6 mm) by using supports.

Bracket attachment with side rail

Bracket attachment with cross member

Locked-force connection, bracket attachment

A movement of the subframe side rail in relation to the chassis side rail is possible with restrictions.•

Perform rigidity strength calculations for each individual side rail.•

Divide up the bending moment according to the moments of inertia.•

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1 Standard fixing bracket (see chassis drawings for number and dimensions)


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The mounting frame is exclusively used for directly receiving attachments. Only screws are permitted for attaching themounting frame at the chassis frame. The mounting frame needs not to cover the entire chassis frame up to the cab - as isthe case with the subframe. (see item 3.3.3. Figure: Bracket attachment with cross-member mounting frame)

The mounting frames does not meet any strength requirements to protect the vehicle chassis.


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When the modified vehicle is brought forward to an inspection or acceptance test, according to EC directive, Brakes,71/320/EEC, the centre-of-mass height must be mathematically proved using a loaded vehicle. Bases of calculation andpermitted centre-of-mass heights can be requested from Volkswagen AG.

If the centre of mass lies high, provide stabilizer bars and reinforced shock absorbers (if available). If the centre-of-massheight exceeds 960 mm at the LT28 / LT35, it is required to use the stabilizer bar at the back (OBC) and reinforced shockabsorbers. Permitted centre-of-mass height: 1050 mm. If the centre-of-mass height exceeds 1,100 mm at the LT 46, it isrequired to use the reinforced stabilizer bar at the back (OBD).

Centre-of-mass heights - base vehicle: (empty, including driver with 75kg)

LT 35 Chassis: h = 780 mm

LT 35 Box-type delivery van: h = 840 mm

LT 35 Station wagon: h = 850 mm

LT 35 Flatbed: h = 805 mmLT 46 Chassis: h = 725 mm

Volkswagen AG does not provide information on the road/braking/steering behaviour of attachments used for loads withan unfavourable centre-of-mass position (e. g. rear, high and side loads). The attachment manufacturer is responsible thatthese attachments do not impede the road-holding qualities of the vehicle.


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Driver s cab:Functioning, smoothness and free movement of instruments and operating equipment as well as the stability of supportingparts must not be impaired by modifications performed at the cab. If the cab is to be built over, the permittedcentre-of-mass position and the permitted front-axle load is to be considered.

Roof loads/roof racks:

Box-type delivery vans and station wagons:

Max. 300 kg (vehicles with high roof: 150 kg) if the load is uniformly distributed over the entire roof surface.•

A stabilizer bar must be installed at the front axle.•

The roof rack must have at least 5 sustainers (with a roof of 300 kg) or 4 sustainers (with a roof of 150 kg). Thesustainers are to be evenly positioned.

•

If the roof rack is shorter, the loading has to be reduced proportionally.•

Vehicles with cab or double cab:

Max. 100 kg if the load is uniformly distributed over the entire roof surface.•

Note: The installation instructions only apply to box-type delivery vans and station wagons.

1 Roof rack

2 Sustainer

3 Brace

Roof heightening (plastic roof):

Install a stabilizer bar at the front axle•

If roof cladding and roof bow are separated and if no continuous profile frame is possible, additional roof bowsare required.

•

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Number:4 Bow with wheel base 3.000 mm5 Bow with wheel base 3.550 mm6 Bow with wheel base 4.025 mm

Arrangement1. behind the driver™s cab doors (B-pillar)2. in the middle of the sliding door (between B-pillar and C-pillar)3. in the middle of the vehicle behind the sliding door (C-pillar)4. to 6. between C-pillar and rear pillar

The connection between bows and side walls must be laid out in such a way that a locked-force connection isensured (flex-resistant connection of bow and roof chassis). The new roof structure must correspond to thestandard roof relating to stiffness. The required minimum moment of inertia (Ix) of the roof bows can be takenfrom the following table.

•

Roof height Moment of inertia (Ix), per bow 250 mm 40.000 mm4 400 mm 65.000 mm4 550 mm 86.000 mm4

These specifications are based on an e-modulus of the plastic roof of 7,000 N/mm2 and a wall thickness of 4mm.

•

Roof height Moment of inertia (Ix), per bow250 mm 40.000 mm4

400 mm 65.000 mm4

550 mm 86.000 mm4

These specifications are based on ane-modulus of the plastic roof of 7,000N/mm2 and a wall thickness of 4 mm.

In case of deviations, it is required to ask the responsible department for a permission.•

Notes:

Plastic roofs are only suitable to a limited extent for mounting roof lamps.•

The roof load is limited.•

Rising roof

If a rising roof is to be mounted, at least two thirds of the original roof surface must be maintained.•

Do not remove any cross-beams or supporting parts.•

Air baffles: Air baffles on the cab roof may only be attached with retainers at the door frame or at the rear welding flange(back wall of roof). Bores in the cab roof are not permitted for attaching components. If other roof attachments (e.g.air-conditioning system) are to be installed, it is required to ask for the permission of Volkswagen AG.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


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At self-supporting attachments, a subframe with appropriate side rails is not necessary, if the cross members keep amaximum distance of 600 mm. This distance may be exceeded in the rear-axle area.

Self-supporting attachments are to be attached at the chassis over all available brackets (2 screws per bracket).


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The forces which are induced punctiformly are to be distributed uniformly via a subframe over the entire chassisframe.

•

For this purpose, the subframe should lie without torsions over the side rails and should be guided up to the cab(procedures according to item 3.3).

•

At a chassis with double cab it may be necessary to shorten the rear chassis overhang. This measure is to becontrolled on the basis of axle-load calculations.

•

High centres of mass for attachments and net-loads impair the driving and braking behaviour. The chassis canbe provided ex-works with stabilizer bars/attenuation.

•

Due to the width and length of the attachment, it may be necessary to modify lighting, markings and exterior mirror. These modifications are listed under items 3.12 - 3.15.

•

The necessary underrun protection and lateral protection is described in items 3.18 and 3.19.•

Moments of resistance of the subframe side rails for flatbed attachments:

Model Wx/side rail in cm3

LT 28LT 35

20

LT 46 30

Profile dimensions see diagram, item 3.3. The specified values refer to normal operating conditions and applicationswithout overhang extension.



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When handling trilateral and rear dumping attachments, arrange the spherically seated bearings at the rear end,close to the rear axle.

•

Provide guide angles for the relevant spherically seated bearings, so that the dumping bridge is guided during thedumping.

•

The maximum inclination angles and dumping bridge lengths can be taken from the axle load calculation,considering the maximum external attachment lengths.

•

The pressing support is to be attached on cross members in the subframe.•

It is recommended to arrange the subframe cross-members over the cross members of the chassis frame.•

At trilateral dumping attachments, the point of application force of the dumping press is to be set in front of thecentre of mass of attachment and net weight.

•

Protection If required, the dumping bridge has to be secured against dropping. Take measures againstunintentional operation. As a visual warning (dumping bridge not in driving position), a control lamp is to beconnected in the cab.

•

SubframeThe subframe must be must be continuously designed and be provided with sufficiently dimensioned crossmembers made of steel. Close the rear area adjacent the box and brace it with diagonal cross. Connect thesubframe with the chassis frame corresponding to the load, according to item 3.3.3.

•

To fix the subframe laterally, weld guide plates in the area of the cross members at the subframe.•

Moments of resistance of the subframe:

Model Wx/side rail in cm3

LT 28LT 35

45

LT 46 60

Profile dimensions seediagram, item 3.3. Thespecified values refer to

normal operatingconditions and applicationswithout overhangextension.


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General informationIt is not permitted to modify spring characteristics, brake system and steering unit. Exceptions must be approved byVolkswagen AG before the modification is carried out.

Note:Changing the steering and braking forces for vehicle conversions for disabled persons is not possible.

Airbag

If the attachment manufacturers modify the structure of the vehicle, e. g.

modifications of the front section of the vehicle•

mounting of belt retractors if the B-pillars are left out•

modifications of the floor structure in the area of the airbag trip device•

modifications of the seats, resulting in altered kinematics of the passengers•

modifications of the airbag-system cabling•

modifications of the system design•

the safe functioning of airbag and belt retractor can no longer be guaranteed. These component parts may only be usedafter having been approved by Volkswagen AG.

Emission behaviour (exhaust gas/noise)

If parts are to be modified that are producing exhaust gas and noise (e. g. engine/injection pump/control unit, exhaustsystem/catalytic converter, air suction installation, tyres, etc.), it is required to perform exhaust gas and noisemeasurements. It is also necessary to adhere to the current versions of the specific national directives and regulations.

For this reason, parts which are installed as standard to reduce emissions should not be removed or changed. Otherwisethe license may expire.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 bodyguidelines). Data status August 2007

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The company Paulisch GmbH & Co. KGEisenbahnstraße 17Postfach [P.O. box] 140597804 Lohr am Main, GermanyPhone +49-9352-855260Fax +49-9352-855102

is our supplier of serial seats for the passenger compartment. This firm is also offering two seat variants which can bepositioned against the driving direction without changing the standard seat mounting points in the 1st row of seats. Thisapplies to the narrow triple seat and the double seat. Since we do not supply these seat variants, it is only possible toorder them directly from this manufacturer. These seats are already provided with (automatic) lap belts. The pre-cut fabriccovering material reference allows for the omission of the three-point belts!

Prices: State 21 November, 1997:

Narrow triple seat based on standard seat, with upper part turned by 180° and with the seat mating-part sets,including the installation materials for the vehicle floor, excluding head restraints. DEM 1292/piece (withoutturnover tax)

•

Double seat, as above, DEM 968/piece (without turnover tax)•

The prices are ex-works from Lohr am Main, Germany, excluding packaging.The head restraints can be ordered as replacement parts from Volkswagen using Part No. 2D0 881 901... The nav_sidemissing here depends on the selected seat cover.

Note:

Since the floor attachment for the above mentioned seat variants are taken over from the standard seat variants without

modifications, it is possible to replace the above mentioned seat variants by the corresponding standard seat variants, if the backrest locking at the side panel, which is required for this, was appropriately retrofitted according to the seriesspecifications.


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At the multi-purpose/box-type delivery van, attachment and base group form a self-supporting unit. Supporting parts of thisself-supporting unit must not be removed without being replaced by another component. Baffles have no supportingfunction. Modifications, even the complete removal, are permitted. If car-body parts are to be modified or to be installed, itis only permitted to weld if bonding is not possible.

Cut-outs in the side wallIf profiles are cut in order to install cut-outs (windows, doors, bonnets, ventilation, air exhaust, etc.), the cut-outsmust be reinforced by an enclosing frame and must be welded to the cut profiles.

•

Roof heightening (plastic roof)refer to item 3.6, Roof design

•

At closed bodies with partition walls ventilation slots are located in the partition wall and the D-pillars. At car modificationsit is only allowed to cover these ventilation slots, if new slots are produced in the cab instead. For example in the cabdoors.


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If the wheel base is to be modified or if the overhang is to be extended, the material quality and dimensions of thelengthening piece must correspond to the chassis frame (St 12.03). Functioning, smoothness and free movement of instruments and operating equipment as well as the stability of supporting parts must not be impaired by the performedmodifications.

Cut-outs in the backwall of the driver™s cab must be provided with an enclosing frame. The remaining diagonal struts andcross-beams are to be reinforced by junction plates and are to be welded to the inserted frame.

The distance between cab and attachment must be at least 50 mm.

Frame modifications

The permitted axle loads must not be exceeded. It is also required not to fall below the permitted minimum frontaxle load.

•

Attach the underrun protection as explained for standard vehicles.•

Extend the subframe up to the frame end.•

Check the function of the towing device.•

Reinforcements must be available for desired towing device.•

The side rails are hollow profiles (cap profiles). If it is required to drill, the appropriate operations may only be performed inthe specified areas.

It is not permitted to drill:

At the upper and lower belt of the chassis frame. Exceptions are boreholes at the rear frame end. However,these boreholes must not lie in the area that are reserved for the supporting functions of the rear axle. In addition,they must not be applied to parts that are attached to the frame.

•

In the range of profile modifications of the frame side-rails (frame drop and frame indent).•

At force-application points (e.g. directly at the spring brackets).•

In special cases, it is permitted to drill boreholes in the crosspiece of the frame side rails.

Distance a: at least 20% of the frame height•

Hole separation b: at least 50 mm•

max. bore diameter: 15 mm•

Grind and ream after drilling. Before usage, distance bushes must be welded in.

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According to item 2.3, the permitted maximum rear overhangs (depending on wheel base and permitted totalweight) are to be kept.

For this purpose, consider the following instructions:

If the frame is to be extended by more than 350 mm, an additional cross member is to be installed.•

It is required to check the permitted trailing load (according to the vehicle registration document). Reduce,if necessary.

•

Overhang extension according to the illustration.•

As an ex-works preparation, the SBBR line can be installed with a spare section of 700 mm. Ordering options canbe taken from the sales documents.

LT28

/

LT35

LT46

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Perform wheel-base extensions of the longest standard base. If the wheel base is to be modified, the next larger standardwheel-base is to be used and shortened. Reinforce the intersecting point with sheet-metal shoes.

Wheel-base modifications based on displacing the rear axle are not permitted.

Separation points are not permitted in the area of:

Force-application points•

Axle guiding and axle spring-suspension•

Profile modifications•

After the wheel base modification, the chassis has to be reinforced by a continuous subframe.

Moments of resistance required for the subframe:

Up to the max. standard wheel-base: 30 cm3.•

Above the max. standard wheel-base: 15% increase.•

The wheel-base modification results in an altered turning circle and changed weight values.

Wheel base modifications lying within the range of the minimum/maximum standard wheel-base, require no specialpermission.

Drive shafts

If wheel-base modifications are to be performed, the drive-shaft arrangement and length must correspond to thatof a comparable standard vehicle.

•

The diameter and wall-thickness of the drive-shaft must correspond to that of the standard vehicle.•

If required, use several drive shafts with intermediate bearings.•

The inflection angles (ß1 = ß2) must not exceed 6° . Deviations impair operating life and noiselevel.

•

Counterbalance drive shafts before mounting them.•

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Volkswagen AG does not provide information on the road/braking/steering behaviour of vehicles whose wheel bases wereextremely changed.

Inflection types


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General informationWhen performing welding operations with electrical welding sets, adhere to the following instructions:

Welding works at the chassis frame may only be performed by trained and sufficiently qualified staff.•

Remove and cover the positive and negative terminals of the batteries.•

Connect earth terminal of the welding set directly to the part to be welded. Caution! The earth terminal of thewelding set must not be connected to any other module (engine, transmission, axles, etc.).

•

Do neither touch the housings of electronic modules (e. g. control units) nor electrical lines with the weldingelectrode or with the earth terminal of the welding set.

•

At cabs which are independently supported, connect the earth terminal of the welding set to the cab.•

Before beginning the welding work, it is required to protect the springs against weld splatters. Do not touchsprings with the welding electrodes or the electrode holder.

•

Caution!It is not permitted to weld:

At modules, such as engine, transmission, axles, etc.•

At the chassis frame (except for wheel base and frame modifications)•

Welding at the vehicle frame At the upper and lower belt of the chassis frame, it is not permitted to weld (except for wheel-base modifications and frameextension).Connect the earth terminal of the welding set directly to the vehicle part to be welded.

Only use well drained electrodes with lime-basic coating. Electrode diameter 2.5 mm.•

Current intensity per mm of the electrode diameter is max. 40 A.•

The electrodes may only be welded together with direct current via the positive pole. In general, the welding hasto be performed from bottom to top.

•

Inert gas shielded arc welding is permitted.•

Weld filler rod size between 1 and 1.2 mm.•

The weld material must at least have the same yield point and tensile strength like the material to be welded.•

To avoid a notch effect caused by weld penetrations, slur weld joints and reinforce them using angular profiles. Avoid weld joints in bend radii. The distance between weld joints and outer edges should be at least 15 mm.•

Only plug weld in the neutral zone is permitted.•

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Air Suction Adhere to the following instructions if the engine air-suction is to be modified:

To ensure the functionality, standard parts, such as filters, tubes, suspensions (oscillating insulation), etc., mustto be mounted according to the same specifications as the standard model.

•

The clean-air side and the connection maintenance indicator must not be modified.•

It is not permitted to the change the installation conditions in the area of the inlet port.•

The flow velocities in the intake range, in front and inside the air intake, must not be increased. Do not confinethe unrestricted cross section.

•

The water separation of the engine air-suction may be impaired even by small modifications in the area of thesuction opening (e. g. the radiator grill). Therefore, modifications in this always require a permission of theresponsible department.

•

Exhaust-gas circulation/exhaust system

Use only original Volkswagen components for modifying the exhaust system.•

Length and mounting position of the flexible metallic hose between exhaust manifold and exhaust pipe must notbe changed.

•

The unrestricted cross section of the exhaust pipe behind the sound absorber must not be reduced.•

Pipe bend max. 90°•

Avoid additional pipe bends.•

Bend radii 2.5 d.•

Minimum distance to plastic lines, electrical cables and spare wheels:200 mm for exhaust systems without shielding,80 mm for sheet shieldings,40 mm for sheet shieldings with additional insulation.

•

Additional shieldings are required:In the area of operating devices•

in the area of modules, attachments and installations , if they are not made of heat-resistant material.•

•

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Cooling:

The cooling system (radiator, radiator grill, air ducts, coolant circuit, etc.) must not be changed.

A sufficient throughput of cooling air must be ensured.

Keep the air intake of the radiator free•

Do not place any warning signs, plaques or other decorative parts in the area in front of the radiator.•

Provide additional cooling devices for modules, devices, etc., if the following conditions apply:

Operation at outdoor temperatures above 35°C.•

If the vehicle is standing and high continuous power is drawn off •

Disk brakes

The cooling must not be impaired by spoilers below the bumper, additional wheel trim panels or brake diskcoverings, etc.

•

Preparation 2nd heat exchanger

At backfitting of a heat exchanger, it is important the bleed the cooling water system completely:

heater output:8,7 kWair-mass flow: 360 kg / hvolume flow: 1500 l / h

the additonal heat exchanger from the T4-selection can be recommended.

•


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General information

Do not loosen or remove the terminal clamps of the batteries with the engine running.•

Only tow-start vehicle with connected batteries.•

Charge batteries only then with a quick-charger, with the batteries being disconnected from the vehicle circuit.Positive and negative terminals must be removed. Adhere to the operating instructions!

•

Installation of additional electrical consumers.•

Coat cables which are to be routed near exhaust systems with fire-proof material.•

Route cables in such a way that abrasion marks can be avoided.•

Electromagnetic compatibility (EMC)

In motor vehicle power-supply circuits, the individual consuming devices cause electrical disturbance variables.Volkswagen AG checks whether electronic components (which are installed by the manufacturer) are electromagneticallycompatible inside the vehicle.

If electrical or electronic systems are to be upgraded or retrofitted, it is also required to check their electromagneticcompatibility.

The following standards supply relevant information:

DIN 40839•

DIN 57879, Part 3•

VDE 0879, Part 3•

VWTL 965•

VWTL 82066•

VWTL 82166•

VWTL 82366•

In addition, it is required to consider the EMC Directive 72/245 EC, version 95/54 EC.

More information can be requested from the responsible department.

Supplementary current-collecting consuming devices

Adhere to the following instructions if additional electrical consuming devices are to be installed later on:

On special request, provide available batteries and generator with higher output.•

Connect no further consuming devices to fuses which are already assigned.•

Connect no additional lines (e. g. with insulation piercing connecting devices) to available lines.•

Protect consumers with additional fuses sufficiently against short circuits.•

Subsequent installation of an additional battery

An additional battery may only be installed in connection with a D+ relay. This battery may only be assigned to additionalconsuming devices, such as auxiliary heater, loading tailboard or electrical devices to be used in mobile homes(refrigerator, etc.). If the additional battery is to be placed in the passenger compartment, the ventilation has to be realisedusing a central degassing tube leading outside.

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Electrical lines

Adhere to the following instructions if electrical lines are to be extended:

Use only FLKR lines with the same cross section and colour as the standard lines.•

The lines must be coated with an insulating hose (GGVS vehicles with a corrugated hose).•

Attach only original Volkswagen plug connectors to the line ends.•

The connection of electrical lines may only be realised via tapping boxes.•

Cables of the anti-lock brake system may only be extended with original Volkswagen cable-sets.•


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In the event of tampering with the structure of the vehicle by the body manufacturer for example.

Modifying the front end•

Attaching belt tensioners with no B-pillar,•

Modifications to the floor structure in the area of the airbag trigger control unit,•

Modifications to the seats and thus to the kinematics of the occupants,•

Modifications to the wiring of the airbag system,•

Modifications to the system design (e.g. installation location of the sensors,•

Installation of parts in the vicinity of the outlets or inflation range (only tested retrofit solutions permissible),•

reliable operation of the airbag, passengerairbag and belt tensioners can no longer be guaranteed. These componentsshould therefore only be used with the approval of the responsible department.


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ChassiswithSinglecab

280032003500

3550 Standard Stabilizer 780 1000/1050130712441204

142713491300

ChassiswithDoublecab

280032003500


147113781322

PanelVan

32003500


14751381

Pickupwithsinglecab

32003500


14711385


32003500 4025 Standard Stabilizer 805 1000/1050

13411271

14791391


32003500


13631310


32003500


13951335

LT 35/LT46

Type

t

KGwheelbasemm

Stabilisatoren

center of gravitybasicvehicle

dimensionmm X

totalcenter of gravityvehicle

dimensionmm Y

maximum legal heightof center of gravity of body

dimension

front-axle

rear-axle

Standard-equipment

withStabilizer HA Z

PanelVan

350040004600

3550 StandardStabilizer reinforced

805 1050/1100140813131249

153414191342

PickupwithSinglecab

350040004600


770 1050/1100148613701292

161414771385


350040004600


770 1050/1100151613871304

164914981399


350040004600


725 1050/1100140913261266

151414181349

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350040004600


725 1050/1100145913591289

157214571376

PanelVan

350040004600


805 1050/1100150413701286

165114881387

PickupwithSinglecab

350040004600


770 1050/1100154914071316

168815211414


350040004600


780 1050/1100155514101318

169515251416


350040004600

4025 Standard Stabilizer reinforced

725 1050/1100 143013401276

153914351361


3500400046000


725 1050/1100146213611290

157514591377


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1) Station wagona) If the passenger compartment is being ordered without standard seats, the station wagon will then generally beprovided ex works with 3 prepared mounting points for the first two rows of seats, including the single-sidedpreparation for connecting the backrests of the standard seats at the contacting side wall with double and narrow tripleseat, respectively, at the wide triple seat, the two-sided connecting preparation.Exception: Station wagons with 2 sliding doors. This variant is not provided with a prepared floor mounting points for thefirst row of seats. For this reason, it is not possible to retrofit standard seats in this case.(Note: Seats are also not available as standard!).

b) It is required to order the prepared floor mounting points for the 3rd row of seats, including the two-sidedconnection preparation for the backrest of the wide triple seat bench at both side panels, with PR.-No. 3WE since theyare not available for the basic version.

Note: A retrofitting of the floor mounting points, including the both-sided connection preparation for the backrest of the

wide triple seat, in the 3rd row of seats is not possible.

c) However, if a double seat is ordered ex works for the 1st and / or 2nd row of seats, the 3rd floor mounting point(which is not required) for the affected row(s) of seats will not be appropriately prepared. A subsequent upgrade to atriple seat is possible (in front only onto a narrow triple seat), but is, however, extremely complicated! If an upgrade to awide triple seat (only for the 2nd row of seats) is to be realised, the connection preparation for the backrest on theprevious passage side of the double seat also has to be retrofitted.

d) For conventional single seats mounted in driving direction (not available ex works; to be supplied by the attachmentmanufacturers) on the vehicle floor of the passenger compartment of the station wagon and/or the boot space of thebox-type delivery van, on the left and right of the side panels, a suggested solution for retrofitting the belt anchorage pointsof three-point belts (to the left and right of the single seats on the vehicle floor and at the corresponding side panels) wasdeveloped and tested by TÜV Rheinland [Testing and Research Laboratory of the Rhineland] in a sprinter. Since theaffected car-body areas are identical with that of the LT, the expert assessment No. 55110226-00, dated 19/10/1995, can

also be applied to the Volkswagen LT (LT 2). The attachment of the single seats on the vehicle floor are not dealt with.The expert assessment is available on request (Fax 49-511-7983895).

2) Box-type delivery vana) The boot space floor is not prepared to be equipped with station wagon standard seats. It is not possible to retrofit thefloor mounting points!Note: A seat package is available ex works for all box-type delivery van versions with a narrow triple seat for the 1st row of seats!

b) Retrofitting of single seats performed by attachment manufacturers: See station wagon, item 1d).


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Designation Box-type deliveryvanLT 28/ LT 35/ LT46Internal dimensionsdrawing

Box-type delivery van andstation wagonLT 28/ LT 35Construction dimensionaldrawing

Box-type delivery van andstation wagonLT 28/ LT 35Construction dimensionaldrawing

Wheelbase 3.000 / 3.550 / 4.025mm

3.000 mm 3.550 mm

JPG Z.-Nr. V03 773 042,434 kB

Z.-Nr. 2D0 000 011, 651 kB Z.-Nr. 2D0 000 011 A, 775kB

DWG Z.-Nr. V03 773 042,248 kB

Z.-Nr. 2D0 000 011, 899 kB Z.-Nr. 2D0 000 011 A, 930kB

DXF Z.-Nr. V03 773 042,217 kB

Z.-Nr. 2D0 000 011, 744 kB Z.-Nr. 2D0 000 011 A, 775kB

IGES Z.-Nr. V03 773 042,310 kB

Z.-Nr. 2D0 000 011, 992 kB Z.-Nr. 2D0 000 011 A, 1023kB

Designation Box-type delivery van andHigh-space station wagon LT 35Construction dimensionaldrawing

High-space box-typedelivery vanLT 46Constructiondimensional drawing

High-spacebox-typedelivery vanLT 46Constructiondimensionaldrawing

Wheelbase 4.025 mm 3.550 mm 4.025 mm

JPG Z.-Nr. 2D0 000 011 B,

772 kB

Z.-Nr. 2D0 000 011 C,

496 kB

Z.-Nr. 2D0

000 011 D,961 kB

DWG Z.-Nr. 2D0 000 011 B,899 kB

Z.-Nr. 2D0 000 011 C,930 kB

Z.-Nr. 2D0000 011 D,930 kB

DXF Z.-Nr. 2D0 000 011 B,744 kB

Z.-Nr. 2D0 000 011 C,775 kB

Z.-Nr. 2D0000 011 D,806 kB

IGES Z.-Nr. 2D0 000 011 B,992 kB

Z.-Nr. 2D0 000 011 C,1 MB

Z.-Nr. 2D0000 011 D,1 MB


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http://www.umbauportal.de/documents/10156/56628/lt_28_35_ka_ko_mr.zip


http://www.uumbauportal.de/documents/10156/56629/lt_28_35_ka_ko_kr.zip


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http://www.umbauportal.de/documents/10156/56630/lt_46_fg_sc_lr.jpg

http://www.umbauportal.de/documents/10156/56630/lt_46_fg_sc_mr.jpg


http://www.umbauportal.de/documents/10156/56627/lt_35_ka_ko_lr_hd.zip

http://www.umbauportal.de/documents/10156/56627/lt_46_ka_mr_hd.zip

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Designation Chassis with driver scabLT 28 / LT 35Constructiondimensional drawing

Chassis with driver scabLT 28 / LT 35Constructiondimensional drawing

Chassis with driver scabLT 35Constructiondimensional drawing


JPG Z.-Nr. 2D3 000 011,775 kB

Z.-Nr. 2D3 000 011 A,744 kB

Z.-Nr. 2D3 000 011 B,744 kB

DWG Z.-Nr. 2D3 000 011,899 kB

Z.-Nr. 2D3 000 011 A,899 kB

Z.-Nr. 2D3 000 011 B,899 kB

DXF Z.-Nr. 2D3 000 011,744 kB

Z.-Nr. 2D3 000 011 A,744 kB

Z.-Nr. 2D3 000 011 B,744 kB

IGES Z.-Nr. 2D3 000 011,

1.023 kB

Z.-Nr. 2D3 000 011 A,

922 kB

Z.-Nr. 2D3 000 011 B,

1 MB

Designation Chassis with driver s cabLT 46Construction dimensional drawing

Chassis with driver s cabLT 46Construction dimensional drawing

Wheelbase 3.550 mm 4.025 mm

JPG Z.-Nr. 2D3 000 011 K, 775 kB Z.-Nr. 2D3 000 011 L, 775 kB

DWG Z.-Nr. 2D3 000 011 K, 930 kB Z.-Nr. 2D3 000 011 L, 961 kB

DXF Z.-Nr. 2D3 000 011 K, 775 kB Z.-Nr. 2D3 000 011 L, 806 kB

IGES Z.-Nr. 2D3 000 011 K, 1 MB Z.-Nr. 2D3 000 011 L, 1 MBNote: 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 bodyguidelines). Data status August 2007

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http://www.umbauportal.de/documents/10156/56627/lt_28_35_fg_sc_mr.zip

http://www.umbauportal.de/documents/10156/56627/lt_35_fg_sc_lr.zip









http://www.umbauportal.de/documents/10156/56627/lt_46_fg_sc_mr.zip


























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Designation Chassis with double cabLT 28 / LT 35Constructiondimensional drawing

Chassis with double cabLT 35Constructiondimensional drawing

Chassis with double cabLT 46Constructiondimensional drawing


JPG Z.-Nr. 2D3 000 011 C, 496kB

Z.-Nr. 2D3 000 011 D, 589kB

Z.-Nr. 2D3 000 011 M, 806kB

DWG Z.-Nr. 2D3 000 011 C, 899kB

Z.-Nr. 2D3 000 011 D, 930kB

Z.-Nr. 2D3 000 011 M, 961kB

DXF Z.-Nr. 2D3 000 011 C, 775kB

Z.-Nr. 2D3 000 011 D, 744kB

Z.-Nr. 2D3 000 011 M, 775kB

IGES Z.-Nr. 2D3 000 011 C, 1MB

Z.-Nr. 2D3 000 011 D, 1MB

Z.-Nr. 2D3 000 011 M, 1MB

Designation Chassis with double cabLT 46Construction dimensional drawing

Wheelbase 4.025 mm

JPG Z.-Nr. 2D3 000 011 N, 772 kB

DWG Z.-Nr. 2D3 000 011 N, 899 kB

DXF Z.-Nr. 2D3 000 011 N, 744 kB

IGES Z.-Nr. 2D3 000 011 N, 992 kBNote: 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 bodyguidelines). Data status August 2007

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http://www.umbauportal.de/documents/10156/56627/lt_28_35_fg_dc_mr.zip

http://www.umbauportal.de/documents/10156/56627/lt_35_fg_dc_lr.zip

http://www.umbauportal.de/documents/10156/56627/lt_46_fg_dc_mr.zip







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Box-type delivery van, short wheelbase (28KKAm)

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Box-type delivery van, medium wheelbase (28MKAm)

High-space box-type delivery van, medium wheelbase (28MHAm)

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Chassis with driver™s cab, short wheelbase (28KFFm)

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Chassis with driver™s cab, medium wheelbase (28MFFm)

Chassis with double cab, medium wheelbase (28MFDm)

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High-space box-type delivery van, long wheelbase (35LHAm)


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Chassis with driver™s cab, short Radstand (35KFFm)

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Chassis with driver™s cab, medium Radstand (35MFFm)

Chassis with driver™s cab, long Radstand (35LFFm)

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Chassis with double cab, medium Radstand (35MFDm)

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Chassis with double cab, long Radstand (35LFDm)



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High-space box-type delivery van, long wheelbase (46LHAm)


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Chassis with driver™s cab, medium wheelbase (46MFFm)

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Chassis with driver™s cab, long wheelbase (46LFFm)

Chassis with double cab, medium wheelbase (46MFDm)

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Chassis with double cab, long wheelbase (46LFDm)


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Body builder guidlines LTBody builder guidelines

Subject to modifications

Edition August 2007

Internet: www.volkswagen-nutzfahrzeuge.de

2007-08_abr_lt_en

Documents