ARL Sprinter 907 2022 ENU Fin

Body and Equipment Guideline
Sprinter – Model Designation 907
Edition MY2023
Mercedes-Benz USA, LLC

Contents
3.6 Vehicle identification data............................39

1 Introduction..................................................6
3.6.1 VIN plate......................................................39
1.1 Purpose of Body and Equipment Guideline......7
3.6.2 QR code rescue sticker................................40
1.2 Conventions...................................................8
3.6.3 Safety Label location....................................41
1.3 Vehicle safety................................................9
3.6.4 Noise Emission Label...................................41
1.4 Operational safety........................................10
3.6.5 Complete Vehicle Identification Label...........41
1.5 Note on copyright........................................10
3.6.6 Incomplete Vehicle Identification Label.........42
1.6 Granting of body technical assistance..........10
3.6.7 Vehicle Emission Control Information Label .....42
1.7 Contact.......................................................11
3.6.8 Airbag Warning Label...................................43
1.8 Definitions...................................................12
3.6.9 Tire and Loading Information Label...............43
1.9 Parts Use.....................................................13
3.6.10 Unloaded Vehicle Weight UVW rating and
Label...........................................................43
2 General.......................................................14 3.7 Vehicle stability............................................44
2.1 Advice for Upfitters......................................14 3.8 Tires............................................................45
2.1.1 Regulatory Overview....................................14 3.9 Bolted and welded connections....................46
2.1.2 Emissions and safety information.................15 3.9.1 Threaded connections..................................46
2.1.3 Vehicle safety standards information ...........15 3.9.2 Welded connections.....................................47
2.1.4 Exhaust emission control information...........16 3.10 Soundproofing.............................................50
2.1.5 Vehicle noise emission control information .. 16 3.11 Maintenance and repairs..............................51
2.2 Upfitter responsibilities ...............................17 3.11.1 Storing the vehicle.......................................52
2.3 Product and vehicle information for upfitters... 18 3.11.2 Battery maintenance and storage.................53
2.3.1 Upfitter Portal..............................................18 3.11.3 Work before handing over the modified
2.3.2 Workshop Information System (WIS).............18 vehicle.........................................................53
2.3.3 XENTRY Kit..................................................19 3.12 Special equipment.......................................55
2.4 Product safety and product liability...............20 3.13 Adhesive decals on the exterior....................56
2.4.1 Product safety..............................................20
2.4.2 Product liability............................................20
4 Technical limit values for planning............58
2.4.3 Safety-relevant features...............................21
4.1 Limit values for the basic vehicle..................58
2.4.4 Guarantee of traceability..............................21
4.1.1 Steerability..................................................58
2.5 Trademarks..................................................22
4.1.2 Maximum permissible position of the center
2.5.1 Mercedes-Benz brand in interaction with
of gravity.....................................................58
external upfitters..........................................22
4.1.3 Vehicle dimensions......................................59
2.5.2 Function of a brand......................................22
4.1.4 Parts which must not be welded:..................62
2.5.3 Trademark protection...................................22
4.1.5 Drilling must not take place..........................63
2.5.4 Trademark rights..........................................22
4.1.6 Service lift points ........................................65
2.5.5 Advice on applying Mercedes-Benz trade-
4.1.7 Weights.......................................................66
marks to vans..............................................23
4.1.8 Weight limits................................................67
2.5.6 Use of Mercedes-Benz trademarks...............23
4.2 Limit values for the suspension....................68
2.5.7 Brand separation/identity............................23
4.2.1 Suspension of Sprinter – BR 907..................68
2.6 Accident prevention.....................................25
4.2.2 Permissible axle loads..................................69
2.7 Recycling.....................................................26
4.2.3 Approved tire sizes.......................................70
2.8 Quality system.............................................27
4.2.4 Diameter of turning circle.............................71
2.9 Key Pre-Upfit Considerations........................28
4.2.5 Modifications to the axles ...........................71
4.2.6 Modifications to the steering........................71
3 Planning of bodies......................................29 4.2.7 Modifications to the brake system ...............71
3.1 Vehicle and model designation.....................30 4.2.8 Modifications to springs, spring suspen-
3.2 Model overview............................................34 sion/shock absorbers .................................71
3.3 Selecting the basic vehicle...........................35 4.2.9 Wheel alignment..........................................71
3.4 Vehicle Modifications...................................36 4.3 Limit values for the body in white.................72
3.5 Dimensions and weights..............................37 4.3.1 Modifications to the body in white................72
2 Mercedes-Benz | Body and Equipment Guideline Sprinter - BM907, Edition 2022-5

Contents
4.3.2 Limit values for the vehicle frame.................72 6.2.10 Cutting the cab roof and B-pillar roof bow...123
4.3.3 Roof/roof load.............................................73 6.3 Engine peripherals/drivetrain.....................126
4.4 Limit values for engine peripherals/dri- 6.3.1 Fuel system...............................................126
vetrain.........................................................74 6.3.2 SCR system...............................................130
4.4.1 Modifications to engine/drivetrain compo- 6.3.3 Exhaust system..........................................132
nents ..........................................................74 6.3.4 Engine cooling...........................................135
4.4.2 Engine cooling system..................................74 6.3.5 Engine air intake........................................135
4.5 Limit values for the interior...........................77 6.3.6 Clearance for major assemblies.................136
4.5.1 Modifications to airbags and seat belt tensi- 6.3.7 Propeller shafts..........................................136
oners...........................................................77 6.4 Interior.......................................................138
4.5.2 Modifications to seats..................................77 6.4.1 General information...................................138
4.5.3 Seat Reference Point...................................79 6.4.2 Safety equipment.......................................139
4.6 Limit values for electrics/electronics...........80 6.4.3 Seats ........................................................147
4.6.1 Vehicle position lamps and side marker 6.4.4 Reducing interior noise..............................148
lamps..........................................................80 6.4.5 Ventilation ................................................149
4.6.2 Retrofitting electrical equipment ..................80 6.4.6 Attachment points for load compartment
4.6.3 Mobile communications systems..................80 trim parts on the side wall/roof..................150
4.6.4 CAN bus......................................................80 6.5 Additional assemblies................................152
4.7 Limit values for additional assemblies...........81 6.5.1 Retrofitting an air conditioning system........152
4.8 Limit values for attachments........................81 6.5.2 Auxiliary heating .......................................154
4.9 Limit values for the box body........................82 6.5.3 Engine power take-off................................154
4.9.1 Assembly frame...........................................82 6.5.4 Retrofitting an alternator............................156
6.6 Attachments..............................................157
5 Damage prevention....................................83 6.6.1 Wind deflectors..........................................157
5.1 Brake hoses/cables and lines......................84 6.6.2 Attachment above cab ..............................157
5.2 Welding work...............................................85 6.6.3 Roof racks ................................................158
5.3 Anti-corrosion protection measures..............86 6.6.4 Shelf systems/vehicle interior installations.... 158
5.4 Painting work/preservation work.................88 6.6.5 Loading cranes..........................................166
5.5 Storing and handing over the vehicle............91 6.6.6 Lifting platform (cargo liftgate)...................169
6.6.7 Trailer hitch................................................172
6 Modifications to the basic vehicle.............92 6.6.8 Underrun protection...................................176
6.1 Suspension..................................................92 6.6.9 Positioning placard holders........................178
6.1.1 General information on the suspension........92
6.1.2 Springs/shock absorbers/stabilizer bars.....94 7 Design of bodies.......................................180
6.1.3 Brake system...............................................94 7.1 Assembly frame.........................................180
6.1.4 Air suspension.............................................98 7.1.1 Material quality, general.............................180
6.1.5 Wheels/tires ...............................................98 7.1.2 Design.......................................................181
6.1.6 Spare wheel...............................................100 7.1.3 Section dimensions/dimensioning ............182
6.2 Body in white/body....................................101 7.1.4 Attachment to the chassis bed...................183
6.2.1 General information on the body in white/ 7.1.5 Assembly frame as floor assembly .............188
body..........................................................101 7.2 Self-supporting bodies...............................189
6.2.2 Attachment to the frame............................105 7.3 Modifications to the interior.......................190
6.2.3 Material for the chassis frame ...................107 7.4 Modifications to closed cargo vans.............192
6.2.4 Overhang extension...................................107 7.5 Platform bodies .........................................196
6.2.5 Modifications to the cab.............................110 7.6 Box bodies.................................................197
6.2.6 Side wall, windows, doors and flaps............111 7.7 Refrigerated vehicles/temperature-control-
6.2.7 Fenders and wheel wells............................114 led vehicles................................................198
6.2.8 Frame end crossmember...........................118 7.8 Vehicles for transportation
6.2.9 Cargo Van/Passenger Van roof..................118 of technical gases......................................199
7.9 Dump trucks..............................................200
Mercedes-Benz | Body and Equipment Guideline Sprinter - BM907, Edition 2022-5 3

Contents
7.10 Light duty truck..........................................201 8.4.4 Additional electric circuits..........................241

7.11 Recovery vehicles......................................204 8.4.5 Operating switches (pre-installation)...........241
7.12 Torsionally stiff body types.........................205 8.4.6 Retrofitting electrical equipment................242
7.13 Lifting work platform..................................206 8.4.7 Retrofitting an alternator ...........................242
7.14 Bodies on chassis with base (F28)..............209 8.4.8 Power tapping............................................243
7.14.1 Base/windshield support structure and 8.4.9 Interface overview......................................248
base with doors F28..................................209 8.4.10 Speed signal..............................................250
7.14.2 Mechanical equipment...............................210 8.4.11 Travel distance signal.................................250
7.14.3 Wiring harness connecting points...............211 8.4.12 Ground bolts..............................................250
7.14.4 Headlamp Assist (code LA2)......................212 8.4.13 Additional ground weld studs.....................252
7.14.5 Rain sensor (code JF1)...............................213 8.4.14 Deep discharge protection (hibernation
7.14.6 Driver’s and front passenger’s doors mode)........................................................253
connection point........................................213 8.5 Illumination................................................254
7.14.7 Headlamp connecting point - series pro- 8.5.1 Adjusting the headlamps............................254
duction packages and special equipment 8.5.2 Mounting additional lamps.........................255
options......................................................214 8.5.3 Tail lamps...................................................255
7.14.8 Connecting point for antenna switchover 8.5.4 Marker lamps.............................................256
box for third-party antennas (code E4A).....215 8.5.5 Exterior lamps............................................256
7.14.9 Pre-installation for upfitter interface H (code 8.5.6 Interior lamps............................................260
E2A) and upfitter interface M (code E5M)...215 8.6 Mobile communications systems................263
7.14.10 Pre-installation for rear speakers (code EP7). 8.6.1 Equipment.................................................263
217 8.6.2 Antenna connection and cable routing
7.14.11 E-call on base vehicles...............................217 (radio communication)...............................264
7.15 RV – Recreational vehicles.........................219 8.7 Electronic ignition lock (EZS)......................265
7.15.1 Body in white of RVs..................................219 8.7.1 General information...................................265
7.15.2 Suspension of RVs.....................................220 8.7.2 Central locking system/post-delivery integ-
7.15.3 Electrics/electronics of RVs.......................221 ration of doors of upfitter...........................265
7.15.4 Additional main fuses for RVs (codes E1R 8.8 Windows and doors....................................269
and E1Y)....................................................221 8.8.1 Window lifters/window hinges....................269
7.15.5 New features for RVs.................................222 8.8.2 Sliding door...............................................269
7.15.6 Airbags for RVs..........................................223 8.8.3 Windshield wipers......................................270
7.16 Bodies on chassis with lowered roof...........224 8.8.4 Outside mirrors..........................................270
7.16.1 Mounting the auxiliary roof frame...............225 8.8.5 Windshield heating/rear window heating....270
7.16.2 Mounting the body on the auxiliary roof 8.9 Driving assistance systems........................271
frame.........................................................225 8.9.1 Electronic Stability Program (ESP®)............272
7.17 Semi-integrated bodies and optional moun- 8.9.2 Crosswind Assist........................................273
ting of free-standing bodies........................226 8.9.3 Active Brake Assist/Active Distance Assist
7.18 Buses and People Mover............................231 (DISTRONIC PLUS) ....................................275
8.9.4 Blind Spot Assist/Rear Cross Traffic Alert
8 Electrics/electronics...............................233 (RCTA)/Exit Warning..................................277
8.1 General information...................................233 8.9.5 Highbeam Assist, Lane Keeping Assist and
8.2 Electromagnetic compatibility (EMC)..........234 traffic sign recognition...............................286
8.3 Battery......................................................235 8.9.6 Rain sensor and Headlamp Assist...............286
8.3.1 Main battery..............................................235 8.9.7 Tire pressure loss detection system............288
8.3.2 Retrofitting an auxiliary battery...................236 8.9.8 Parking Package with 360° camera (JB6)/
8.3.3 Battery maintenance and storage...............238 Parking Package with reversing camera (JB7)...289
8.4 Interfaces..................................................239 8.9.9 Reversing camera......................................290
8.4.1 CAN bus and networking............................239 8.9.10 Parktronic sensors.....................................295
8.4.2 Electric lines/fuses....................................239 8.10 Parameterizable Special Module (PSM/
8.4.3 Cable extension.........................................239 MPM)........................................................296

Contents
8.10.1 PSM (MPM) Functions................................297

8.10.2 PSM (MPM) Pin Assignment.......................298
8.10.3 Additional information on PSM (MPM)........299
8.11 Signal acquisition and actuation module
(SAM)........................................................300
8.12 Electrical circuit diagrams..........................301
8.13 Telematics.................................................301
8.13.1 Overview of the Infotainment system..........302
8.13.2 Antennas...................................................303
8.13.3 Speakers...................................................307
8.14 Connectivity solutions
Mercedes me connect...............................308
8.14.1 Mercedes me connect for personal use......308
8.14.2 Mercedes me connect for business use......308
9 Calculations..............................................309
9.1 Center of gravity........................................309
9.1.1 Determination of the center of gravity in the
x-direction.................................................309
9.1.2 Determination of the center of gravity in the
z-direction.................................................311
9.2 Location of fifth wheel coupling..................315
10 Technical details.......................................316
(SAM)........................................................316
10.2 Bulb ratings of exterior lights......................317
10.2.1 Conventional headlamps............................318
10.2.2 Conventional tail lamps..............................319
10.2.3 Conventional tail lamps on cab-chassis with
code L90...................................................319
10.2.4 LED tail lamps on cab-chassis with
code L91...................................................320
10.2.5 Additional lighting functions.......................321
10.3 Trailer hitch hole patterns...........................322
10.3.1 Installation dimensions, version 1...............323
10.4 Soundproofing...........................................326
Index......................................................................327

1 Introduction
This Body and Equipment Guideline (BEG) provides The BEG provides upfitters with engineering and tech-
upfitters and converters, hereinafter referred to nical data for educational and informational purposes
collectively as "upfitters", with important technical only. The specifications and descriptions contained in
information which should reflect a vehicle that is safe this book are believed to be accurate at time of publi-
and compliant. The attachments, bodies, equipment, cation. Nevertheless, upfitters should consult with legal
or modifications installed and implemented by the counsel to ensure compliance with pertinent federal,
upfitter are subsequently referred to as "upfit work". state, and local laws and regulations.
In the Body and Equipment Guideline (BEG) for Mer- Periodically, this book will be updated without notice as
cedes-Benz vans, different models and vehicle variants new products are introduced and additional information
directly released from a production plant are grouped regarding these products become available. It is the
together under the generic term "basic vehicle". responsibility of the upfitter to ensure they have the
Mercedes-Benz Sprinter models and vehicle variants most up-to-date version.
are listed in Chapter 3.1 Vehicle and model designation The latest copies of this BEG, 2D drawings, and model
(→ page 30). specifications may be obtained 24 hours/day and
This Body and Equipment Guideline (BEG) is based on 7 days/week through the Upfitter Portal. Other rele-
the development of the Sprinter vehicles - BM 907 for vant information and guidelines that supplement the
the U.S. and Canada market. BEG are also available for download on the Upfitter
Portal under "Technical Information", same location
Please refer to the Upfitter Portal for the Body and as the BEG.
Equipment Guideline (BEG).
www.UpfitterPortal.com ⑴ NOTE
Due to the large number of upfitters and upfit types, As an upfitter, you must always bear in mind that only
Mercedes-Benz AG cannot take into account all the the upfit work described in the BEG is permissible.
possible modifications to the vehicle, e.g. performance, All upfit work not described here is prohibited. If any
stability, load distribution, center of gravity and han- upfit work not described here is necessary, please
dling characteristics, that may result from upfit work. consult with Upfitter Management Vans and appro-
For this reason, Mercedes-Benz AG cannot accept any priate support teams through the Upfitter Portal for
liability for accidents or injuries sustained as a result eXpertUpfitters.
of such modifications to your vehicles. The upfitter
undertakes to ensure that their body modifications are
free from defects - including with regard to the overall Upfitters, as the final-stage manufacturer and / or
vehicle - and do not cause danger to persons or prop- alterer, are completely responsible for its upfitting
erty. If this obligation is violated in any way, the upfitter (including any and all associated van modifications),
shall assume full product liability. designing, validating the upfit, along with ensuring that
the upfit complies with all applicable local, state and
This Body and Equipment Guideline (BEG) is aimed at
federal regulatory guidelines and laws.
professional upfitters. As a result, BEG assumes that
the upfitter has suitable background knowledge.
Moreover, the upfitter must adhere to the operator's
manual valid for the respective vehicle. Please be
aware that certain types of work (e.g. welding work
on load-bearing components) may only be carried out
by appropriately qualified personnel. This will avoid
the risk of injury and will attain the degree of quality
required for the upfit work.

1 Introduction
1.1 Purpose of Body and Equipment Guideline
The Body and Equipment Guideline (BEG) is divided into ⓘ To ensure the operational reliability and road safety
10 interlinked chapters to help you find the information of the overall vehicles, the information given in this
you require more quickly: Body and Equipment Guideline must be strictly
Chapter 1 Introduction (→ page 6) followed.
Chapter 2 General (→ page 14)

ⓘ On account of the ongoing technical evolution of
Chapter 3 Planning of bodies (→ page 29) Mercedes-Benz van products, the upfitters are
Chapter 4 Technical limit values for planning notified at points between the regular publication
(→ page 58) dates about the latest topics or contents/updates
as part of a “BEG Addendum”.
Chapter 5 Damage prevention (→ page 83)
Chapter 6 Modifications to the basic vehicle
ⓘ The “BEG Addendums” are available for free access
(→ page 92)
in the Upfitter Portal (www.UpfitterPortal.com)
Chapter 7 Design of bodies (→ page 180) along with the Body and Equipment Guideline. BEG
Chapter 8 Electrics/electronics (→ page 233) Addendums are extensions of the latest BEG for the
van model in question and must be complied with
Chapter 9 Calculations (→ page 309)
by the upfitters.
Chapter 10 Technical details (→ page 316)
If you are using a printed version of the Body and
Appendix: Equipment Guideline, the following should be noted:
Index (→ page 327) important revisions to BEG, such as updates in the time
period before a new full BEG release will be published
For more information see 2.3 Product and vehicle infor-
as "Addendums" on the Upfitter Portal.
mation for upfitters (→ page 18).
On the publication in the Upfitter Portal, these revisions
The index in PDF format is linked to help you find the
to the BEG become a component of the current BEG or
information you require quickly.
supersede the previous version of the BEG and must be
Make certain that you observe the limit values complied with.
described in Chapter 4 Technical limit values for plan-
Illustrations and schematic drawings are examples only
ning (→ page 58) as planning must be based
and serve to explain the texts and tables.
on these values.
The chapters entitled "Modifications to the basic vehi- ⑴ NOTE
cle", "Design of bodies" and "Electrics/electronics" are
the main source of technical information contained in All graphics are for illustrative purposes only and they
this Body and Equipment Guideline. do not depict all the technical details faithfully.
You can obtain further information from any

Mercedes-Benz Service Partner.

1 Introduction
1.2 Conventions
The following conventions are used in this Body and

Equipment Guideline:
⚠ WARNING
Warning notes draw attention to issues which could
endanger the health or life of yourself or others. Basic vehicle
Action Under this symbol you will find information concerning
the delivered basic vehicle (cab chassis, cargo van,
crew van, and passenger van).
⑴ NOTE
This note draws your attention to possible damage to
the vehicle and/or other objects.
Action
ENVIRONMENTAL NOTE
An environmental note provides you with notes on Body
environmental protection.
Under this symbol you will find information concerning
Action the modification or mounting/attachment of the body
by the upfitter.
ⓘ This symbol indicates useful notes or further infor-

mation and information sources which could be
helpful to you.
→ This symbol indicates where you can find further

information about a topic.
Action

1 Introduction
1.3 Vehicle safety
⚠ WARNING ⑴ NOTE
Before installing any upfit bodies or aftermarket National and local laws, directives and registration
equipment, please read the relevant chapters of the regulations must be complied with.
Body and Equipment Guideline, the instructions and
information from the equipment supplier, and the
owner's manual for the base model vehicle. You could ⚠ WARNING
otherwise fail to recognize dangers, which could Rollover stability is an important consideration in
result in serious injury to yourself or others. the safety design of a vehicle. Stability is influenced
by many factors including chassis and body config-
Notes on vehicle safety uration, suspension, axle track width, tire size, tire
We recommend that you only use Mercedes-Benz pressure, etc. The cargo type and weight (payload),
parts, assemblies, conversion parts, and/ or accessory the body size, shape, and center of gravity height are
parts that have been recommended by Mercedes-Benz particularly important.
for the specific model of Sprinter in question. • Therefore, alterations or installation of additional
If using non-recommended parts, assemblies, conver- equipment to the Sprinter by any upfitter or
sion parts, and/ or accessory parts, it is the upfitter's intermediate and/or Final-Stage Manufacturer may
sole responsibility to ensure the safety and correct adversively affect rollover stability of the vehicle.
fit as outlined in this BEG for the model of Sprinter in The Office of Vehicle Safety Research at NHTSA
question. (National Highway Traffic Safety Administration) has
conducted research and established guidelines to
⑴ NOTE improve rollover stability. Upfitters are advised to
consult with that Office and/or visit the NHTSA web-
Make absolutely sure that you comply with national,
site at www.nhtsa.gov for more information.
state, and local registration regulations as well as
Department of Transportation requirements as upfit
work to the vehicle may change the vehicle type for Inspections conducted by official test centers or official
registration purposes and may invalidate the operat- approvals do not inevitably guarantee compatibility with
ing permit. This applies in particular to: all the functions and systems in the basic vehicle.
• modifications which change the vehicle type For any questions regarding the compatibility valida-
approved in the general operating permit tion, please contact Mercedes-Benz through the Upfit-
ter Portal. See Chapter 1.7 Contact (→ page 11).
• modifications which could endanger road users
• modifications which adversely affect exhaust gas
emissions or noise levels.
Vehicle modifications by the upfitter

Before starting upfit work, the upfitter must check
whether
• the vehicle is suitable for the planned upfit
• the vehicle model and equipment are suitable for the
operating conditions intended for the upfit
The upfitter must ensure that the vehicle meets the
local and national registration requirements after the
modifications have been carried out.

1 Introduction
1.4 Operational safety 1.6 Granting of body technical assistance
Modifications by upfitters should not affect the safety

⚠ WARNING
of the Sprinter or its occupants. Mercedes-Benz AG
Modifications to electronic components, their will offer technical assistance concerning Sprinter,
software or wiring can impair their functioning and/ including technical data and drawings and product info
or the functioning of other networked components. brochures, but it is the sole responsibility of upfitter to
Safety-relevant systems, in particular, may also be ensure modifications do not affect safety of the vehicle.
affected and, therefore, they may no longer function Mercedes-Benz AG neither approves nor disapproves
properly and/or compromise the operational safety Sprinter modifications or equipment installations made
of the vehicle. by upfitters, or dealers/agents of upfitters.
As a result, there is a heightened risk of accident Mercedes-Benz AG do not control the actions and
and injury! manufacturing techniques of such upfitters and dis-
As such, upfitter should avoid making any modifica- claims all liability and responsibility with regard to any
tions to the wiring and electronic components claims for damages related to any modifications and
or their software. Have all work on electrical and equipment installations that upfitter performs on any
electronic equipment carried out at a qualified Sprinter.
specialist workshop.
We recommend that you use an authorized
Mercedes-Benz Sprinter Service Center for this
purpose.
Some of the safety systems only function when the

engine is running. For this reason, do not switch off the
engine when the vehicle is in motion.
1.5 Note on copyright
All the text, illustrations and data contained in these

Body and Equipment Guidelines are protected by copy-
right.
This also applies for the editions on CD-ROM, DVD or
other media.
If you have any questions, please contact
Upfitter Management Vans through the Upfitter Portal.
www.UpfitterPortal.com

1 Introduction
1.7 Contact
Technical advice on body compatibility and on the For all other inquiries non-related to upfitting or
basis vehicle modifying Sprinter, but pertaining to model availability,
To obtain technical assistance or product/parts infor- ordering/purchasing a van, service center capabilities
mation ONLY as it pertains to upfitting and modifying and to get local support, please contact an authorized
Sprinter vans please contact the Upfitter Management dealership authorized by Upfitter Management Vans.
Vans through the Upfitter Portal: The most current list of dealers can be found here:
Mercedes-Benz www.mbvans.com
To contact Upfitter Management Vans, create an USA Dealers
inquiry through the Upfitter Portal inquiry center Mercedes-Benz www.mercedes-benz-vans.ca
(please allow up to 5 business days for more complex Canada Dealers
inquiries).
Technical advice on the parameterizable special

module (PSM)
The PSM (parameterizable special module) familiar
from the Metris BM 447 and Sprinter BM 906 vans has
been developed further. For the new Sprinter model
designated as BM 907, PSM is now internally labeled
as Multi-Purpose Module (MPM). MPM can still be
ordered under the option code ED5 (PSM).
Additional information on PSM or MPM can be found
under chapter Chapter 8.10 Parameterizable Special
Module (PSM/ MPM) (→ page 296)
Advanced support for eXpertUpfitter program

members.
Members of the self-certification quality program, or
eXpertUpfitters can enjoy a dedicated eXpertUpfitter
Dashboard that is reached via a special login on the
Upfitter Portal. From the dashboard, eXpertUpfitters
can receive VIP Technical Support and have the ability
to propose upfit solutions for review by Upfitter Man-
agement Vans. Proposed solutions will be considered
based on scale and complexity and should fall outside
of the contents described in this BEG. For more infor-
mation about the eXpertUpfitter program please visit
www.UpfitterPortal.com/en-us/upfitters/
program-overview

1 Introduction
1.8 Definitions
Upfitters include Final-Stage Manufactures, Intermedi- Incomplete vehicle means an assembly consisting, as
ate Manufacturers, Incomplete Vehicle Manufacturers, a minimum, of a frame and chassis structure. Power-
Vehicle Alterers and Equipment Manufacturers. train, steering system, suspension system and braking
Complete vehicle means a vehicle that requires no fur- system, to the extent that those systems are to be part
ther manufacturing operations to perform its intended of the completed vehicle that requires further manu-
function, other than the addition of readily attachable facturing operations, other than the addition of readily
components, such as mirrors, tires or tire and rim attachable components, such as mirrors or tire and
assemblies, of finishing operations such as painting. rim assembles, or minor finishing operations such as
painting, to become a completed vehicle.
Completed Sprinters “As Delivered” mean
Sprinters manufactured by Mercedes-Benz AG reas- Incomplete vehicle manufacturer means a person who
sembled if necessary by Mercedes-Benz AG’s designee, manufactures an incomplete vehicle by assembling
certified to comply with all applicable laws and regula- such components that none of the components, taken
tions and delivered as a complete vehicle (cargo, crew, separately, may constitute an incomplete vehicle.
and passenger vans) to dealers, upfitters and others Vehicle alterer is a person or company who modifies a
engaged in the manufacturing and marketing of new previously certified vehicle other than by the addition,
motor vehicles and equipment. substitution or removal of readily attachable com-
Mercedes-Benz parts mean genuine parts, accesso- ponents. Readily attachable components can mean
ries for installation on or attached to vehicles, com- mirrors, tire and rim assemblies, or minor finishing
ponents, aggregates and assemblies, including those operations such as painting. Alterers are responsible
for exchange or replacement which are supplied by or for ensuring the previously certified vehicle meets all
through MBUSA, MBCAN, and MBVANS or any of its emissions and FMVSS/CMVSS (Federal/Canadian
parent companies, affiliates or subsidiaries. Motor Vehicle Safety Standards) standards; compre-
hensive regulatory information is available at
Dealers mean entities authorized by MBUSA, MBCAN, www.nhtsa.gov.
and MBVANS to sell and/or service Sprinters.
Final-stage manufacturer means a person who per-
forms manufacturing operations on an incomplete
vehicle such that it becomes a completed vehicle.
Final-stage manufacturers are responsible for ensuring
the previously certified vehicle meets all emissions
and FMVSS/CMVSS (Federal/Canadian Motor Vehicle
Safety Standards) standards.

1 Introduction
1.9 Parts Use
⚠ WARNING
Mercedes-Benz AG strongly recommends that
upfitters use genuine Mercedes-Benz parts and
Mercedes-Benz replacement and conversion parts,
or replacement and conversion parts and acces-
sories expressly approved for the Sprinter by Mer-
cedes-Benz in order for upfitters to maintain regula-
tory compliance of these components or equipment
as well as the durable and safe operation of Sprint-
ers. In areas beyond regulatory compliance, upfitters
may elect to use other parts or conversion parts or
accessories and assume the manufacturers’ warranty
of these parts themselves.
In the case that these conversion parts cause damage

to the original Mercedes-Benz parts, the warranty of
the original Mercedes-Benz parts will become void. It is
the upfitters responsibility to ensure that non-approved
replacement conversion parts and accessories do not
render the vehicle unsafe.

2 General
2.1 Advice for Upfitters
2.1.1 Regulatory Overview Upfitters should consult with their legal counsel con-
cerning the final certification status of the vehicle.
The U.S and Canadian Governments have established
emission standards and motor vehicle safety standards Further, it is the upfitters’ responsibility to ensure that
for new engines and/or new vehicles and equipment such modifications do not affect the safety of the vehi-
under the provisions of the Clean Air Act, the Noise cle. Contact the Environment Protection Agency (U.S.
Control Act and the National Traffic and Motor Vehicle EPA) and the California Air Resources Board (CARB)
Safety Act in the U.S., and the Canadian Motor Vehicle concerning the applicable U.S. and California exhaust
Safety Act in Canada (“Acts”). The acts govern origi- emissions and noise standards, and the National High-
nal equipment manufacturers of the Mercedes-Benz way Traffic Safety Administration (NHTSA) concern-
Sprinter vans, dealers, upfitters and others engaged in ing the applicable U.S. vehicle safety standards. For
the manufacturing and marketing of new motor vehicles Canadian standards, contact Environment Canada and
and equipment. Transport Canada respectively.
Part 568 of the Title 49 Code of Federal regulations Upon completion of the modified vehicle, the u pfitter
(CFR) specifies detailed regulatory requirements for is required by law (Title 49 of the Code of Federal
vehicles manufactured in two or more stages, including Regulations S567.7 in the United States, the Clean Air
Final Stage Manufacturers. This document is intended Act section 203(a), and under provisions of, EPA CFR
to fulfill a part of Daimler AG’s obligations as the Part 86 section 86.09911; Emissions standards for
original equipment manufacturer or as an incomplete 1999 and later model year diesel heavy duty engines
vehicle manufacturer. Section 2.1.2 Emissions and and vehicles) to certify that it continues to comply with
safety information (→ page 15) identifies regulatory all applicable Federal and Canada Motor Vehicle Safety
requirements to assist Intermediate and Final Stage standards/Regulations. In addition, the modified vehi-
Manufacturers in determining their obligations to con- cle must continue to comply with all applicable Federal,
form to these standards. Canada and/or California Emissions regulations. In
the United States, sale of a non-complying new vehi-
Completed Sprinters “As Delivered” are certified to
cle is illegal and is punishable by a fine of up $25,000
comply with the aforementioned applicable standards.
(Federal) and $5,000 (California) per vehicle for emis-
Compliance labels affixed to Sprinters and engines
sions non-compliance, $1,000 per vehicle for safety
provide the status of initial compliance at the date of
non-compliance, plus a recall and other sanctions.
manufactured by Daimler AG (DAG).
Upfitters are responsible for certifying the altered
Upfitters and dealers who make any modifications that
vehicle pursuant to Title 49 of the Code of Federal
may affect the final certification of the engine, vehicle
Regulations S567.7 and S568.8 in the United States
or equipment assume the sole responsibility for the
or to Section 9 of the Canadian Motor Vehicle safety
vehicle.
Regulations in Canada.
Daimler AG and Upfitter Management Vans make no
representations with regard to conformity of the altered
vehicle to any other Federal or Canada Motor Vehicle
Safety Standards or Regulations that may be affected
by the vehicle alteration; it is the responsibility of the
upfitter to certify that the vehicle conforms to any other
standards affected by the vehicle alteration.

2 General
2.1.2 Emissions and safety information Provisions of the Clean Air Act also prohibit any per-
sons, including but not limited to, dealers or upfitters to
A complete Sprinter Van “As Delivered” or a Chassis
remove or render inoperative any devices or elements
Cab/Cutaway, i.e. an incomplete vehicle, delivered by
of design installed in a motor vehicle engine in compli-
MBUSA, MBCAN and MBVANS to dealers or upfitters is
ance with the regulations.
certified for by Mercedes-Benz AG for compliance with
the U.S. and Canadian emissions and safety standards
at the time of manufacture. If this vehicle is altered, 2.1.3 Vehicle safety standards information
after delivery by MBUSA, MBCAN and MBVANS, upfit- In the U.S. National Traffic and Motor Vehicle Safety
ters and/or dealers assume the regulatory responsibil- Act of 1966 and NHTSA’s FMVSS regulations and in
ity for certification. Canada, Motor Safety Act of 1993 and Transport Can-
This section provides general information concerning ada’s (TC) CMVSS, identify certain requirements and
applicable emissions and safety standards at the time certification responsibilities for the various stages of
of the vehicle manufacture. This section is written to vehicle manufacturing.
assist upfitters in understanding the U.S. EPA and the Therefore, upfitters and dealers need to review all regu-
CARB exhaust emission and noise standards, Federal latory requirements carefully to ensure compliance with
Motor Vehicle Safety Standards (FMVSS) and Canadian applicable standards.
Motor Vehicle Safety Standards (CMVSS). Upfitter Man-
Please consult with an attorney to ensure compliance
agement Vans neither approves nor recommends any
with applicable laws or standards.
modifications or additions to the Sprinter vehicle, which
may cause noncompliance with any EPA or FMVSS or All vehicles as manufactured by Mercedes-Benz AG
CMVSS standards, or render the vehicle unsafe. meet all safety and emissions standards as set forth
by the National Highway Traffic Safety Administration
Questions concerning the content of this Section can
(NHTSA) and the Environmental Protection Agency
be directed to MBUSA, MBCAN or MBVANS designee
(EPA). If any modifications or alterations are made to
through the Upfitter Portal:
the vehicle that takes the vehicle out of compliance
Contact via website with federal and local regulations, it is the responsibility
www.UpfitterPortal.com of the vehicle alterer, intermediate manufacturer, or
final stage manufacturer to ensure the vehicle meets all
Engine calibrations such as fuel output settings, injec-
emissions and FMVSS/CMVSS standards.
tion timings, emission control device calibration and
location, charge air and cooling system calibration and For manufacturers who are defined as alterers, please
locations are prohibited from any alterations from the visit www.nhtsa.gov for regulatory direction.
certified configurations. For intermediate or final stage manufacturers please
visit www.nhtsa.gov as well as reviewing the Incomplete
Vehicle Document (IVD) that is included in each incom-
plete vehicle as manufactured by Mercedes-Benz AG.
At no time the BEG should ever be used as a regula-
tory source for certification. Each alterer or modifier
is advised to have their own regulatory department or
consultant.

2 General
2.1.4 Exhaust emission control information 2.1.5 Vehicle noise emission control information
The Sprinter engines, Mercedes-Benz OM642, The Noise Control Act of 1972 and the 40 CFR Part
Mercedes-Benz OM651 and Mercedes-Benz M274 205 U.S. EPA regulations, “Transportation Noise Emis-
are certified with the U.S. EPA, and the Environment sion Controls”, require new medium and heavy trucks
Canada and CARB, to comply with the heavy-duty over 10,000lbs. GVWR to comply with an exterior
diesel engine exhaust emission standards under Title drive-by noise standard of 80 dB(A). In Canada, CMVSS
II, Section 206 of the Clean Air Act and 40 CFR Part 1106 Noise Emissions Standard requires an additional
86 regulations. Proof of this EPA certification is shown interior sound level certification at 90 dB(A).
by an exhaust emission control label, i.e., an “import- All Sprinter vehicles come equipped with extensive
ant Engine information” label, 3.6.7 Vehicle Emission NVH equipment.
Control Information Label (→ page 42), affixed to the
rocker cover of the engine for diesel powered vehicles Upfitter should, however, consult with an attorney con-
and VEC I label affixed to the front cross member for cerning interpretations of the applicable laws and reg-
gasoline power vehicles. ulations and determine if the modifications the upfitter
made to the Sprinter may affect the final certification of
Provisions of the EPA regulations require that the emis- compliance of the vehicle.
sion-related components functions in-use over the pre-
scribed full useful life period as certified, i.e., 5 years Furthermore, it is the upfitter’s responsibility to ensure
or 100,000 miles (short term emission control system) modifications do not render the vehicle unsafe.
and 7 years or 70,000 miles (long term emission con-
trol system), whichever occurs first. To be certain that
these components function properly, the end users are
required to use appropriate fuels and lubricants and
maintain these components properly in accordance
with the Operator’s Manual and Service Booklet.
Additionally, there is a requirement for applicable noise
control packages that were tested at over 100% reduc-
tion in noise levels below the aforementioned noise
standards. Final Stage Manufacturers should consult
with their attorney concerning the compliance of their
vehicles with appropriate regulations and laws once
they have been altered or modified. The law and regu-
lations prohibit tampering with noise control devices or
components.
Specifically, the removal or rendering inoperative of
any devices or elements of design incorporated into
any new vehicle for the purpose of noise control is not
permitted. Such devices or elements are identified as
noise emission related components, such as engine
calibrations including governor settings, exhaust sys-
tem components, air induction system components,
radiator, shield, fan/drive, noise shields or acoustical
absorptive material, etc.
The regulations also require maintenance of the noise
control performance in use, to comply with the U.S.
EPA 40 CFR Part 202, or DOT 49 CFR part 325, Exte-
rior Drive-By Noise Emission Standards for Interstate
Motor Carrier.

2 General
2.2 Upfitter responsibilities
Each completed Sprinter “As Delivered” in the U.S. Any alterations or installations by upfitters must comply
is certified for the U.S. EPA or CARB exhaust emissions with the following:
in accordance with 40 CFR Part 86, or Title 13 of CCR, • Do not alter or modify Sprinter components forward
and an exhaust emission control information label is of the rear cab wall for Cab Chassis or forward of
affixed thereto. While the complete Sprinter van “As the seating reference point for Sprinters, unless
delivered” is certified to comply with the applicable modifications are approved component installations
FMVSS safety regulations in accordance with 49 CFR (such as air conditioning, radio, etc.) which are man-
Section 567.4 and a complete vehicle certification ufactured, approved or endorsed by Mercedes-Benz
label is affixed thereto, the Chassis Cab is certified to AG, MBUSA, MBCAN, MBVANS, or their designee,
comply with the applicable FMVSS safety regulations Upfitter Management Vans.
in accordance with 49 CR Section 567.5 and 568.4
and an incomplete vehicle certification label is affixed • Do not alter the location or impair functional reliabil-
thereto. ity and or the clearance of all movable chassis com-
ponents, i.e., axles, springs, drive shafts, steering
In addition, every individual Sprinter Cab Chassis systems, braking systems, gearshift linkages, exhaust
contains an Incomplete Vehicle Documentation infor- systems, etc.
mation packet. Sprinter vehicles intended for Canada
are similarly certified and labeled in accordance with • Do not drill, alter, impair or damage the frame top
the Canadian regulations. and bottom flanges.
Once these Sprinter vehicles are altered or completed • Do not alter, damage, or relocate the Sprinter fuel
with the installation of additional equipment, system, seat belt assemblies and anchorages, brak-
upfitters assume the responsibility of final certifica- ing system and steering.
tion to all applicable emissions and safety regulations, • Do not impair the operational reliability, road wor-
including labeling and documentation, affected by their thiness and drivability of the Sprinter by body or
modifications. accessory equipment installation of modification.
Chapter 2.1 of these Guidelines provides upfitter with Upfitter is responsible for ensuring that modification
general information concerning modifications. Provi- or equipment installation does not affect the safety of
sions of 49 CFR Sections 567.5 through 567.7, and the Sprinter. MBUSA, MBCAN, MBVANS, and Upfitter
568.8 specifically set the regulatory responsibility for Management Vans are not responsible for any final
the upfitters to comply with the vehicle safety stan- certification or claims for damages related to product
dards. These provisions are available in full at www. liability of breach of warranty which result from any
nhtsa.gov. upfitters should consult with legal counsel component, assembly, or system being altered, or
concerning these responsibilities. which cause non-compliance with any of the emission
control standards of motor vehicle safety standards,
or which would otherwise cause the vehicle to be or
become defective or unsafe.

2 General
2.3 Product and vehicle information for upfit-

ters
As a upfitter, you are also able to obtain detailed infor- 2.3.2 Workshop Information System (WIS)
mation on our products and systems in addition to the
The Workshop Information System (WIS) is available
possibility of directly contacting the upfitter support
under the following website:
staff at 1.7 Contact (→ page 11).
https://www.startekinfo.com/home
2.3.1 Upfitter Portal https://xentry.daimler.com
Upfitters can purchase access to WIS also under this
General link.
The Upfitter Portal is the central communications plat- For example, WIS contains:
form between Mercedes-Benz and you, our partners
• Basic data (dimensions, tightening torques)
in the body manufacturing industry. The Upfitter Portal
provides information and access to body-related topics • Function descriptions
for all model series of Mercedes-Benz vans. The portal • Circuit diagrams
can be accessed at the following address:
• Repair instructions
www.UpfitterPortal.com/en-us/
• Maintenance sheets
Technical Information
In the Technical Information section of the portal, you
can find the relevant technical data sheets, 2D chassis
drawings, technical bulletins, and the Body and Equip
ment Guideline.
Design data
From the beginning of 2018, 3D standard data pack-
ages in STEP AP214 format will be available for eXpert-
Upfitters to download for the Sprinter BM 907 in the
Upfitter Portal.

2 General
2.3.3 XENTRY Kit

Xentry kit is a Mercedes-Benz diagnostic tool that
performs a complete vehicle diagnosis. Xentry kit can
analyze the electronic control units on the vehicle and
read or erase the fault codes on the control units.
For example, fault codes that arise while upftting the
vehicle can be detected and deleted using a Xentry
kit. Xentry kit can also be used to upload PSM/MPM
programs to the connected vehicle.
XENTRY kit is available for purchase to all eXpertUpfit-
ters and customers. For more information on obtaining
a Xentry kit, please visit the following website:
"http://www.startekinfo.com/home"
www.startekinfo.com/home
For any questions or issues on a Xentry kit hardware
or software, please reach out to Star Diagnosis Support
Desk by phone at 201-505-4630 or by email at
[email protected]. The help desk is open
Monday through Friday from 8 a.m. to 8 p.m. (EST).
For any further questions, please contact
[email protected]."

2 General
2.4 Product safety and product liability
2.4.1 Product safety 2.4.2 Product liability

Both vehicle manufacturers and upfitters must always The upfitter bears sole legal responsibility for the oper-
ensure that the products they manufacture are safe ational characteristics and road safety of the upfit work
when they are brought into circulation and do not pres- that he or she performs, and in particular for:
ent any danger to persons or property. Otherwise there • Testing and maintaining the operating and driving
may be consequences under civil, criminal or adminis- safety of the vehicle after the body/equipment is
trative law. Every manufacturer is always liable for the mounted (the body and/or equipment must not have
product they manufactured. a negative effect on the driving, braking or steering
The upfitter must guarantee compliance with standards characteristics of the vehicle)
relating to functional safety (preferably ISO 26262). • The effects of upfit work on the chassis
• Consequential damage arising from upfit work
• Consequential damage resulting from retrofitted
electrical and electronic systems
• Maintaining the functional reliability and unob-
structed movement of all moving parts of the chassis
(e.g. axles, springs, propeller shafts, steering, gear-
shift linkage, etc.) after the upfit work is complete;
even in the case of diagonal torsion of the vehicle
Work carried out or modifications on the chassis or
body must be entered in the maintenance booklet,
section "Confirmations of the upfitter".

2 General
2.4.3 Safety-relevant features The following customer-related influences must be

considered when evaluating safety relevance:
Components and systems are safety-relevant when
their fault or failure could result in an immediate danger • Extreme operating conditions
to the life and health of vehicle occupants and other of • Wear and tear
road users.
• Ambient conditions
Mercedes-Benz AG recommends that an assessment of
the safety relevance of the components or functions be Documentation
carried out for the following work:
If safety relevance is identified according to the ten
• Chassis modifications safety aspects, these aspects are to be appropriately
• Vehicle installations marked as safety-relevant in paper and data records
and the associated functions and features documented
• Interface between vehicle and body (mechanical
as well as the measures taken to avoid the dangers.
components, electrics/electronics, power take-offs,
hydraulic components, pneumatics)
2.4.4 Guarantee of traceability
A component or function must be classified as safe-
ty-relevant if one of the following ten safety functions in There is a possibility that body-related hazards may
particular is affected: only be detected after the vehicle is delivered, making
retroactive market measures necessary (customer
• Occupant protection in accidents information bulletins, warnings, recalls). To ensure that
• Avoiding momentary loss of road view these measures can be implemented as efficiently as
• Avoiding steering failure possible, it must be possible to trace the product after
delivery.
• Avoiding loss or partial failure of braking function
We strongly recommend that upfitters file the serial
• Avoiding failure of driving function number/identification number of their body together
• Avoiding uncontrolled drive with the vehicle identification number of the basic
• Avoiding sudden failure of drive force vehicle in their databases for this purpose and to allow
them to use the NHTSA or Transport Canada to deter
• Avoiding leakage of operating fluids/risk of fire mine the affected vehicle owners. On this note, the
• Avoiding loosening of cargo/trailers/parts/bodies/ storage of customer addresses is also recommended
semitrailers as is giving subsequent owners the possibility to regis
• Avoiding injury while driving and during alternative ter their details.
operation of the vehicle

2 General
2.5 Trademarks
2.5.1 Mercedes-Benz brand in interaction with 2.5.4 Trademark rights

external upfitters
The "Mercedes star", the "Mercedes badge" and the
In terms of the relationship between Mercedes-Benz "Mercedes-Benz" wordmark/logo are registered trade-
and upfitters, it is not just product safety and product marks of Mercedes-Benz AG.
liability which are of particularly high importance.
The usage of the brand is also very important.
The aim of these guidelines is to explain the brand-
related interests of Mercedes-Benz for Sprinter vehicles
to upfitters.
The individual provisions of the guidelines do not
release upfitters from their liability for aftermarket
modifications to Mercedes-Benz vehicles.
2.5.2 Function of a brand

Every company which wishes to operate a successful
brand must ensure that the characteristics of the brand
are consistently protected. This also applies to the
brands of Mercedes-Benz AG and Upfitter Management
Vans.
The brand indicates the origin of a product and allows
the product to be recognized and remembered. The
brand acts as a guarantee for the quality of a product,
embodying its characteristic values and identity.
2.5.3 Trademark protection

The trademark protection laws give Mercedes-Benz AG
and Upfitter Management Vans the exclusive right to
use its brands.
In particular, this applies to the use of Mercedes-Benz
trademarks on vehicles and vehicle parts/accessories
(e.g. rims) and in communication of the brand name.

2 General
2.5.5 Advice on applying Mercedes-Benz 2.5.7 Brand separation/identity

trademarks to vans
Principle
If you have any questions about applying Mercedes-
Benz trademarks to Mercedes-Benz vans, the Upfitter Mercedes-Benz model series have specific characte-
Management Vans will be pleased to assist you. Please ristics and values as well as a brand-specific design.
contact via Upfitter Portal: The modifications should be in the style of the
Mercedes-Benz design characteristics.
Separating the Mercedes-Benz trademarks from the
2.5.6 Use of Mercedes-Benz trademarks upfitter trademarks ensures that a distinction can be
made between the brands. This applies, in particular,
Principle to product origin and the resulting responsibilities.
Only Mercedes-Benz trademarks may be applied to Mercedes-Benz reserves the right to demand imme-
completely unchanged Mercedes-Benz vehicles. diate removal of the Mercedes-Benz trademarks if the
vehicle fails to comply with the requirements of Mer-
Modification of the Mercedes-Benz trademarks on
cedes-Benz.
vehicles of the Mercedes-Benz brand is not permitted.
The application of Mercedes-Benz trademarks to vehi- Trademarks on the front of the vehicle
cles and parts other than those of the Mercedes-Benz
brand is not permitted. Use of the Mercedes star
• On vehicles with genuine Mercedes-Benz cabs, the
Mercedes-Benz trademarks on vehicles with Mercedes star must be retained in the as-delivered
technical modifications state.
When vehicles are modified in accordance with the • On vehicles with a cab designed separately by the
Mercedes-Benz Body and Equipment Guidelines, the upfitter, the Mercedes star may be applied to the
Mercedes-Benz trademarks may remain unchanged on front-end assembly in the center in order to identify
the vehicle. the chassis. If the upfitter brand is also applied, it
Extensive vehicle modifications significantly change the must be applied at an appropriate distance from the
original condition of the vehicle e.g. through modifica- Mercedes star.
tions to the suspension, body structure, engine, brake
system and on-board electronics. These modifications Use of the Mercedes badge
are generally not covered by the Body and Equipment • The Mercedes badge signifies an original
Guidelines. This can result in deterioration of the overall Mercedes-Benz design. It may only be retained on
vehicle with associated risks which Mercedes-Benz is vehicles with a genuine Mercedes-Benz cab.
not liable for according to product liability and product • The use of the Mercedes badge is not permissible
safety legislation. on vehicles with a cab separately designed by the
For extensive vehicle modifications, an evaluation with upfitter.
the responsible department is necessary. As part of the
eXpertUpfitter program, please refer to www.Upfitter- Model series and vehicle model designation
Portal.com. at front of vehicle
If the vehicle does not meet the requirements of The Sprinter does not have any model series des-
Mercedes-Benz, Mercedes-Benz reserves the right to ignations at the front of the vehicle. Model series
demand removal of its trademarks. designations may not therefore be applied to vehicles
modified by upfitters.

2 General
Trademarks at the vehicle rear
Use of the Mercedes star

When the Mercedes star is applied to the rear of vehi-
cles whose appearance has been extensively changed
by a body or other modifications, Mercedes-Benz
reserves the right to demand immediate removal of
the Mercedes star. It is recommended that the upfitter
should discuss the matter with Upfitter Management
Vans before application.
Upfitter trademarks in combination

with Mercedes-Benz trademarks
Upfitters that attach their trademarks to their body
must ensure that they are located at a suitable distance
away from Mercedes-Benz trademarks or badges.
Use of Mercedes-Benz trademarks in

communication
• The use of Mercedes-Benz trademarks in communi-
cation instruments such as, e.g. brochures, flyers,
advertisements or pennants will be governed
in future by the style guide for the upfitters of
Mercedes-Benz AG.
• The upfitter must be clearly identifiable in all its
communication media and channels as the originator
of the communication.
• When displaying modified vehicles that comply with
the Mercedes-Benz guidelines and that bear our
trademarks, care should be taken to ensure that
any modification to the vehicle or the vehicle body
made by the upfitter is visible in the display. Only the
obvious accentuation of Mercedes-Benz trademarks
without any visible attachment, extension or conver-
sion is not permissible.
• The use of Mercedes-Benz trademarks in corporate
design, i.e. on letterhead paper, business cards, on
work clothes, etc. and in the showrooms, offices and
workshops is not permitted.

2 General
2.6 Accident prevention
The upfit and attached or installed equipment must

comply with all applicable laws and regulations, and
with health and safety and accident prevention regula-
tions, safety regulations and information sheets issued
by accident insurers.
The laws, standards, directives etc. for work safety
and accident prevention regulations when operating
vehicles, equipment and machines (general machinery
directives) are to be complied with to avoid any unsafe
operating conditions when using the vehicle, and all
necessary technical measures shall comply with the
latest state of the art technology.
National and local laws, directives and registration
regulations must be complied with.
The upfitter shall be responsible for compliance with
these laws and regulations.

2 General
2.7 Recycling
• Wherever possible, components should not be

ENVIRONMENTAL NOTE painted or coated; pigmented plastic parts are to be
used instead.
When planning bodies or equipment, the following
principles for environmentally compatible design and • Components in areas at risk from accidents must be
material selection is recommended to be taken into designed in such a way that they are damage-toler
account. ant, repairable and easy to replace.
• All plastic parts are to be marked in accordance
with the VDA Materials Leaflet 260 ("Components
Upfitters shall ensure that attachments and bodies (or
of motor vehicles; identification of materials"),
conversions) comply with current environmental legisla
e.g. "PP - GF30R".
tion and applicable regulations.
The installation documentation for the conversions
shall be kept by the vehicle owner and, if the vehicle is
to be scrapped, handed over to the dismantling com
pany concerned at the time of vehicle handover. This
is intended to ensure that even converted vehicles are
processed in an environmentally responsible manner.
Materials with risk potential such as halogen addi
tions, heavy metals, asbestos, CFC and CHC, are to be
avoided.
• It is preferable to use materials which permit recy
cling and closed material cycles.
• Materials and production processes that generate
only low quantities of easily recyclable waste during
production must be selected.
• Plastics are to be used only where they provide
advantages in terms of cost, function or weight.
• In the case of plastics, and composite materials in
particular, only compatible substances within one
material family are to be used.
• For components which are relevant to recycling, the
number of different types of plastics used must be
kept to a minimum.
• It must be assessed whether a component can be
made from recycled material or with recycled ele
ments.
• It must be ensured that components can be disman
tled easily for recycling, e.g. by snap connections,
predetermined breaking points, easy accessibility, or
by using standard tools.
• It must be ensured that service fluids can be
removed simply and in an environmentally responsi
ble manner by means of drain screws etc.

2 General
2.8 Quality system
World-wide competition, increased quality standards

demanded by the customer from the van as a whole,
national and international product liability laws, new
organizational forms and rising cost pressures make
efficient quality assurance systems a necessity in all
sectors of the automotive industry.
The requirements for a quality management system of
this kind are described in DIN EN ISO 9001.
For the reasons quoted above, Mercedes-Benz AG
urgently advises all upfitters to set up and maintain
a quality management system, based on the specifi-
cations in DIN EN ISO 9001, including the following
requirements among others:
• To define responsibilities and authorities including
organizational planning
• To describe processes and procedures as well as
their interactions
• To carry out contractual inspections and structural
rigidity checks
• Comprehensible development documentation
including risk assessment of process and product for
scopes relevant in terms of safety, compliance and
emissions (SCE).
• Comprehensible management of SCE scopes in
production, quality assurance and service
• Definition of product-related quality goals,
SCE-relevant scopes here with target value "Zero".
• To carry out product tests in accordance with the
specified procedure stated in the test instructions
• To regulate the handling of faulty products
• To document and archive test results
• To ensure that all employees have currently valid
proof of the qualification required
• To systematically monitor the test equipment
• To systematically identify materials and parts
• To carry out quality assurance measures at the
suppliers
• To ensure that the instructions for processes, work
and inspections are up-to-date and available in all
departments and at all workplaces

2 General
2.9 Key Pre-Upfit Considerations

• Aftermarket seats comply with FMVSS/CMVSS
207/210. (Reference: 7.3 Retrofitting additional
⑴ NOTE seats (→ page 190))
The following topics represent key pre-upfit consid- • Modifications to upper roof interior comply with
erations based on frequency of exposure during the FMVSS/CMVSS 201. (Reference: 7.4 Modifications
conversion process. As a result, these considerations to closed cargo vans (→ page 192))
are not comprehensive and shall be considered • When adding an auxiliary power take-off device
along with all other applicable requirements as stated (alternators, compressors), utilize N62/63 bracket
in the BEG. for a connection to the vehicle. (Reference: 6.5.3
Engine power take-off (→ page 154)) (Reference:
• Upfitted vehicle is compliant with the given limit of
6.2.9 Cargo Van/Passenger Van roof (→ page 118))
Unloaded Vehicle Weight (UVW). (Reference: 4.1.8
Weight limits (→ page 67)) • For Cargo Vans with Window Prep package, after-
market Emergency Window Exit is installed for Bus
• Upfitted vehicle is compliant with the given limit of
conversions (per FMVSS/CMVSS 217). (Reference:
max. Center of Gravity (CoG). (Reference: 4.1.2 Max-
7.18 Buses and People Mover (→ page 231))
imum permissible position of the center of gravity
(→ page 58)) • Aftermarket rear view camera meets FMVSS 111.
(Reference: 8.9.9 Reversing camera (→ page 290))
• Upfitted vehicle does not exceed/undercut the
required axle load. (Reference: 3.5 Dimensions • Front seats re-installed per BEG seat belt torques.
and weights (→ page 37), 4.1.1 Steerability (Reference: 4.5.2 Modifications to seats (→ page 77))
(→ page 58)) • It is strongly recommended that the upfitter does not
• The label information correctly reflects modification modify the seat cover in any way. It is the upfitter’s
to vehicle. (Reference: 3.6 Vehicle identification data responsibility to ensure that all applicable technical
(→ page 39)) and regulatory requirements are met. (Reference:
6.4.3 Seats (→ page 147))
• No heavy equipment is installed on the doors/
especially rear doors. (Reference: 6.2.6 Side wall, • EK1 (Upfitter Connector) is utilized, if connection to
windows, doors and flaps (→ page 111)) vehicle power is required. (Reference: 8.4.8 Power
tapping (→ page 243))
• Load attached to the roof does not exceed BEG
recommendation. (Reference: 6.6.3 Roof racks • Additional batteries to the starter and auxiliary
(→ page 158), 6.6.4 Shelf systems/vehicle interior battery connected with a charge limiter of 80A.
installations (→ page 158)) (Reference: 8.3.2 Retrofitting an auxiliary battery
(→ page 236))
• No equipment is installed in front of sensors/
radar which are located in the front and rear • If the discharged demand is above 25A, E2I / E2M
bumper. (Reference: 8.9 Driving assistance systems (auxilliary battery) and E36 (Cut-off Relay) are uti-
(→ page 271)) lized. (Reference: 8.3.1 Main battery (→ page 235))
• Painted bumpers are compliant with BEG recommen- • No connection to CAN Bus, ED5 (PSM – Parametric
dation in regards to not affecting the sensors/radar. Special Module) is utilized. (Reference: 8.10 Param-
(Reference: 5.4 Painting work/preservation work etrizable Special Module (PSM/MPM) 8.10.1 PSM
(→ page 88)) (MPM) Functions (→ page 297))
• No drilling through the top and bottom chord of the • Modifications to safety relevant lights comply with
longitudinal members. (Reference: 4.1.5 Drilling FMVSS/CMVSS108. (Reference: 8.5 Illumination
must not take place (→ page 63)) (→ page 254))
• No Mercedes-Benz lift points are blocked by upfit- • Modifications to the width of the vehicle, which
ted equipment (Reference: 4.1.6 Service lift points exceed 80 inches, comply with FMVSS/CMVSS108.
(-->page 62)) (Reference: 8.5.4 Marker lamps (→ page 256))
• Corrosion protection compliant with BEG. • The Mercedes-Benz logo is not used for upfit-
(Reference: 5.3 Anti-corrosion protection measures ted equipment. (Reference: 2.5 Trademarks
(→ page 86)) (→ page 22))

3 Planning of bodies
General
The relevant operating conditions of the subsequent
complete vehicle are crucial to the selection of a suit-
able basic vehicle or chassis when planning work on
the vehicle body. Observe the following points:
• Customized design of vehicle or chassis
• Body variant
• Standard and special equipment
For better orientation when planning, the identification
plate, the model designation and the vehicle identi-
fication number (VIN) must be used as well; see 3.6
Vehicle identification data (→ page 39).
For more information on the chassis and body
variants on offer, see 3.2 Model overview
(→ page 34) or under 1.7 Contact (→ page 11).
For the most up-to date model overview and
specifications please visit www.UpfitterPortal.com
(see section 1.7)
⑴ NOTE
It is important when planning bodies that along with
a user-friendly and maintenance-friendly design,
the materials are chosen carefully and, consequently,
the associated anti-corrosion protection measures
are observed (→ page 86).

3.1 Vehicle and model designation
ⓘ For information on the position of the identifica-

tion plates, see 3.6 Vehicle identification data
(→ page 39).
This Body and Equipment Guideline is valid for
the following vehicle model designations of the
Sprinter BM 907 (see tables on next pages).
The table "Base versions and model designations" on
the following pages provides model information on
the standard Sprinter variants. Note that the following
table only lists the base Sprinter variants and does not
include all available Sprinter variants.

Base versions and model designations
Model Label/GVWR Wheelbase Roof German Type Engine Model Mercedes-Benz

designation Model
Cargo 1500 144’’ WB Standard roof 3,88 t A2 LH1 Gas 907.643.13 M1CA4G
Vans (8,550 GVWR)
2500 144’’ WB Standard roof 4,1 t A2 LH1 Gas 907.643.13 M2CA4G
(9,050 GVWR) Standard roof 4,1 t A2 LH1 4 Cyl 907.643.13 M2CA44
Standard roof 4,1 t A2 LH1 6 Cyl 907.643.13 M2CA46
Standard roof 4,1 t A2 LH1 4x4 907.643.13 M2CA4X
170’’ WB High roof 4,1 t A3 LH2 Gas 907.645.13 M2CA7G
High roof 4,1 t A3 LH2 4 Cyl 907.645.13 M2CA74
High roof 4,1 t A3 LH2 4x4 907.645.13 M2CA7X
170’’ WB Ext. High roof 4,1 t A4 LH2 4 Cyl 907.647.13 M2CAE4
High roof 4,1 t A4 LH2 6 Cyl 907.647.13 M2CAE6
High roof 4,1 t A4 LH2 4x4 907.647.13 M2CAEX
3500 144’’ WB Standard roof 4,53 t A2 LH1 4 Cyl 907.653.13 M3CA44
(9,990 lbs for Standard roof 4,53 t A2 LH1 6 Cyl 907.653.13 M3CA46
U.S. and 170’’ WB High roof 4,53 t A3 LH2 4 Cyl 907.655.13 M3CA74
9,900 lbs for High roof 4,53 t A3 LH2 6 Cyl 907.655.13 M3CA76
Canada GVWR) 170’’ WB Ext. High roof 4,53 t A4 LH2 4 Cyl 907.657.13 M3CAE4
3500XD 144” WB Standard roof 5,0 t A2 LH1 4 Cyl 907.653.13 MXCA44
(11,030 GVWR) Standard roof 5,0 t A2 LH1 6 Cyl 907.653.13 MXCA46
Standard roof 5,0 t A2 LH1 4x4 907.653.13 MXCA4X
170’’ WB High roof 5,0 t A3 LH2 4 Cyl 907.655.13 MXCA74
High roof 5,0 t A3 LH2 6 Cyl 907.655.13 MXCA76
High roof 5,0 t A3 LH2 4x4 907.655.13 MXCA7X
170’’ WB Ext. High roof 5,0 t A4 LH2 4 Cyl 907.657.13 MXCAE4
High roof 5,0 t A4 LH2 6 Cyl 907.657.13 MXCAE6
High roof 5,0 t A4 LH2 4x4 907.657.13 MXCAEX
4500 144” WB Standard roof 5,5 t A2 LH1 4 Cyl 907.653.13 M4CA44
(12,125 GVWR) Standard roof 5,5 t A2 LH1 6 Cyl 907.653.13 M4CA46
170” WB High roof 5,5 t A3 LH2 4 Cyl 907.655.13 M4CA74
170” WB Ext. High roof 5,5 t A4 LH2 4 Cyl 907.657.13 M4CAE4

Model Label/GVWR Wheelbase Roof German Type Engine Model Mercedes-Benz

designation Model
Crew 2500 144” WB Standard roof 4,1 t A2 LH1 Gas 907.643.13 M2CV4G
Vans (9,050 GVWR) Standard roof 4,1 t A2 LH1 4 Cyl 907.643.13 M2CV44
Standard roof 4,1 t A2 LH1 6 Cyl 907.643.13 M2CV46
Standard roof 4,1 t A2 LH1 4x4 907.643.13 M2CV4X
170” WB High roof 4,1 t A3 LH2 Gas 907.645.13 M2CV7G
High roof 4,1 t A3 LH2 4 Cyl 907.645.13 M2CV74
High roof 4,1 t A3 LH2 4x4 907.645.13 M2CV7X
3500 144” WB Standard roof 4,53 t A2 LH1 4 Cyl 907.653.13 M3CV44
(9,990 GVWR) Standard roof 4,53 t A2 LH1 6 Cyl 907.653.13 M3CV46
170” WB High roof 4,53 t A3 LH2 4 Cyl 907.655.13 M3CV74
3500XD 144” WB Standard roof 5,0 t A2 LH1 4 Cyl 907.653.13 MXCV44
(11,030 GVWR) Standard roof 5,0 t A2 LH1 6 Cyl 907.653.13 MXCV46
Standard roof 5,0 t A2 LH1 4x4 907.653.13 MXCV4X
170” WB High roof 5,0 t A3 LH2 4 Cyl 907.655.13 MXCV74
High roof 5,0 t A3 LH2 6 Cyl 907.655.13 MXCV76
High roof 5,0 t A3 LH2 4x4 907.655.13 MXCV7X
4500 144” WB Standard roof 5,5 t A2 LH1 4 Cyl 907.653.13 M4CV44
(12,125 GVWR) Standard roof 5,5 t A2 LH1 6 Cyl 907.653.13 M4CV46
170” WB High roof 5,5 t A3 LH2 4 Cyl 907.655.13 M4CV74
Pas- 1500 144” WB High roof 3,88 t A2 LH1 Gas 907.743.13 M1PV4G
senger (8,550 GVWR)
Vans 2500 144” WB Standard roof 4,1 t A2 LH1 Gas 907.743.13 M2PV4G
(9,050/ 12 seater 11+1
9,480 GVWR) Standard roof 4,1 t A2 LH1 4 Cyl 907.743.13 M2PV44
11+1
Standard roof 4,1 t A2 LH1 6 Cyl 907.743.13 M2PV46
11+1
Standard roof 4,1 t A2 LH1 4x4 907.743.13 M2PV4X
11+1
170” WB High roof 4,3 t A3 LH2 4 Cyl 907.745.13 M2PV74
15 seater 14+1
High roof 4,3 t A3 LH2 6 Cyl 907.745.13 M2PV76
14+1
Cab 3500XD 144” WB n/a 5,0 t A2 4 Cyl 907.153.1 MXCC44
Chassis (11,030 GVWR) n/a 5,0 t A2 6 Cyl 907.153.1 MXCC46
170” WB n/a 5,0 t A3 4 Cyl 907.155.1 MXCC74
n/a 5,0 t A3 6 Cyl 907.155.1 MXCC76
4500 144” WB n/a 5,5 t A2 4 Cyl 907.153.1 M4CC44
(12,125 GVWR) n/a 5,5 t A2 6 Cyl 907.153.1 M4CC46
170” WB n/a 5,5 t A3 4 Cyl 907.155.1 M4CC74
n/a 5,5 t A3 6 Cyl 907.155.1 M4CC76

Legend of Mercedes-Benz
Digit 1 Digit 2 Digits 3 and 4 Digit 5 Digit 6

Brand GVWR Body Style Wheelbase Engine
M (Mercedes-Benz) 1 (1500) CA (Cargo) 4 (144”) 4 (4-Cyl DSL)
2 (2500) CV (Crew Van) 7 (170”) 6 (6-Cyl DSL)
3 (3500) PV (Passenger) E (170 EXT”) X (4x4 DSL)
X (3500XD) CC (Cab Chassis) G (Gas)
4 (4500)
Engine variants
Code Engine Gas/Diesel Details Max. power

MM3 4 cyl. M274 Gas 350 Nm at 2500-3500 rpm 188 hp
9G-TRONIC -SULEV- 140 kW
MG5 6 cyl. OM642 Diesel 440 Nm at 1400 -2400 rpm 188 hp
7G-TRONIC PLUS - SULEV/ 140 kW
ULEV-
MG3 4 cyl. OM651 Diesel 360 Nm at 1400-2400 rpm 161 hp
7G-TRONIC PLUS -SULEV- 120 kW
MU5 4 cyl. OM654 Diesel 400 Nm (295 lb-ft) at 1300- 168 hp
2400 rpm 9G-TRONIC-SULEV- 125 kW
M5N 4 cyl. OM654 Diesel 450 Nm (332 lb-ft) at 1400- 208 hp
2400 rpm 9G-TRONIC-SULEV- 155 kW
Special codes and body designs (selection)
Code Version
D03 High roof
Technical advice on body compatibility and on the basis

vehicle (→ page 11)

3.2 Model overview
1500 2500 3500 3500XD 4500

GVWR 8,550 lbs GVWR 9,050 lbs GVWR 9,990 lbs GVWR 11,030 lbs GVWR 12,125 lbs
Single Tires Single Tires Super Single and Super Single and Dual Rear Wheel
DRW DRW
Cargo Van 144” SR 144” SR 144” SR 144” SR 144” SR
HR HR HR HR HR
170” HR 170” HR 170” HR 170” HR
170” EXT HR 170”EXT HR 170”EXT HR 170”EXT HR
Crew Van 144” SR 144” SR 144” SR 144” SR
HR HR HR HR
170” HR 170” HR 170” HR 170” HR
Passenger Van 144” SR 144” SR
(12 Seater) HR (12 Seater) HR
170” HR
(15 Seater)*
Cab Chassis 144” 144”
170” 170”
* 170" Passenger van (15 Seater) GVWR 9,480 lbs
ⓘ Detailed drawings with dimensions are available

on the Upfitter Portal under 'Technical Information'
in '2D Drawings' page.

3.3 Selecting the basic vehicle
In order to ensure safe operation of the vehicle, it is ⓘ On the Mercedes-Benz homepages, you can
essential to choose the basic vehicle carefully in accor- assemble your vehicle in the Configurator and view
dance with the intended use. the available items of special equipment:
Planning should therefore consider the following items www.mbvans.com
in particular: www.mercedes-benz-vans.ca
• Wheelbase
• Engine/transmission
• Final drive ratio
• Permissible gross mass
• Position of the center of gravity
and adapt them for the intended use.
⑴ NOTE
Before carrying out any work on the body or mod-
ification work, the delivered basic vehicle must be
submitted to a check to verify whether it fulfills the
necessary requirements.
For more information on the chassis and body variants

on offer, see 3.2 Model overview (→ page 34) or
subchapter 1.7 Contact (→ page 11). Further infor-
mation are available in the Upfitter Portal:

3.4 Vehicle Modifications
Before starting vehicle modifications, the upfitter must

check whether ⑴ NOTE
• the base vehicle is suitable for the planned body, On no account should modifications be made to the
• the chassis model and equipment are suitable for the noise encapsulation.
operating conditions intended for the body.
The upfitter can request for 2D chassis drawings,
Vehicle approval
product information, and technical data from the
Upfitter Portal (→ page 18). The upfitter must inform the officially recognized
approval authority or inspector of any modifications to
Furthermore, you should note the special equipment
the chassis.
that is available from the factory (→ page 55).
The vehicles must comply with local and national ⑴ NOTE
regulations after modifications have been carried out.
Federal and local laws, directives and registration
regulations must be complied with!
⑴ NOTE
Adequate clearances must be maintained in order to
ensure the function and operational safety of major
assemblies.
⚠ WARNING
Any modifications to the steering and the brake sys-
tem may result in these systems malfunctioning and
ultimately failing. This could cause the driver to lose
control of the vehicle. There is a risk of accident!
Do not carry out any modifications to the steering or
brake system!

3.5 Dimensions and weights
On no account should modifications be made to the Vehicle dimensions and weights may also be
vehicle width, vehicle height or vehicle length if they obtained from Mercedes-Benz Service Partners
exceed the limit values specified in the current version or directly from the Workshop Information System
of the Body and Equipment Guideline. (WIS) documents about wheel alignment. Informa-
Dimensions and weights are located in the 2D chas- tion on the Mercedes-Benz WIS can be found under
sis drawings and technical data in the Upfitter Portal Chapter 2.3.2 Workshop Information System (WIS)
1.7 Contact (→ page 11) and in the Technical Limit (→ page 18).
Values. They are based on a vehicle that is fitted with The information on the vehicle curb weight and
standard equipment. Items of special equipment are corresponding axle loads before and after upfit
not taken into consideration. Weight tolerances of up to work, "Checking wheel alignment" in Chap-
+5 % in production must be taken into consideration. ter 3.11.3 Work before handing over the modified
The permissible axle loads and the maximum permis- vehicle (→ page 53), Chapter 3.12 Special equip-
sible gross mass must not be exceeded. Information ment (→ page 55), Chapter 4.2.9 Wheel alignment
on the axle loads and the maximum permissible gross (→ page 71) and Chapter 6.1.1 General information
mass is available on Chapter 4 Technical limit values for on the suspension (→ page 92) must be imple-
planning. Information about weight limits can be found mented.
here (→ page 67).
⚠ WARNING
Before beginning any upfit work, the actual vehi-
cle upfitted curb weight and the corresponding The vehicle tire load capacity must not be exceeded
axle loads must be determined and documented by overloading the vehicle beyond its specified gross
by weighing (see notes on weighing under Chap- vehicle weight. The tires could otherwise overheat
ter 9.1.1 Determination of the center of gravity in and suffer damage. This could cause the driver to
the x-direction (→ page 309)), or by means of the
vehicle identification number with the aid of the lose control of the vehicle. There is a risk of accident,
curb weight of your vehicle ex factory and its load personal injuries and death if such systems no longer
distribution from your Mercedes-Benz partner. function correctly!
On completion of all the upfit work, the mea- The braking distance may increase considerably
surement of the actual vehicle curb weight by when the vehicle is overloaded.
weighing must be repeated (Chapter 9.1.1 Deter-
mination of the center of gravity in the x-direction
(→ page 309)). The corresponding axle loads are Refer to 3.6 Vehicle identification data (→ page 39)
likewise to be determined by weighing. The three for further information about the vehicle weights.
variables of vehicle curb weight in the completed
state, the front axle load and rear axle load in the
completed state, must be documented again.
In the case of a permanent axle load increase
of 250 kg/551 lbs or more at the front axle on
completion of all upfit work compared to the actual
base model vehicle delivered to the upfitter (curb
weight in standard configuration), the suspension
must be measured and the correct toe and camber
values must be set at the front axle.

⚠ WARNING
If the permissible axle loads are exceeded, the
ESP® system may not function correctly on vehicles
equipped with this feature. This could cause the
driver to lose control of the vehicle. There is a risk of
accident, personal injuries and death if such systems
no longer function correctly!
Make sure that you do not exceed the permissible
axle loads.
⚠ WARNING
Do not exceed the unloaded vehicle weight rating
(UVW), the gross axle weight rating (GAWR) and the
gross vehicle weight rating (GVWR). Information
about GAWR and GVWR is contained in the “Techni-
cal limiting values” section 4 Technical limit values for
planning (→ page 58).
⑴ NOTE
All bodies must comply with the individual axle loads
and the permissible gross mass
Following vehicle modifications which can result in
the longitudinal and lateral inclination (e.g. installa-
tion of heavy equipment), the sensor cluster must be
re-calibrated in order to ensure the ESP® is function-
ing properly.
Mercedes-Benz AG recommends that you have this

work performed at a qualified specialist workshop.
Further information on the operating principle of the
ESP® is available in Chapter 8.9.1 Electronic Stability
Program (ESP®) (→ page 272).
The permitted number of vehicle occupants and a
sufficient margin for the payload must also be taken
into account. Take the weight of special equipment into
consideration when making calculations. Local and
national regulations and guidelines must be observed.

3.6 Vehicle identification data
The following Mercedes-Benz compliance labels are 3.6.1 VIN plate

affixed at the locations noted below.
The vehicle identification number (VIN) and the vehicle
⚠ WARNING identification plate may neither be changed nor fitted to
a different point on the vehicle.
Do not remove any of these labels!
The vehicle identification number is embossed in the
The depicted labels below are not intended to be belt rail in the engine compartment.
used as a source for certification, but as a pictorial
For certain countries, the externally visible vehicle
description and visual location indicator. These may
identification number is attached as a plate to the lower
not be the most updated pictures. For vehicle label-
end of the windshield.
ing requirements please visit the national highway
traffic safety administration online at www.nhtsa.gov The identification plate bearing the vehicle identifica-
and the environmental protection agency online at tion number and details of the permissible weights is
www.epa.gov. located at the side on the base of the driver's seat.
⑴ NOTE
On the following sections, data shown on the labels
are for illustration purposes only.
Position of vehicle identification data
ⓘ The VIN decoder for the Sprinter is available on the

Upfitter Portal www.UpfitterPortal.com

3.6.2 QR code rescue sticker Rescue crews can thus immediately see where airbags,
battery, fuel tanks, high-voltage lines (above 30 V AC,
above 60 V DC), pressure cylinders and other compo-
nents critical for the rescue are located, enabling them
for example to use rescue shears with low risk.
If parts such as airbags, batteries, fuel tanks, high-volt

age lines (above 30 V AC, above 60 V DC), pressure
cylinders and other rescue-relevant components are
removed, modified or added, the ex-factory rescue stick-
ers will be rendered unusable. In this case, the upfitter
must produce a new rescue card to ISO17840-1 to 4 for
the vehicle which illustrates this information. The rescue
cards can be made available either online or via a QR
code, or can be provided in the vehicle in printed form
(preferably behind the driver's sun visor).
If the QR code is destroyed in the course of your upfit
N00.01-2720-00
work, but the rescue-relevant components remain
Attachment (example) of QR code rescue sticker on left B- unchanged, you must obtain a replacement via your
pillar (driver’s side) Mercedes-Benz Service Partner and affix it to the
B-pillars. Alternatively, the same partner can provide
All vehicles are supplied with a QR code rescue sticker
you with a printed version of the vehicle's rescue card.
from production. The rescue stickers in the Sprinter are
affixed to the left and right B-pillars.
ⓘ Further information on the rescue sticker
When the QR code on the sticker is scanned using a in Mercedes-Benz vehicles is available from:
smartphone or tablet and there is an existing internet http://rk.mb-qr.com/en/
connection, the rescue card for the vehicle is displayed.
ⓘ Rescue cards for the individual model series can be
downloaded from:
http://rk.mb-qr.com/en/#rescue-card-selector

3.6.3 Safety Label location 3.6.5 Complete Vehicle Identification Label
Vehicle identification plate, USA

Location: on driver’s seat base, outward facing
1 Vehicle manufacturer
N00.01-2813-00
2 VIN (vehicle identification number)
1 Noise Emission Label 3 Permissible gross mass
2 Safety Certification Label 4 Permissible gross mass of vehicle combination
Location: below driver’s seat, outward facing 5 Permissible front axle load
6 Permissible rear axle load
7 Date of manufacture
3.6.4 Noise Emission Label 8 Paint code
Location: below driver’s seat, outward facing
Vehicle identification plate, Canada

3 Permissible gross mass
4 Permissible gross mass of vehicle combination
5 Permissible front axle load
8 Paint code

3.6.6 Incomplete Vehicle Identification Label 3.6.7 Vehicle Emission Control Information Label
Vehicle identification plate, USA

8 Paint code
Vehicle identification plate, Canada

8 Paint code

3.6.8 Airbag Warning Label 3.6.10 Unloaded Vehicle Weight UVW rating and
Label
N00.01-2819-00
Example UVW Label

Location: on sun visor
Location: engine compartment above grill
The UVW definition is found under FMVSS guidelines

in 49 CFR 571.3 and 40 CFR 86.1803-01. This is the
curb weight of the base Sprinter vehicle + a maximum
upfit weight on the vehicle (including maximum capac-
ity of all fluids necessary for operation of the vehicle
but without cargo, passengers or accessories that are
usually removed from the vehicle when not in use).
GVWR (Gross Vehicle Weight Rating) is a theoretical
maximum weight that can handle the base vehicle weight
and upfit weight as well as the weights of the cargo/lug-
gage and passengers.
Location: on sun visor
Do not exceed the maximum permissible gross vehicle
weight or the maximum gross axle weight rating for the
3.6.9 Tire and Loading Information Label front or rear axle.
N00.01-2818-00
Location: on driver’s door frame
⚠ WARNING
For an alterer, there is a re-labeling required
if any of the equipment installed changes
• payload limit data
• seating data
of the vehicle!
Additional Tire and Loading Information:

4.2 Limit values for the suspension (→ page 68).

3.7 Vehicle stability
Refer to Chapter 4 Technical limit values for planning

⚠ WARNING
(→ page 58) for the permissible center of gravity
heights. If the permissible axle loads are exceeded, the ESP®
Mercedes-Benz AG will make no statements concerning system may not function correctly on vehicles which
are equipped with this feature. This could cause the
• driving characteristics driver to lose control of the vehicle. There is a risk of
• braking characteristics accident, personal injuries and death if such systems
• steering characteristics no longer function correctly!
• ESP® control response Make sure that you do not exceed the permissible
axle loads.
This applies to bodies intended for operation with loads
with unfavorable centers of gravity (e.g. loads at the Following vehicle modifications which can result in
rear end, high loads and side loads), as these aspects changes to the longitudinal and lateral inclination
are primarily influenced by the upfit work and can (e.g. the installation of heavy parts), the sensor clus-
therefore be assessed exclusively by the upfitter. ter must be recalibrated in order to ensure that the
ESP® is functioning correctly.
⚠ WARNING
If an attachment to the body, mounted equipment or This work should be performed at your nearest
modifications cause an extreme displacement of the Mercedes-Benz authorized dealer.
center of gravity on a vehicle equipped with ESP®, Further information on the operating principle of the
it may be necessary to deactivate ESP® if this is ESP® is available in Chapter 8.9.1 Electronic Stability
possible while still observing and complying with all Program (ESP®) (→ page 272).
national registration requirements. Additional information on permissible weights is
If ESP®has been deactivated, the driver will then available in the identification data on the vehicle
have to adapt his/her style of driving accordingly (→ page 39).
(reducing cornering speed, avoiding sudden steer-
ing wheel movements, etc.). When driving dynamics
become critical, the vehicle behaves like a vehicle
without ESP®. The permissible axle loads, gross
vehicle masses and center of gravity locations must
be complied with.
For more information, reach out on the Upfitter Portal.

See Chapter 1.7 Contact 1.7 Contact (→ page 11).
The permissible wheel and axle loads and the permissi-
ble gross masses must not be exceeded in all situations
including after upfit and/or equipment installation.

3.8 Tires
The upfitter must ensure that: displayed in the instrument cluster and is important for
• There is always a sufficient space between the tire controlling the driving assistance systems. The display
and the fender or wheel arch, even when snow accuracy of the speedometer and the odometer is gov-
or anti-skid chains are fitted and the suspension erned by law. The determination of the speed informa-
is fully compressed (also allowing for axle twist) tion depends on the tire size and the rolling circumfer-
(→ page 114) and that the relevant data in the 2D ence of the wheels and thus on their rim diameter. The
chassis drawings are observed rim diameter is always given in inches.
• Only tire sizes approved by Mercedes-Benz are used Therefore, the control units of the vehicle can be coded
(see “Permissible wheel and tire combinations for for the following three wheel size groups:
BM 907 (RWD)”) (→ page 70)
Wheel size group Tires BR 907
In particular, comply with local and national regulations Wheel size group 1: 195/75 R16C
concerning the approval of tires. These regulations 205/75 R16C
may define a specific type of tire for the vehicle or may 235/65 R16C
restrict the use of certain tire types which are approved 235/60 R17C
in other countries. Wheel size group 2: 225/75 R16C
Wheel size group 3: 225/75 R16C FA
⚠ WARNING
285/65 R16C RA
Exceeding the specified tire load capacity or the per-
missible tire maximum speed can lead to tire damage ⓘ It is recommended to stay within one wheel size
or tire failure. This could cause you to lose control group when changing tires. This avoids the need to
of the vehicle and cause an accident with possible recode control units.
injury to yourself and others.
Therefore, only use Mercedes-Benz approved tires for • When changing the tires and if the wheel size group
your vehicle model and observe the tire load capacity changes for the new tires, please recode the control
required for your vehicle and the tire speed rating. units of the vehicle at a local dealership.
If you have other wheels (not approved by • If the control units are not recoded, then the accu-
Mercedes-Benz) fitted: racy of the speedometer and the odometer will be
outside the legal restrictions. The speedometer and
• The brakes or components of the suspension sys-
the odometer can deviate downwards, e.g. the cur-
tem could be damaged
rent vehicle speed is higher than the speed indicated
• Wheel and tire clearance can no longer be by the speedometer.
guaranteed
• Driving assistance systems may be impaired in their
• The wheel brakes or components of the suspension functionality in the event of a deviation outside the
system may no longer function correctly. tolerance range or may detect a fault and shut down.
ⓘ For more information, please contact the Upfitter

Portal (→ page 18) and chapter 4.2.3 Approved
tire sizes (→ page 70).
⑴ NOTE
If different tires (not certified by Mercedes-Benz) are
used on the vehicle, the vehicle driving assistance
systems may have impaired functionality.
For further information, please refer to chapter 8.9
Driving assistance systems (→ page 271).
The determined speed information of the vehicle is

3.9 Bolted and welded connections
3.9.1 Threaded connections • Using Mercedes-Benz tightening torques requires the

corresponding part that has to be screwed to have a
For the threaded connections between the body and
total friction factor in the range µtot = 0.08-0.14.
the basic vehicle or the vehicle frame, Mercedes-Benz
recommend the use of flange bolts and flanged nuts. • If bolts are tightened to the required torque and
tightening angle by Mercedes-Benz, a constructive
If it is necessary to replace standard bolts/nuts, only
modification is not possible.
bolts/nuts
• The Mercedes-Benz Workshop Information System
• of the same diameter
(WIS) must be used to determine whether bolts and
• of the same strength grade nuts of suspension components must only be tight-
• of the same bolt standard or type ened when the vehicle is in ready-to-drive condition.
• of the same surface coating (anti-corrosion protec- • Additionally clamped components of the body must
tion, coefficient of friction) exhibit an identical or higher strength than the previ-
ous clamped assembly.
• with the same thread pitch
may be used. ⓘ Information is available from any Mercedes-Benz
We recommend the use of standard Mercedes-Benz Service Center.
parts.
⚠ WARNING
⚠ WARNING
Bolts or nuts with locking splines, microencapsulated
Do not modify any bolted connections that are rele- bolts and self-locking nuts must always be replaced
vant to safety, e.g. that are required for wheel control, after a single use. Before new microencapsulated
steering or braking functions. They may otherwise bolts are screwed in, the mating thread must be recut
no longer function correctly. This could cause the or the nuts replaced to remove all residual screw
driver to lose control of the vehicle. There is a risk of locking compound. Finally, the recut through-tapped
accident! or blind-tapped holes must be blown out with air
Parts must be refitted in accordance with because any adhesive residue in the thread would
Mercedes-Benz service instructions and using suit- prevent correct tightening of the bolts.
able standard parts. We recommend Mercedes-Benz If these instructions are not observed, bending forces
GenuineParts. could act on the bolt due to the lack of pretension
and cause the bolt to break. The driver could lose
• VDI (The association of German Engineers) guideline control of the vehicle and cause an accident.
2862 must be applied to all installation work.
• It is prohibited to shorten the free clamping length,
change to a stretch shank or use bolts with a shorter
free thread.
• When re-tightening threaded connections on the
vehicle, check that a tightening torque specified by
Mercedes-Benz is documented and this must be
complied with by the upfitter. Further information
can be found on WIS or obtained from your nearest
Mercedes-Benz dealer.
• The settling properties of threaded connections must
be taken into account.

Choice of welding method

⚠ WARNING
The mechanical properties of weld seams depend on
There is an increased risk of injury when loosening selection of the welding method and on the geometry
microencapsulated bolts due to the breakaway torque of the elements to be joined.
associated with these bolts. For this reason, ensure
If overlapping sheets are to be welded, the choice of
you have sufficient freedom of movement when loos-
welding procedure will depend on whether only one or
ening microencapsulated bolts.
both sides of the workpiece is/are accessible:
Accessible sides 1 Gas-shielded plug

ⓘ For special screw connections, refer to the Mer-
welding
cedes-Benz Workshop Information System (WIS) or
2 Resistance spot
to 1.7 Contact (→ page 11).
welding
3.9.2 Welded connections

Resistance spot welding
General Resistance spot welding is used for welding overlap-
In order to maintain the high standard of welding ping parts which are accessible from both sides. Spot
demanded by Mercedes-Benz, the work must only be welding of more than two sheet layers must be avoided.
carried out by appropriately qualified welders.
Distance between spot welds
For high-quality weld seams, we recommend that you:
To avoid shunt effects, the specified distances between
• clean the area to be welded thoroughly the spot welds must be maintained (d = 10e + 10 mm)
• make several short welding beads rather than one or (d = 10e + 0.39 in).
long bead
• make symmetrical beads to limit shrinkage
• avoid more than 3 welds at any one point
• avoid welding in strain-hardened zones
⑴ NOTE
The battery must be disconnected before any welding
work is carried out and airbags, the airbag control
unit and seat belts must be protected from welding
splashes or removed if necessary.
Ratio of sheet thickness to distance between spot welds
d Distance between spot welds

e Sheet thickness

Distance from sheet edge Gas-shielded plug welding

To avoid melting core damage, the specified distances If overlapping sheets are only accessible from one side,
to the sheet edge must be maintained (L = 3e +2 mm) use either gas-shielded plug welding or tack welding for
or (L = 3e + 0.08 in). the weld joint.
If the joint is produced by stamping or drilling followed
by plug welding, the drilled area must be deburred
before welding.
Ratio of sheet thickness to distance from the edge
e Sheet thickness
L Distance from sheet edge
Ratio of sheet thickness to plug hole diameter
D = Plug hole diameter e = Sheet thickness

4.5 mm/0.18 in 0.6 mm/0.02 in
5.0 mm/0.2 in 0.7 mm/0.03 in
5.5 mm/0.22 in 1.0 mm/0.04 in
6.0 mm/0.24 in 1.25 mm/0.05 in
6.5 mm/0.26 in 1.5 mm/0.06 in
7.0 mm/0.28 in 2.0 mm/0.08 in

Mechanical quality can be additionally improved by the Do not perform welding work on
use of "elongated holes" (l = 2b). • assemblies such as the engine, transmission, axles,
etc.
• chassis frames except on longitudinal frame mem-
bers for wheelbase modifications or overhang modi-
fications.
ⓘ For additional information, see Chapters 4 Techni-

cal limit values for planning (→ page 58) and 5
Damage prevention (→ page 83) as well as the
section 6.2.1 General information on the body in
white/body (→ page 101) and the Mercedes-Benz
Workshop Information System (WIS).
Ratio of width to length of elongated holes
Anti-corrosion protection after welding
b Width of elongated hole On completion of all welding work on the vehicle, you
I Length of elongated hole must comply with the specified anti-corrosion protec-
tion measures (→ page 86).
Tack welding
⑴ NOTE
In case of sheet thicknesses > 2 mm/0.08 in, over-
lapping sheets may also be joined by tack welding When carrying out welding work, observe the instruc-
(30 mm/1.18 in < L < 40e; d > 2L). tions specified by Mercedes-Benz AG under 5.2
Welding work (→ page 85) and "Modifications to
the basic vehicle" (→ page 101).
Dimensions for tack welds
d Distance between tack weld centers

e Sheet thickness
L Length of tack weld

3.10 Soundproofing
If modifications are carried out on any parts whose

operation produces noise, e.g.:
• Engine
• Exhaust system
• Air intake system
• Tires, etc.
sound level measurements must be taken.
Federal and local regulations and guidelines must be
observed.
Noise-insulating parts fitted as standard must not be
removed or modified.
The level of interior noise must not be adversely
affected.
⑴ NOTE
To ensure that modifications do not change the
vehicle's sound levels, the interior sound levels must
be minimized when planning bodies 6.4.4 Reducing
interior noise (→ page 148).

3.11 Maintenance and repairs

In model designation 907 RWD (rear wheel drive), two
Maintenance and repair of the vehicle should not be auxiliary batteries for retrofitted consumers are avail-
made unnecessarily difficult by the body. The opera- able:
tor's manual must be observed.
• E2I: Auxiliary battery for retrofit consumers,
• Maintenance points and major assemblies must be interior (92 Ah AGM)
easily accessible (→ page 65).
• E2M: Auxiliary battery for retrofit consumers,
• Stowage boxes must be fitted with maintenance flaps engine compartment (70 Ah AGM)
or removable rear panels.
• For maintenance and servicing purposes, accessi-
bility to the attachment points of series production
parts on the basic vehicle shall be ensured. This also
affects parts on the door mechanism (e.g. hinges on
hinged doors, guide rails/carriages of load compart
ment sliding door etc.).
ⓘ Any additional work that arises due to the body in

terms of warranty-related work, maintenance or
repair work will be assessed in each instance by
Mercedes-Benz AG and may not accept liability.
Should you have any queries, please get in touch N82.00-3421-00
with your contact person at Mercedes-Benz Service. E2I: Auxiliary battery in front passenger seat base
• The battery box must be sufficiently ventilated, with
provision for air to enter and exit.
• Check the condition and capacity of batteries and
service them in accordance with the manufacturer's
specifications (→ page 53).
⑴ NOTE
Leaving the vehicle non-operational for long periods
of time can lead to battery damage. This can be
avoided by disconnecting the battery and storing
it in an appropriate manner (→ page 53) or by
activating hibernation mode (power-saving function)
(→ page 253).
E2M: Auxiliary battery in engine compartment

1 Auxiliary battery
1 Arrow Direction of travel
If the vehicle is to be started using an external power

supply, then either the jump-start connection point or
the main battery must be used.
⑴ NOTE
N54.10-2563-00 The auxiliary battery (E2I, E2M) must not be used for
Schematic installation position of the main battery connection to an external power supply as this could
result in damage to the vehicle (→ page 235).
1 Main battery

Any additional work which arises due to the body in Storing the vehicle outside (< 1 month)
terms of warranty-related work, maintenance or repair Carry out the same procedure as for storing in an
work will not be paid for by Mercedes-Benz. enclosed space.
The following must be observed by the upfitter before Close all air inlets and set the heating system to
delivery of the vehicle: "Off".
Check the headlamp adjustment or have this Chapter 3.11.2 Battery maintenance and storage
checked at a qualified specialist workshop. We (→ page 53) must be observed.
recommend a Mercedes-Benz Service Center.
Retighten the wheel nuts/wheel bolts to the speci- Storing the vehicle outside(> 1 month)
fied tightening torque. Carry out the same procedure as for storing in an
enclosed space.
Mercedes-Benz recommends adapting the scopes
of maintenance work on the body to each individual Fold the windshield wipers away from the wind-
shield.
vehicle using the relevant Mercedes-Benz maintenance
systems. This applies to both the scope and type of Close all air inlets and set the heating system to
"Off".
service work, and for determining the service due
dates for servicing intervals based on time elapsed or Chapter 3.11.2 Battery maintenance and storage
distance covered. (→ page 53) must be observed.
The upfitter must provide the vehicle with operator's Maintenance work on the stored vehicle (in storage
manual and maintenance instructions for the body and for > 1 month)
any additional assemblies installed. These instructions Check the oil level once a month.
must be in the language of the country in which the
Check the coolant once a month.
vehicle is to be used.
Check the tire pressures once a month.
3.11.1 Storing the vehicle
Removing the vehicle from storage
Storing the vehicle Check the fluid levels in the vehicle.
Clean the entire vehicle. Observance of manufacturer-specific information
on operating fluids (e.g. maximum durability
Check the oil and coolant levels. useful life, seasonal use etc.) and, where applicable
Inflate the tires to 0.5 bar above the specified tire replacement of respective operating fluids.
pressures. Adjust the tire pressures to the manufacturer’s
Release the parking brake and chock the wheels. specifications.
Chapter 3.11.2 Battery maintenance and storage Check the battery charge and install the battery.
(→ page 53) must be observed. Clean the entire vehicle.

3.11.2 Battery maintenance and storage 3.11.3 Work before handing over the modified
vehicle
For long non-operational times or storage, ensure that
the battery is always in a charged state (more than 80% The upfitter must confirm the work and modifications
which corresponds to an open circuit voltage of approx- carried out by making an entry in the maintenance
imately 12.55 V). booklet.
For non-operational periods longer than 4 weeks, the
Checking the overall vehicle
batteries must comply with one of the following:
Check the vehicle for perfect condition.
The battery main switch (code E30) must be
isolated and fuse 32 must be removed. For more Damage must be repaired where necessary.
information on code E30, please refer to the Special care shall be taken to not impair or nega-
Upfitter Portal technical bulletin: Sprinter MY2019+ tively impact the following systems and areas: heat
Emergency Battery management, electrical systems, driver assistance
Hibernation mode (energy-saving mode) must be systems, reliability, durability, fit and finish of
activated (→ page 253) Mercedes-Benz parts, functionality of drivetrain,
weight/dimensions (other than explicitly labeled)
⚠ WARNING and any other customer expectation and perfor-
mance of the vans.
If the E30 battery main switch or the battery itself is Do not remove Mercedes-Benz heat shields.
disconnected on a vehicle with an automatic trans-
Use Mercedes-Benz defined engine coolant
mission, the fuse 32 (10A red) “automatic trans- (Antifreeze).
mission” in the fuse holder driver’s seat fuse block
Do not use after-market wheel ends, wheels
F55/4 must be removed if the vehicle is inactive.
spacers, wheels studs.
For further questions, please reach out via Upfitter-
Portal.com. To reactivate the vehicle, reinstall the Do not change, modify or relocate steering gear,
linkage, power steering hose or steering column.
10A fuse (red) at fuse position 32, fuse block F55/4
and connect the E30 battery main switch. Do not change, modify or relocate any driver assis-
tance systems such as backup cameras, sensors
etc.
If the vehicle is unused for longer than 4 weeks,xe
Do not change, modify or relocate any airbags,
remove and store the battery in an upright position
seatbelts or other Mercedes-Benz restraining
at a dry place at temperature between 0 °C/32 °F
systems.
and 30 °C/86 °F.
The battery must be charged before removal and Checking the brake system
storage.
The brake fluid must be renewed regularly in accor-
The residual charging current should be less than dance with the Mercedes-Benz specifications, but
5A and the voltage higher than 13.5V. at least every two years.
The battery must be recharged every 4 weeks If it is not known how long a vehicle equipped with
when installed on the vehicle, or every 6 months a hydraulic brake system has been non-operational,
if removed from the vehicle, until the residual the brake fluid must be renewed.
charging current is less than 5A.
Check electric and hydraulic lines for damage of
The battery voltage must be kept above 12.55 V any kind and repair or replace if necessary.
at all times. If the battery voltage drops below
12.55 V but not below 12.1 V, the battery must
be recharged.
⑴ NOTE
If the open circuit voltage (unloaded for 4 hours in
the removed state) of the battery voltage drops below
11 V, the battery is damaged and will have to be
replaced.

Checking the batteries Deactivating transport mode

Check, and correct if necessary, the charge levels To avoid excessive discharge of the battery during long
of the vehicle battery and the auxiliary battery periods of non-operation, the electrical system of the
before handing over the vehicle.
Sprinter is in transport mode by default ex-factory,
which is only deactivated right before vehicle delivery.
Checking the tires
Before delivering the vehicle, check that the tires In transport mode, the speed is limited to 40 km/h or
are inflated to the specified air pressure and check 25 mph and limited electrical and electronic systems
the tires for damage. Damaged tires must be are active. This results in lower power consumption and
replaced. reduces battery load.
For eXpertUpfitters where conditions dictate that the
Checking wheel alignment
vehicles are idle for long periods of time, it is possi-
We recommend that the suspension geometry (toe ble to deactivate transport mode at the registered
adjustment etc.) be checked if modifications have
Mercedes-Benz service center just before vehicle
been made by a body repair workshop.
operation. Please contact Mercedes-Benz for further
information.
⑴ NOTE
It is possible to operate vehicles in transport mode.
The information under 3.5 Dimensions and weights However, please note that transport mode must always
(→ page 37) on the vehicle curb weight and cor- be deactivated before the vehicle is operated on public
responding axle loads before and after body mount- roads.
ing work, 4.2.9 Wheel alignment (→ page 71)
To deactivate transport mode with button combinations
and 6.1.1 General information on the suspension
before the vehicle is taken in to service:
(→ page 92), must always be complied with.
Press the starter button once to switch on the
ignition (terminal 15R). The emergency blinkers
More detailed information is contained in the must be switched off.
Mercedes-Benz Workshop Information System (WIS). Activate the left turn signal for at least 2 blinking
cycles
Quality control
Activate the right turn signal for at least 2 blinking
• All relevant quality control documentation should be cycles
saved by the upfitter. Switch off the turn signals
• It is recommended to upfitter keeps quality control Switch on the emergency blinkers for at least 2
records including pictures, customer information, blinking cycles
and copy of quality control sheets, VIN #, PO #, Switch off the emergency blinkers
Height, Weight and other relevant information (ex. Activate the left turn signals for at least 2 blinking
part numbers of installed equipment) in an electronic cycles
quality control system. Activate the right turn signals for at least 2 blinking
• Upfitter is responsible for any damages incurring cycles
during or due to modification while in his possession. Switch off the turn signals
Vehicles arrive at upfitter with a completed factory Press the starter button for a second time (terminal
inspection/ready for dealer delivery. 15) and check that the message "Transport Mode"
is no longer displayed on the instrument cluster

3.12 Special equipment
⚠ WARNING
The use of unapproved parts, major assemblies, con-
version parts, or accessory parts can have detrimen-
tal effects on the safety of the vehicle.
Before starting any work on the vehicle, please read
the chapters of the vehicle owner's manual relevant
to the upfit and the operating and installation guides
from the manufacturers of accessories and equip-
ment. You could otherwise fail to recognize dangers
which could result in injury to yourself or others.
We recommend the use of special equipment available

as Mercedes-Benz option codes, if possible, to ensure
that the special equipment is properly fitted to the
vehicle.
Information about the special equipment available as
codes is available from your Mercedes-Benz Service
Center 1.7 Contact (→ page 11).
ⓘ On the following homepages, you can assemble

your vehicle in the Configurator and view the avail-
able items of special equipment:
www.mbvans.com
www.mercedes-benz-vans.ca
Special equipment (e.g. reinforced springs, frame rein-
forcements, additional fuel tanks, stabilizer bars etc.) or
retrofitted equipment increases the curb weight of the
vehicle.
The actual vehicle mass and axle loads must be deter-
mined by weighing before mounting.
On completion of all body mounting work, the measure-
ment of the actual vehicle curb weight and the corre-
sponding axle loads by weighing must be repeated; for
this, comply with e.g. 9.1.1 Determination of the center
of gravity in the x-direction (→ page 309).
The measured values must be documented and
checked. Refer to the following sections for more infor-
mation: 3.5 Dimensions and weights (→ page 37),
3.11.3 Work before handing over the modified vehicle
(→ page 53), 4.2.9 Wheel alignment (→ page 71)
and 6.1.1 General information on the suspension
(→ page 92).
Be aware that problems may occur when retrofitting an
auxiliary equipment.

3.13 Adhesive decals on the exterior
The following specifications must be observed for adhe-

sive films (wrapping) on the exterior of the vehicle:
• Films may only be applied to the exterior surfaces
of the vehicle that are not labeled as impermissible
areas in the schematic diagrams below (cargo van
model designation).
• In areas with sensors, films are generally not per-
mitted; also refer to Chapter 8.9.4 Blind Spot
Assist/Rear Cross Traffic Alert (RCTA)/Exit Warning
(→ page 277).
• All local and national legal requirements of any
kind pertaining to the application of films or similar
materials on vehicles must be observed and com-
plied with. In particular, the regulations on wrapping
around the windshield, the windows and lighting Front of vehicle - speckled areas: Areas where wrapping is
systems must be adhered to. not permissible (example cargo van model designation,
schematic diagram)
⚠ WARNING
When applying decals to the exterior of the vehicle, the
Depending on the type and thickness, paints or films
upfitter should ensure compatibility to the vehicle paint.
can cause attenuation of radar waves. This could lead
to malfunction or system failure. This could cause the Please note the following points during decal
driver to lose control of the vehicle. application:
There is a risk of accident! • Ensure that the surface is clean before applying
(free of fingerprints, grease, oil etc.)
• Check the decal material supplier’s recommenda-
tions for an appropriate cleaning solution mixture
• Apply adequate contact pressure at every point on
the vinyl surface to reduce risks of failure
• It is recommended to test at various extreme
environmental conditions when choosing an appro-
priate material for decals (consider temperature,
humidity, etc.)

Sides of vehicle - speckled areas: Areas where wrapping is

not permissible (example cargo van model designation,
schematic diagram)
1 With Blind Spot Assist, code JA7
1 1
Rear of vehicle - speckled areas: Areas where wrapping is

not permissible (example cargo van model designation,
schematic diagram)
1 With Blind Spot Assist, code JA7

4 Technical limit values for planning
4.1 Limit values for the basic vehicle
4.1.2 Maximum permissible position of the

⑴ NOTE center of gravity
This chapter contains the technical limit values of
the basic vehicle which are important for planning an y-axis: The maximum wheel load (1/2 the axle
upfit. In addition, you will find more information in the load) of the laden vehicle may only be
other chapters of the current version of the Body and exceeded by 4%.
Equipment Guideline.
Maximum permissible center of gravity height
The overall height of the center of gravity of a vehicle
has a significant influence on its braking and handling
characteristics. When designing bodies and attach-
ments, care must therefore be taken to ensure that the
center of gravity of the basic vehicle and of the laden
vehicle is kept as low as possible.
The basic function of the ESP® is designed for an
4.1.1 Steerability overall center of gravity no more than 1300 mm/51.2
In all load states, the front axle load must represent at in above the road. The overall center of gravity height
least the following proportion of the gross permissible must not exceed 1300 mm/51.2 in.
vehicle mass: Irrespective of this, the tendency of vehicles to tip over
becomes more likely as the center of gravity height in-
General Up to 4.2 t > 35% of gross vehicle mass creases. The ESP® in the Sprinter is optimized to
Up to 5 t > 30% of gross vehicle mass reduce the vehicle’s tendency to tip over at overall cen-
ter of gravity heights up to approx. 1000 mm/39.4 in.
The permissible axle loads must be observed regard- In this context, it must always be ensured that the ve-
less of the load situation. hicles are fitted with the recommended suspension and
Sprinter is equipped with electric power steering. ESP® variants. This applies in particular to vehicles with
an overall center of gravity higher than 1000 mm/39.4 in.
⚠ WARNING Make sure that the correct variant is selected when
Modifications must not be made to the steering sys- ordering the vehicle. The calculation of the vehicle
tem. This includes any change and/or limiting of the centers of gravity and compliance with the information
steering angle. in the MY22 Dealer Ordering Guide (DOG) must be
ensured by the upfitter.
Modifications to the steering can cause the power
steering assistance to fail. The upfitter is responsible for determining and complying
with the vehicle maximum center of gravity restrictions.
There is a risk of accident, personal injuries and
death if such systems no longer function correctly! For any questions, please contact the Mercedes-Benz.
ⓘ For more information see Chapter 9.1 Center of

gravity (→ page 309).
Information on vehicle selection and the configura-
tion of the basic vehicle can be found in the MY22
Dealer Ordering Guide (DOG).

4.1.3 Vehicle dimensions

This chapter provides information about the maximum
permissible dimensions of the vehicle including the upfit.
Side mirrors based on vehicle width
Mirror/code Box/vehicle width

Standard mirror ≤2100 mm/83 in
(non-cab chassis)
Special equipment 2190 mm/86 in to
Code FS1 – 2300 mm/91 in
Extended mirror bracket
Standard mirror for cab 2300 mm/91 in to
chassis 2440 mm/96 in
Code FS2 –
Extra-long mirror bracket
Maximum permissible vehicle dimensions

The maximum dimensions provided in the following
tables must not be exceeded:
• The maximum box width is 96 in.
• The maximum box height is 109 in (measured from
the top of the chassis frame to the top of the box)
or 138 in (measured from the ground level).
• If roof mounts on top of the box exceeds the height
of 157 in (measured from the ground level), then
option code JA8 needs to be deactivated by activat-
ing option code JA0. (Please reach out to the
nearest local dealer for deactivation).
Dimension Description
a 2440 mm/96 in Maximum permissible width of the upfitted box
b 2770 mm/109 in Maximum permissible distance measured from the top of the chassis frame to the top of
the upfitted box
c 735 mm/29 in Body frame height measured from ground level (may vary depending on load,
suspension)
b+c 3505 mm/138 in Maximum permissible box height from ground level (excluding roof mounts)
d 4000 mm/157 in Maximum permissible height with roof mounts from ground level (with code JA8)
e 2776 mm/109.3 in Width of the vehicle including the extended mirrors (with code FS2)
f 2019 mm/79.5 in Width of the vehicle without mirrors and upfit
Consider both the maximum box height and width as Additionally, for frontal surface areas higher than
well as the maximum frontal surface area of the vehicle 6.8 m2/10540 in2, the following requirements are
when determining the measurements of the box. mandatory (for smaller frontal surface areas these
A nose cone may be installed on the front surface of requirements are preferable but not mandatory):
the box to reduce wind resistance. • The transition between cab housing and box has to
be chamfered by 45˚.
• The box is required to have edge radii ≥ 100 mm/
3.94 in (especially in the rear area) for improving
aerodynamics.

The following diagrams and tables show the general and the maximum side surface areas of Sprinter cab chassis vans.
The point of origin for the dimensions as well as for the 3D data (available for eXpertUpfitters on www.UpfitterPortal.com)
is located in the middle of the front axle.
Dimension Comment
144” 170”
g 3665 mm/144 in 4325 mm/170 in Wheelbase
h Maximum permissible overhang for vehicles equipped without
option code X2R. Does not require an UPFITTER MANAGE-
1850 mm/73 in 2200 mm/87 in
MENT VANS review.(See chapter 6.2.4 Overhang extension
(→ page 107))
i Maximum permissible overhang for vehicles equipped with option
code X2R. The overhang value does not include small rear protrud-
ing components (e.g. spare tire, bike rack attachments).
2200 mm/87 in 2600 mm/102 in
Does require an UPFITTER MANAGEMENT VANS review. Visit
www.UpfitterPortal.com (See chapter 6.2.4 Overhang extension
(→ page 107))
j Maximum permissible height of center of gravity (4.1.2 Maximum
permissible position of the center of gravity (→ page 58)
1300 mm/52 in 1300 mm/52 in For vehicles with center of gravity height greater than 1,000 mm,
please refer to section 4.2.1 'Suspension of Sprinter - BR907'
(→ page 69).
⑴ NOTE ⑴ NOTE
RV's (Recreational Vehicle) may have a maximum over- The extended permissible overhang with the option code
hang that is 60% of the wheelbase, but must not exceed X2R is only available for RV upfits. This is due to the
2600 mm/102 in (measured from the middle of the specific drive characteristics of RV’s; the relatively even
rear axle to the rear of the upfitted box). Please note weight distribution; and the predefined high rear axle
that auxiliary attachments (e.g. trailer hitch or addi- load with the unladen vehicle. These basic assumptions
tional bumpers) are not included in this measurement. cannot be made for other upfitted vehicles, so the basic
limits must apply to all other vehicles.
ⓘ For additional information about Crosswind Assist, please refer to chapter 8.9.2 Crosswind Assist.

Dimension Comment
k 1021 mm/40 in Distance between front end and point of origin
l 1503 mm/59 in Distance between point of origin and the back of the B-pillar
m Up to 4.2t > 35% of gross vehicle mass
Front axle load (see chapter 4.1.1 Steerability)
Up to 5t > 30% of gross vehicle mass
Dimension Description
n Minimum permissible distance between back of B-pillar and non-integrated body/box upfits
50 mm/2 in
(see chapter 4.9 Limit values for the box body (→ page 82)).
o Minimum permissible distance between the rear edge of the door and an integrated body
20 mm/0.8 in
(see chapter 4.9 Limit values for the box body (→ page 82)).
p 726 mm/29 in Distance from back of B-pillar to point ‘t’ (see bottom of table).
q up to 200 mm/ Alcove length measured from ‘t’ where no sensors are impaired (see chapter 8.9.5 Highbeam Assist,
7.9 in Lane Keeping Assist and traffic sign recognition and 8.9.6 Rain sensor and Headlamp Assist).
r Alcove length measured from ‘t’ where option codes LA2 (Headlamp assist sensor at upper posi-
up to 400mm/ tion) and JF1 (Rain sensor) may have impaired functionality. Therefore, option code LA3 (headlamp
15.8 in assist sensor at lower position) can be ordered (see chapter 7.14.4 Headlamp Assist (code LA2)
and 7.14.5 Rain sensor (code JF1)). If the option code LA3 is ordered, the rain sensor (code JF1)
cannot be ordered.
s Maximum permissible alcove overhang. Option code LA2 (Headlamp assist sensor at upper
up to 1150 mm/
position) and JF1 (Rain sensor) are covered by the shade of the alcove and the functionality will be
45 in
impaired. Therefore, option code LA3 (Headlamp assist sensor at lower position) can be ordered.
t - Accessible start point for measuring the alcove overhang (outer edge of windshield).

Permissible towing capacities when relocating the trailer coupling point
Permissible Wheelbase Relocation of trailer coupling point from standard configuration

gross mass 0-200 mm 201-500 mm/ 501-600 mm/ 601-700 mm/ > 700 mm/
0-8 in 8-20 in 20-24 in 24-28 in > 28 in
1500, 2500 3665 mm/ 3500 kg/ 3000 kg*/ 2500 kg*/ 2000 kg*/ * +**
144 in 7720 lbs 6610 lbs 5510 lbs 4410 lbs
4325 mm/ 3500 kg/ 3000 kg*/ 2500 kg*/ 2000 kg*/ * +**
170 in 7720 lbs 6610 lbs 5510 lbs 4410 lbs
3500, 3500XD, 3665 mm/ 3500 kg/ 3500 kg*/ 3000 kg*/ 2500 kg*/ * +**
4500 144 in 7720 lbs 6610 lbs 6610 lbs 5510 lbs
4325 mm/ 3500 kg/ 3500 kg*/ 3000 kg*/ 2500 kg*/ * +**
170 in 7720 lbs 6610 lbs 6610 lbs 5510 lbs
* If the trailer coupling point is relocated by > 200 mm/8 in in relation to the standard configuration, the
Trailer Stability Assist (TSA) must be deactivated through the use of code O19.
** If the relocation of the trailer coupling point from the standard configuration is > 700 mm/28 in, we recommend
seeking the advice of the relevant department1.7 Contact (→ page 11).
4.1.4 Parts which must not be welded:

• On the A and B-pillars
• On the upper and lower flange of the frame
• In bending radii
• In the vicinity of the airbags, airbag sensors, airbag
control unit, and seat belts
• Plug welding is only permissible in the vertical webs
of the longitudinal frame member.
• In the area of the assistance systems, (e.g. front and
rear radars for Parktronic or Distronic)
ⓘ Additional information can be found under Chapter

3.9 Bolted and welded connections (→ page 46),
Chapter 5.2 Welding work (→ page 85), Chapter
6 Modifications to the basic vehicle (→ page 92),
6.2 Body in white/body (→ page 101) and the
Mercedes-Benz Workshop Information System
(WIS).

4.1.5 Drilling must not take place Drilling must not take place:
This chapter provides information about areas which • On the A and B-pillars
should not be modified or changed due to safety and • In the upper or lower flange/chord of the longitudinal
crash reasons. frame member
The following pictures show the safety and crash rel- • In the vicinity of load application points (e.g. spring
evant areas. Mercedes-Benz recommends not to drill brackets)
into the marked areas.
• In the vicinity of front axle or rear axle supporting
points
• On underbody reinforcement or longitudinal supports
under the B-Pillar
• In the vicinity of the airbags, airbag sensors, airbag
control unit, seat belts
• In the area of the assistance systems, (e.g. front and
rear radars for Parktronic or Distronic)
⑴ NOTE
Holes in the longitudinal frame member are the
result of the production process and are not suitable
for body mounting work. On no account may holes
resulting from the production process be used, as
this could damage the frame.
Safety and crash relevant areas (marked in blue)
For mounting of partition walls, please use existing
The diagram below shows where drilling into the
holes.
longitudinal member is not allowed.
Longitudinal member, non-drilling areas

Underbody reinforcement non-drilling areas Underbody reinforcement non-drilling areas
Both views show the reinforcement piece with grooves

in the highlighted region. Drilling should not take place
in this area because of its structural importance.
In relation to the highlighted zone, an important note
about fuel-related part integrity is below.
⑴ NOTE
Clearances for fuel filler necks, fuel tank lines and
fuel lines must be maintained. Sharp edges of the
upfit can impact the fuel integrity of the vehicle.
ⓘ Additional information can be found under 3.9

Threaded and welded connections (→ page 46)
and 5.2 Welding work (→ page 85).

4.1.6 Service lift points Rear lifting points

This section provides information about the location of
Front lifting points the lifting points in the rear part of the underbody.
This section provides information about the location of
the lifting points in the front part of the underbody. C
D D
A B
Rear lifting points

3) Rear jack tube on front rear spring bracket
Front lifting points 4) Rear jack tube on longitudinal frame member
1) Front support to spring clamp plate 6) Mount on front rear spring bracket
2) Front support to longitudinal member 011) Lifting platform
011) Lifting platform 013) Long support plate
012) Support plate 014) V-block
013) Long support plate 016) Ram
017) Support drift
Front underbody non-drilling areas Rear underbody non-drilling areas
• Vehicles which have been modified in areas of main-

tenance points/lifting points are not serviceable at
Mercedes-Benz dealerships.
• Due to safety reasons Mercedes-Benz dealerships
will not use any other lifting points than those desig-
nated by Mercedes-Benz standards (see above).
• Mercedes-Benz highly recommends not to modify
the highlighted areas.

4.1.7 Weights
The upfitter has to comply with certain limit values of
the vehicle. This subsection explains where the maxi-
mum limits can be found and how they are connected
to each other.
Nomenclature Meaning Description Location

Gross Vehicle Weight Gross Vehicle Weight Permissible total weight of the Can be found on this sticker2:
Rating (GVWR1) Rating vehicle (limited)
Payload1 Payload Includes driver, passengers, Can be found on this sticker2:

cargo, luggage, etc.
Curb Weight (CW1) Curb Weight Weight of the vehicle, depend-

ing on the option code (actual Has to be calculated by formula1
value)
UVW1 Unloaded Vehicle Weight Maximum weight of the vehicle Can be found on this sticker2:
including the upfit (limited)
1 Specific to vehicle
2 Refer to subsection 3.6 Vehicle identification data
(→ page 39) for further information and labels

4.1.8 Weight limits A = Base Curb Weight (BCW). BCW is the sum of the
Sprinter vehicle weight and liquids necessary for vehi-
The diagram below provides an overview of the
cle operation at full capacity (e.g. fuel). The weight of
weight limits that must be considered when upfitting
the vehicle is variable and depends on the variant of
a Sprinter. This chapter serves as a guide to upfitters
the Sprinter and the option codes included in the spe-
when modifying their vehicles, but this cannot serve as
cific vehicle. Liquids that are not necessary for vehicle
a replacement for reviewing the latest version of federal
operation should not be included.
and local regulations on weight limitations. It is the
upfitter’s responsibility to ensure compliance with all B = Unloaded Vehicle Weight (UVW). UVW is the sum of
federal and local regulations on weight limitations. the BCW value and the weight of permanently installed
equipment added by the upfitter. Liquids that are not
The table below contains the maximum weight limit
necessary for vehicle operation as well as any acces-
values for Sprinters based on the model type. Do not
sories should not be included. The UVW restriction
exceed the maximum weight limits of UVW, GVWR, and
does not include the driver, passengers, cargo/luggage
GCWR, listed below.
items in its weight limit.
C = Gross Vehicle Weight Rating (GVWR). GVWR is
the sum of UVW value and the driver and passenger(s)
weights as well as weights of the added cargo and/or
luggage.
D = Gross Combination Weight Rating (GCWR). GCWR
is the sum of GVWR value and the weight of any
attached trailer and the cargo in the trailer.
Payload before the upfit is payload of the vehicle without
any upfit modifications and is calculated by subtracting
the BCW from the GVWR. The payload value is provided
on the tire label located on the B-pillar driver side door.
Payload after the upfit includes the weight of perma-
nently installed equipment added by the upfitter and
is calculated by subtracting the weight of the vehicle
after the upfit from the GVWR. The label with payload
(tire label on the B-pillar driver side door) provided by
Mercedes-Benz will need to be updated by the upfitter
with the payload after upfit value.

4.2 Limit values for the suspension
4.2.1 Suspension of Sprinter – BR 907 Code overview

Please find up-to-date suspension packages and codes
Use of the suspension design on the Upfitter Portal:
Mercedes-Benz provides a range of suspension pack- www.UpfitterPortal.com
ages to meet varying customer needs for a wide range
of body possibilities.
Suspension package overview
Code Description
CB1 Suspension for comfort and load protection
CB7 Stabilization level I - roll stabilization with high body damping
CB8 Stabilization level II - enhanced roll stabilization with higher body damping compared to CB7
CB4 Stabilization level III - maximum roll stabilization with higher body damping compared to CB8
CT1 Rear spring vibration absorbers
A50 Front axle reinforced
CE8 Raised rear body mounts
Contents of the suspension packages
Code Benefit
CB1 Enhanced comfort due to adapted damper characteristics and the use of progressive
spring characteristics.
CB7 CB7 compensates for rolling behavior due to high centers of gravity of loads or bodies. Torsion
bars with an increased diameter are added to the front and rear axles. Furthermore, shock absorbers
with an adapted characteristic are installed.
CB8 Additional roll stabilization and body damping compared to CB7. Increases torsion bar diameters at
the front and rear axles and provides an adapted shock absorber characteristic. Furthermore, rear axle
springs with increased rigidity are installed.
CB4 Suspension with maximum roll stabilization for upfitted vehicles. CB4 includes the stabilization stage
II (CB8) with adapted springs/shock absorbers, stabilizer bar characteristics and the use of a progres-
sive spring characteristic.
CT1 Includes vibration absorbers fitted on the left and right rear spring and lowers the resonant vibrations
of the rear springs, thus hindering noise development.
A50 Includes an increased load capacity of the front axle, such that heavier bodies and equipment can be
fitted. The higher capacity front axle caters for heavier cabs and special equipment (e.g. for fire-fighting
vehicles and ambulances).
CE8 Raised body on rear axle (35mm). For RV only.

An additional ESP variant is available for the Sprinter 4.2.2 Permissible axle loads
van models in the form of the option code B01 (vehicle
See Chapter 2 General (→ page 14).
version for high loads). The code B01 can be ordered for
vehicles with high loads and is recommended for upfitted ⚠ WARNING
vehicles with high centers of gravity.
If the permissible axle loads are exceeded on vehicles
For more information, please refer to Chapter 4.1.2
equipped with the ESP® system, this may no longer
Maximum permissible position of the center of grav-
function correctly. Furthermore, any overloading may
ity (→ page 58) and Chapter 9.1 Center of gravity
result in damage to the suspension and load-bearing
(→ page 309)
parts. This could cause the driver to lose control
Code B01 contains a combination of suspension, of the vehicle. There is a risk of accident, personal
tires, ESP parameters, driver assistance system param- injuries and death if such systems no longer function
eters specially designed and developed for upfitted vehi- correctly!
cles with a center of gravity of more than 1000 mm/39
Permissible axle loads are not to be exceeded.
in above the ground level. This also applies to all-wheel
drive vehicles. Code B01 is not available for 3500,
3500XD, or 4500 vans with 144" wheelbase. For information on axle loads and maximum permis-
sible gross mass, see 1.7 Contact (→ page 11).
In the Dealer Ordering Guide (DOG) (please review
www.UpfitterPortal.com) the suspension matrix will
provide a recommendation for the specific suspensions
depending on the vehicle characteristics. If the
upfit/body required by the customer is not included in
the suspension matrix, then please reach out via
www.UpfitterPortal.com.

4.2.3 Approved tire sizes

The table below provides a general overview of tires
according to tonnage.
Gross mass Equipment Tire size Weight and speed rating

Reference: 1500/2500 LT245/75 R16 120/116Q
2 LT245/75 R16 120/116Q
Reference: 3500/3500XD 1 (on front axle) 225/75 R16 C 121/120R (122L)
Super Single 1 (on rear axle) 285/65 R16 C 131R See note
1 (as spare wheel) 225/75 R16 C 121/120R (122L)
Reference: LT215/85 R16 115/112Q
3500/3500XD/4500 2 LT215/85 R16 115/112Q
1 With super single tires special equipment, code R9A

2 All-wheel drive (4x4) ⑴ NOTE
The tire sizes listed comply with the approved weight
and speed ratings for each vehicle tonnage rating.
The table below outlines the tire pressures on Sprinter

vehicles. These tire pressures are the same, regardless
of tire brand and are measured as fully laden. Weights
quoted are GVWR values.
Tire Front axle (psi) Rear axle (psi) Spare tire (psi)
Vehicles below 10,000 lbs.
LT 215/85 R16 (without code A50) 55 54 55
LT 215/85 R16 (with code A50) 61 54 61
LT245/75 R16 (without code A50) 46 70 70
LT245/75 R16 (with code A50) 52 70 70
225/75 R16C (without code A50) 49 - 100
225/75 R16C (with code A50) 54 - 100
285/65 R16C - 67 -
Vehicles above 10,000 lbs. and below 12,
125 lbs.
LT 215/85 R16 (without code A50) 55 58 -
LT 215/85 R16 (with code A50) 61 58 -
285/65 R16C - 67 -
Vehicles at 12,125 lbs.
LT 215/85 R16 (with code A50) 65 62 -
285/65 R16C - 75 -

4.2.4 Diameter of turning circle
Wheelbase Diameter of turning circle

RWD 4x2 4x2 4x4
1500, 2500 3500XD, 4500 1500, 2500, 3500, 3500XD
3665 mm/144 in 13.4 m/528 in 13.2 m/520 in 14.0 m/551 in
4325 mm/170 in 15.3 m/602 in 15.2 m/598 in 16.1 m/634 in
4.2.5 Modifications to the axles 4.2.8 Modifications to springs, spring

suspension/shock absorbers
No modifications may be made to the suspension or
the axles (→ page 92). Modifications to spring suspension, shock absorbers,
and stabilizers using non-Mercedes Benz parts are not
4.2.6 Modifications to the steering recommended.
No modifications may be made to the steering system If modification to the suspension system is desired,
(→ page 92). then only Mercedes-Benz parts must be used. When
replacing the suspension package, the entire suspen-
⑴ NOTE sion system must be replaced including all the relevant
parts and the software system. Please reach out to the
Modifications must not be made to the steering sys- local dealership for obtaining all the necessary parts
tem . This includes any change and/or limiting of the and flashing of the software system.
steering angle.
On no account should modifications be made to the
Modifications to the steering can cause the power spring suspesnsion (→ page 92).
steering assistance to fail.
4.2.9 Wheel alignment
No modifications may be made to the steering geome-
4.2.7 Modifications to the brake system try and to the wheel alignment settings (→ page 92).
No modifications may be made to the brake system. If the upfit or any permanent equipment that belongs
No modifications may be made to disk brake air inflow to the vehicle leads to increased vehicle curb weight or
and air outflow (→ page 94). if the vehicle is mostly used in fully loaded state, refer
to the notes under 6.1.1 General information on the
suspension (→ page 92).
This could apply to, for example, recovery vehicles,
fire-fighting vehicles, ambulances, semitrailer trucks,
workshop vehicles or RVs.

4.3 Limit values for the body in white
4.3.1 Modifications to the body in white 4.3.2 Limit values for the vehicle frame
See "Modifications to the basic vehicle" (→ page 101) If the frame is extended, the material of the extension
for more information. element must have the same quality and dimensions as
• No modifications may be made to the crossmember the standard chassis frame, see Chapter 7.1 Assembly
structure from the front of the vehicle back to, and frame (→ page 180).
including, the B-pillar.
Vehicle name Model designation Material
• No modifications may be made to the rear portal Sprinter 907 CR240 LA or
including the roof area (→ page 111). S235 JRG
• In the event of modifications to the load-bearing
structure, the total equivalent rigidity of the structure
fitted by the upfitter must equal that of the standard
vehicle.
• Clearances for fuel filler necks, fuel tank lines and
fuel lines must be maintained.
• It is not permissible to drill holes in or perform weld-
ing work on the A-pillar or B-pillar.
• If modifications are made to the side wall of the
cargo van or the passenger van, the rigidity of the
modified body must equal that of the basic vehicle.
• If bodies are mounted on basic vehicle cabs, a fuel
level sensor shield may be necessary depending
on the body type. See section 6.3.1 Fuel system
(→ page 126).

4.3.3 Roof/roof load

The following chapter provides information and limit
values for applying loads to the roof.
Exterior roof mounts:

Please review chapter 6.2.9 Cargo Van/Passenger Van
roof (→ page 118). Mercedes-Benz recommends to
utilize roof rails and order option code D13 (mounting
rails for roof rack) to mount equipment or distribute the
load evenly over the entire roof surface.
Maximum roof loads

Cargo van High roof cargo van High roof cargo van Cab
LH1 LH2 (static) LH2 (dynamic)
300 kg/661 lbs 300 kg/ 661 lbs 150 kg/331 lbs 100 kg/220 lbs
⑴ NOTE Wheelbase Quantity required

3665 mm/144 in ≥ 5 bows
For high roof vans (LH2), if a vehicle is parked on a 4325 mm/170 in ≥ 6 bows
horizontal plane, the maximum permissible static
roof load on a stationary vehicle is 300 kg or 661 Roof bows Position
lbs, evenly distrbuted. For example, the weight of an 1 Behind the front doors (B-pillar)
occupied pop-up roof with passengers included can 2 At the center of the sliding door to
be up to 300 kg or 661 lbs. the load compartment (between the
B- and C-pillars)
Interior roof mounts: 3 At the center of the vehicle behind
If equipment needs to be installed in the interior under- the load compartment sliding door
neath the roof, it is recommended to utilize a support- (C-pillar)
ing structure to distribute loads through the sidewalls 4-6 Between the C-pillar and the rear
and not through roofbows itself. The limit values may area of the vehicle (rear pillar)
be used from the table above.
If the upfitter decides to use the roof bows to mount Roof height Moment of inertia Ix per roof bow
equipment, Mercedes-Benz recommends to order increase
option code D17 (interior roof rack). The maximum ≤ 250 mm/10 in ≥ 40 000 mm4/0.096 in4
interior roof load with option code D17 is limited to ≤ 400 mm/16 in ≥ 65 000 mm4/0.156 in4
50Kg / 110lbs. ≤ 550 mm/22 in ≥ 86 000 mm4/0.201 in4
General roof information: Refer to 8.9.2 Crosswind Assist (→ page 273) for
modifications to the projected lateral face.
The sheet metal thickness of the roof bows is 0.8mm.
Roof bows or load-bearing parts may not be removed
or damaged without being replaced.
For further information in regards of roof modification,
please review see Chapter 6.2.9 Cargo Van/Passenger
Van roof (→ page 118).
The connection between the roof bow and the
side wall must be of sufficient bending resistance
(→ page 111).

4.4 Limit values for engine peripherals/drive-

train
4.4.1 Modifications to engine/drivetrain 4.4.2 Engine cooling system

components
a) Vehicles with engine OM651/OM642
Modifications to the engine timing/performance On no account should modifications be made to the
enhancement cooling system (cooler, radiator grille, air ducts, coolant
circuit, etc.) because a sufficient flow of cooling air
⑴ NOTE
must be guaranteed.
Any interference in the engine timing by customers The flow areas of the cooling air intake areas are to be
and upfitters is not permitted. kept free. This means:
Manipulations or modifications to the engine timing • At least 11 dm2 free air cross-section for the front
cause changes in the certified engine data and emis- grill (coolant radiator and condenser)
sion values, and thus result in the immediate invalida-
tion of the operating permit. • At least 7 dm2 free air cross-section for the opening
in the bumper (charge air cooler flow)
Further changes to engine/drivetrain
• On no account should modifications be made to the
air intake system.

• On no account may any modifications be made to
the propeller shafts. If any modifications are neces

sary (e.g. adjustment of the lengths), these may only
be carried out by a company qualified in propeller
shaft engineering. This company shall be responsible
for the effects on the vehicle (e.g. NVH behavior,
durability, package). When modifications are made, Engine cooling, specification for intake air cross-section
the fastening elements must not be reused. 1 Front radiator grille
• It is not possible to retrofit any engine speed regula- 2 Charge air cooler
tion equipment, other than that which is available as
Mercedes-Benz special equipment. b) Vehicles with engine OM654
• On no account should modifications be made to the The cooling module for the engine OM654 is shown in
exhaust system, especially in the vicinity of exhaust the following figure.
gas aftertreatment components (diesel particulate
filter, catalytic converter, lambda sensor etc.). The cooler components A/C condenser, low-tempera-
ture cooler (LT cooler), high-temperature cooler (HT
cooler) and electric E suction-type fan are arranged in
succession. The new water-cooled charge air cooler
and the transmission oil cooler (with automatic trans-
mission) are positioned on the engine and the LT cooler
supplies them.
To prevent any return flow of heated recirculated air
from the engine compartment, the cooling module with
air recirculation partitions or air ducting are sealed off
all the way round (for details, see description below).


Cooling module for engine OM654

1 A/C condenser
2 LT cooler
3 HT cooler
4 E suction-type fan
5 Air recirculation partitions (exemplary, circumferential
installation)
6 Coolant expansion reservoir
Modifications may not be made to the cooling system

(cooler components, air ducting, hoses and other
detachable parts that are part of the cooling system).
Modifications to the front of the vehicle can fundamen-
tally be made under the following boundary conditions.
The free cross-section areas of the cooling air intake
openings in total from the upper front grate plus the
lower bumper grille (see figure "Cooling air intake
openings at front of vehicle" (→ page 76)) must be
complied with for technical reasons with the following
limit values:
• Minimum: 18.2 dm² / 282 in2
• Maximum: 26.4 dm² / 409 in2

Adding equipment to Mercedes-Benz vehicle grille Modifications may not be made to covers for the lower
For vehicles with a genuine Mercedes-Benz Van vehicle opening area in the bumper grille (see following figure).
front, detachable parts (horn, front flasher or similar)
can be mounted in the hatched areas 1 and 2 of the
front grille (see following schematic diagram).

Cooling air intake openings at front of vehicle

1 2
1 Front grille
2 Bumper grille
Front grille of genuine Mercedes-Benz Van vehicle front
1, 2 Areas in which detachable parts can be mounted

(schematic diagram)
As the detachable parts are to be placed outside the

marked areas 1 and 2 in the front grille, the resulting
cooling output should be verified through the test cycle
specified at the end of this chapter. eXpertUpfitters
should open a new UIS on the Upfitter Portal in relation
to this upfit.
If the free cooling air intake openings are reduced in
size, the cooling output of the air conditioning system
is lowered and - depending on the given operating
status - the duration and intensity of fan operation is
increased.

4.5 Limit values for the interior
4.5.1 Modifications to airbags and seat belt 4.5.2 Modifications to seats

tensioners
⚠ WARNING
⚠ WARNING
Only seat combinations that match as-delivered state
Modifications to or work incorrectly carried out on are permitted. It is not permissible to rotate seats or
restraint systems (seat belt and seat belt anchorings, to create conditions which do not match the series
seat belt tensioners or airbags) or their sensor sys- production state.
tems of wiring could cause the restraint systems to Modifications to the seat system, particularly in the
stop functioning correctly. This means, for example, case of seats with a seat occupancy sensor, or the
that airbags or seat belt tensioners may be activated mounting of seats to the wheel well are not permit-
inadvertently or may fail in the event of an accident ted. Otherwise the seats could become detached
even though the rate of deceleration exceeds the from their anchorages in the event of an accident.
deployment threshold.
Furthermore, the functioning of safety-relevant driver
There is a risk of accident, personal injuries and assistance systems cannot be guaranteed. (See 8
death if such systems no longer function correctly! Electrics/electronics (→ page 233))
Modifications to restraint systems are therefore not Seat covers and protective covers could interfere
permitted. with the functioning of the thorax/pelvis side airbag
and the seat occupancy recognition system.
• On no account should modifications be made to
airbag components or in the vicinity of airbag compo-
nents and sensors. Seat Covers
• On no account should modifications be made to the • Seats with integrated thorax-pelvis-airbags feature
headliner or its attachment if the vehicle is equipped security seam with the flag “Airbag”.
with window airbags. • Modifications to the seat or seat cover requires
• The vehicle interior must be designed in such a way compliance with applicable technical and regulatory
that airbags can fully deploy without impediment requirements.
(→ page 139). • Aftermarket seat covers may affect the performance
• On no account should modifications be made around of the thorax-pelvis-airbag.
the airbag control unit (→ page 139).
ⓘ More information can be found under "Modifica-

tions to the basic vehicle" (→ page 139).

B-Pillar cover removal and reinstallation
N91.60-2212-00
Front Seat with integrated Thorax-Pelvis-Airbag
More information can be found under "Modifications to N91.60-2213-00
the basic vehicle" (→ page 147) and "Modifications to Image outlining the B pillar cover
the interior" (→ page 190).
1 Trim coat hook
If modifications/alterations to the seats are necessary, 2 Coat hook
refer to 1.7 Contact (→ page 11). 3 Seat belt
If a rear bench seat with 2 or 3-point seat belts devi- 4 Trim B-pillar
5 Cargo tie-down
ates from the standard seat design, it must comply
6 Seat belt height adjustment mechanism
with the requirements from Chapters 6.4.1 General
information (→ page 138), 6.4.2 Safety equipment
(→ page 139) and 6.4.3 Seats (→ page 147). Removal of B-Pillar Cover
If a rear bench seat with 2 or 3-point seat belts devi- Pull coat hook trim (1) upwards and remove coat
ates from the standard seat design, it must comply with hook (2).
the requirements concerning “Anchoring of seat belts”. Remove the cargo tie down (5) or cover.
Any retrofitted rear bench seat with two- or three-point Remove the seat belt (3) from the seat (if needed).
seat belts must comply with the FMVSS/CMVSS 210. Remove the assist handle covers and remove the
screws (optional equipment). Remove the assist
handle from the passenger side B-pillar.
Pull the trim (4) on the B-pillar out of clip connec-
tions starting at top and remove downward.
Remove the seat belt (3) from the trim (4) (if
needed).

Reinstallation of B-Pillar Cover Dampening Device on Height Adjustment (Partition

Pull the seat belt through the B-pillar cover. Wall Only)
IMPORTANT: Slide adjustment part of B-pillar cover Sprinter Cargo Vans with partition walls (D50, D51,
to top position before reinstallation. Insure that D53, D93 and D64) come with a (1) dampening device
the seat belt height adjustment fits correctly into (left and right side) on top of the height adjustment
guide. Make sure that the door rubber seals are mechanism. Make sure dampening device is fitted
seated correctly.
properly into height adjustment before reassembly.
⑴ NOTE
Dampening devices are not used on Sprinter Cab
Chassis and Passenger Vans.
N91.60-2214-00
Correct Alignment of B pillar cover
Install the trim onto B-pillar and seat clips starting

from bottom moving upwards. Install the seat belt
to the seat. Install the cargo tie down or cover.
Install the coat hook and seat trim fully. Bolt the
end fitting to seat. Please refer to WIS or contact N91.60-2215-00
the local dealership for the most accurate torque
Left: Dampening Device Interior, Right: B-Pillar Cover Exterior
values.
Check seat belt and its height adjustment for
proper functionality otherwise check step 2 again. 4.5.3 Seat Reference Point
The rear most Seat Reference Point of the front seats
⑴ NOTE
has the following coordinates:
If the seat is removed and reinstalled, please make X = 1111 mm/ 43.74 in
sure that the seat is torqued to the correct value. The
Z = 530 mm/ 20.87 in
torque value is found on WIS or the local dealership.

4.6 Limit values for electrics/electronics
See Chapter 8 Electrics/electronics (→ page 233). 4.6.3 Mobile communications systems

The maximum transmission output (PEAK) at the base
4.6.1 Vehicle position lamps and side marker of the antenna must not exceed the values from the
lamps local and federal laws on the maximum transmission
Vehicle marker and clearance lamps are output.
required by law on all vehicles with total width of
2032 mm/80 inch and above according to FMVSS/ 4.6.4 CAN bus
CMVSS standards.
CAN bus or the components connected to it.
4.6.2 Retrofitting electrical equipment
The parameterizable special module (PSM/ MPM, code
All electrical equipment fitted must be tested in accor- ED5) can be used to access individual types of data
dance with FCC, CE and UL in the US, and with CSA available on the CAN bus (→ page 296).
and ULC in Canada.
⑴ NOTE
In isolated cases there may be some inconveniences.

4.7 Limit values for additional assemblies 4.8 Limit values for attachments
If additional assemblies (e.g. additional air conditioning • A lateral protection is necessary when:
compressors, pumps, etc.) are retrofitted, the following - the distance between the rear of the vehicle and
must be observed: the rear axle is more than 1000 mm/39 in.
• The operation of vehicle components must not be - with the vehicle in its unladen condition, the
adversely affected. distance between the roadway and the chas-
• The freedom of movement of vehicle parts must be sis or main parts of the body is greater than
guaranteed in all driving situations. 550 mm/21 in across the entire width of the
• Refer to option codes N62 and N63 (→ page 154). vehicle.
• The maximum permissible lifting load of a lifting
platform is 500 kg/1102 lbs on a cargo van and
1000 kg/2205 lbs on chassis. Attachment as
per section 6.6.6 Lifting platform (cargo liftgate)
(→ page 169) is essential.
Attachment to the rear frame section:
On cab-chassis, the reinforcement of the trailer cou-
pling in the left/ right rear longitudinal member for BR
907 is installed on the vehicle as standard. If this is not
required, it must be deleted when the vehicle is ordered
(code QW1). For cargo and passenger vans, the longi-
tudinal member reinforcement must be ordered at the
same time (code Q11).

4.9 Limit values for the box body
min. 20 mm
0.8 in
Box body
See Chapter 7 Design of bodies (→ page 180).
⑴ NOTE
The standard fuel filler cap must not be removed or
covered with any "blocking" parts, see Chapter 6.2.5
Modifications to the cab (→ page 110).
⑴ NOTE
The minimum distance between the cab and a sepa-
rate body must be > 50 mm/2 in. N40.00-2053-00
Minimum distance between rear edge of door and integrated

⑴ NOTE box body
The minimum distance between the rear edge of

the door and an integrated box body must be 4.9.1 Assembly frame
> 20 mm/0.8 in. Otherwise the rear edge of the door
may come into contact with the box body in the event Minimum section modulus required for assembly
of an accident, and in extreme cases the door may frame Wx1
be jammed. Version Platform/ Dumper/ Loading
box body2 lifting work crane
⚠ WARNING platform
All weight 17 cm /
3 30 cm3/ 40 cm3/
Do not attach side bars to the outside of the under- variants 1.04 in3 1.83 in 3 2.44 in3
body. In the event of an accident (e.g. a side crash),
these could bend updwards and block the door. This 1 The minimum section modulus required for assembly
could mean that the rescue services are not able to frames applies for the material properties specified in
the table below, and each individual longitudinal member
open the door and could make recovery of the occu-
of the assembly frame must have this section modulus.
pants more difficult. 2 Up to the maximum standard wheelbase; above that:
+10%.
ⓘ Observe any differing specifications which may

apply, see 7.5 Platform bodies (→ page 196) and
7.9 Dump trucks (→ page 200).
Material quality of specified assembly frames made

of steel
Material Yield strength Tensile strength

CR240LA 260-340 N/mm2 ≥ 240 N/mm2
37700-49300 psi ≥ 34800 psi
S235JRG2 ≥ 235 N/mm2 340-510 N/mm2
≥ 34075 psi 49300-73950 psi

5 Damage prevention
General
⚠ WARNING
Tampering with or unauthorized installations in vehi-
cle systems, safety-relevant components and driver
assistance systems can impair the functioning of
these systems. This may lead to the failure or mal-
functioning of components or safety-relevant com-
ponent parts. There is a risk of accident, personal
injuries and death associated with such tampering
and unauthorized installations!
Always have work on vehicle systems, safety-relevant
components and driver assistance systems per-
formed at a qualified workshop.
ⓘ Tampering with the vehicle, safety or driver assis-

tance systems and safety-relevant components can
invalidate the warranty or the general operating
permit.

5 Damage prevention
5.1 Brake hoses/cables and lines
Test each of the systems for chafing points, pressure

⑴ NOTE loss and sealing after installing compressed-air lines
Any work carried out on the vehicle must comply with and hydraulic lines.
accident prevention regulations. No other lines may be attached to brake hoses and
brake lines.
⑴ NOTE No other lines may be attached to brake lines, other

than those installed as standard.
Comply with all national directives and laws.
Lines must be protected from heat by means of insula-
tion.
Cover plastic lines and brake hoses before carrying out
any welding, drilling and grinding work or before work- ⚠ WARNING
ing with cutting disks. If necessary, the plastic lines and Work carried out incorrectly on the brake hoses or
brake hoses should be removed. cables may impair their function. This may lead to the
failure of components or safety-relevant component
parts. There is a risk of accident, personal injuries
and death associated with such tampering and unau-
thorized installations!
Have all work on brake hoses and cables carried out
at a qualified specialist workshop.

5 Damage prevention
5.2 Welding work
• Before welding, cover springs and air suspension

⚠ WARNING
bellows to protect them from welding spatter. Do
Welding in the vicinity of the restraint systems (air- not touch springs with welding electrodes or welding
bags, airbag sensors, airbag control unit, or seat belt tongs.
components) can cause these systems to no longer • Welding work is not permitted on assemblies such as
function correctly. the engine, transmission, axles.
If restraint systems no longer function correctly, the • Disconnect the positive and negative terminals from
occupants may be unprotected in the event of an the batteries and cover them.
accident. There is a risk of accident, personal injuries
and death if such restraint systems no longer func- • Connect the welder ground clamp directly to the
tion correctly! part to be welded. Do not connect the ground clamp
to assemblies such as the engine, transmission or
Welding is therefore not permitted in the vicinity of axles.
the restraint systems.
• Do not touch electronic component housings (e.g.
control units) and electric lines with the welding elec-
⚠ WARNING trode or the ground clamp of the welder.
Welding work that is not performed correctly could • Weld only with electrodes connected to the positive
lead to failure of components relevant to safety. It pole of a direct current source. Always weld from
would then not be possible to rule out the risk of an bottom to top.
• The maximum current may be 40 A per mm/
and death if such work is carried out incorrectly!
1016 A per in of electrode diameter.
Have welding work carried out by a qualified special-
• Use only completely dry basic-coated electrodes
ist workshop.
(diameter 2.5 mm/0.098 in).
• Gas-shielded welding is permissible.
⚠ WARNING
• Only use welding wires with a thickness of between
If handled incorrectly, welding work can result in a 1 mm and 1.2 mm/0.04 in and 0.05 in.
fire. There is a risk of accident, personal injuries and
• The yield and tensile strength of the welding material
death if such work is carried out incorrectly!
must be at least equal to that of the material to be
Always comply with the legal requirements when welded.
performing welding work.
For this reason, the following safety measures must
always be observed during any work involving welding: • Weld seams must be ground down and reinforced
with angular profiles to prevent notching from weld-
• Welding work on the chassis may only be carried out ing penetration.
by trained personnel.
• Avoid welds in bends.
• Before performing welding work, components which
may contain flammable or explosive gases, e.g. fuel • There must be at least 15 mm/0.59 in between the
system (→ page 126), must be removed or pro- weld seams and the outer edges.
tected from sparking with a fire-resistant covering.
ⓘ For further information on welding, see Chapter
• Before performing welding work in the vicinity of the
3.9 Bolted and welded connections (→ page 46),
seat belts, airbag sensors or the airbag control unit,
Chapter 4.1.4 Parts which must not be welded
these components must be removed for the duration
(→ page 62), Chapter 6 Modifications to the
of the work. Important information about handling,
basic vehicle (→ page 92), 6.2 Body in white/
transporting, and storing airbag units is available
body (→ page 101) and the Mercedes-Benz Work-
under 6.4 Interior (→ page 138).
shop Information System (WIS).

5 Damage prevention
5.3 Anti-corrosion protection measures
Surface and anti-corrosion protection measures must Preventing contact corrosion by means of electrical
be carried out on the affected areas after modifications insulation
and installation work have been performed on the
vehicle.
⑴ NOTE
Only preservation agents tested and approved by
Mercedes-Benz may be used for any anti-corrosion
protection measures performed.
Planning measures
Anti-corrosion protection measures should be included
in the planning and design stages by selecting suitable
materials and designing components accordingly.
ⓘ A galvanic connection occurs if two different

metals are brought into contact with each other Preventing contact corrosion
through an electrolyte (e.g. air humidity). This
1 Insulating washer
causes electrochemical corrosion and the less
2 Insulating sleeve
noble of the two metals is damaged. The further
apart the two metals are in the electrochemical Contact corrosion can be prevented by using electrical
potential series, the more intense electrochemical insulation such as washers, sleeves or bushings.
corrosion becomes.
For this reason, electrochemical corrosion must be Avoid welding work on inaccessible cavities.
prevented by insulation or by treating the compo-
nent parts accordingly, or it can be minimized by Component design measures
selecting suitable materials. Corrosion can be prevented by design measures, in
particular the design of joints between different materi-
als or the same kind of materials:
There is a risk of dirt or moisture accumulating in cor-
ners, edges, creases and folds.
Design measures for counteracting corrosion can be
implemented using inclined surfaces and drains, and by
avoiding gaps in the joints between components.

5 Damage prevention
Gaps inherent in the design of weld joints and how

to avoid them
Examples of types of weld joints

A Correct (through-welded)
B Incorrect (gap)
Coating measures
The vehicle can be protected against corrosion by
applying protective coatings (e.g. galvanization, paint-
ing or zinc coating applied by flame) (→ page 88).
After all work on the vehicle:

• Remove drilling chips
• Deburr sharp edges
• Remove any burned paintwork and thoroughly pre-
pare surfaces for painting
• Prime and paint all unprotected parts
• Preserve cavities with wax preservative
• Carry out anti-corrosion protection measures on the
underbody and frame parts

5 Damage prevention
5.4 Painting work/preservation work
• Sensors of the Parking Packages (→ page 289)

⑴ NOTE
• Active Brake Assist/Active Distance Assist
For drying the paint, the object temperature must be (DISTRONIC-PLUS) (→ page 275)
maximum 60 °C/140 °F and the drying time must • Blind Spot Assist sensors (→ page 277)
be 30 min. Control units or other components can be
damaged at higher temperatures. • Parking Package with 360° camera/Parking Package
with reversing camera and sensors (→ page 289)
Painting or preservation damaged by the upfitter must ⓘ Additional information on paintwork and preserva-
be repaired by the upfitter. tion can be found at
Observe the following points: https://xentry.daimler.com
• Mercedes-Benz quality standards for initial painting
and repair paintwork must be adhered to.
⚠ WARNING
• Only materials tested and approved by
Mercedes-Benz or equivalently suitable materials Depending on the type and thickness, paints or films
may be used for any painting or preservation work can cause attenuation of radar waves. This could lead
performed. to malfunction or failure of the system and may even
• The upfitter must observe the coat thickness for cause the driver to lose control of the vehicle.
each individual coat as specified by the factory. There is a risk of accident, personal injuries, and
• Paint compatibility must be guaranteed when death if the system no longer functions correctly!
repainting.
In repair cases, the existing coat of paint must be
ⓘ You can obtain information on the paint materials removed in such a way that the plastic cover is not
and coat thicknesses used at the factory damaged and the material thickness of the cover is
and Mercedes-Benz paint numbers from any not significantly reduced. The new paint coat structure
Mercedes-Benz Service Center. must not exceed the following limits:
• A maximum of 2 color coats with a thickness of 15
μm plus 2 clearcoats may be applied.
Mask at least the following areas before painting:
• With metallic silver, only one coat with a thickness
• Disk brakes
of 15 μm plus one coat in white 15 μm thick are
• Brake hoses permissible.
• Transmission unit of the park brake • The material thickness must be homogeneous in
• Contact areas between disk wheels and wheel hubs order to prevent distortion of the radar waves.
• Contact surfaces of wheel nuts/wheel bolts • Specified thickness for unpainted covers: 2.42 mm
(0.095 in) front bumper/ 2.72 mm (0.107 in) rear
• Brake fluid reservoir
bumper, each +/-0.1 mm (0.004 in), without paint
• Breathers on transmissions, axles, etc.
• Specified thickness for painted covers: 2.42 mm
• Sealing surfaces (0.095 in) front bumper/ 2.72 mm (0.107 in) rear
• Windows bumper, each +0.1 mm/-0.2 mm (+0.004 in/ -0.008
in), without paint
• Door locks
• Door catches in the hinges of the hinged rear door
• Door catches and opening limiters in the center
guide rails
• Contact surfaces on the runner rails of sliding doors
• Moving parts of the sliding door carriage
• Airbags and seat belts

5 Damage prevention
⑴ NOTE
For the subsequent painting of sensors, particular
instructions in the relevant chapters on the sensors
concerned must be observed.
• Active Brake Assist/Active Distance Assist
(DISTRONIC PLUS) sensor (→ page 275)
• Blind Spot Assist/Rear Cross Traffic Alert (RCTA)
sensors (→ page 277)
• Parking Package with 360° camera/ Parking
Package with reversing camera and sensors
(→ page 289)
Sensors affected by paint

The “Parktronic”, “Collision Prevent Assist” and “Blind
N88.20-2183-00
Spot Assist” sensors are located inside and behind
Rear bumper sensors
the plastic bumpers of the vehicle. Modifications
to the bumper exterior surface must comply with 1 In case of a step at the rear bumper, the sensors of the
Mercedes-Benz standards. All integrated bumper Parking Package are located in the step
sensors must be accounted for and considered when
re-painting. Legend
Sensor Front Rear
bumper bumper
A Parking Package 6 6
B Active Brake Assist/ 1 0
Active Distance Assist
C Blind Spot Assist 0 2
Among other things, radar sensors are sensitive to:

• the thickness of the paint layers
• the relative permittivity of the paint
• the amount of conductive materials in the paint (e.g.
metals, graphite, etc.)
Available Codes:
• Code CM0: painted metallic front and rear bumper
N88.20-2182-00
• Code C72: bumper front/rear primed
Front bumper sensors
• Code CM9: primed side moldings
Recommended paint brands:
• Mercedes-Benz paints only
• USA: Glasurit, R-M, Standox, Spies Hecker, PPG
• Canada: Glasurit, R-M, Standox
Thickness limitation for metallic paint:
• max. 15 μm/5.9e-4 in of paint + 1 layer of clear coat
Thickness limitation non metallic paint:
• max. 15 μm/5.9e-4 in of paint + 2 layers of clear
coat

5 Damage prevention
Locations of the sensor affecting areas on the front bumper:
N88.20-2184-00
Front view
Locations of the sensor affecting areas on the rear bumper:
N88.20-2185-00
Side view

5 Damage prevention
5.5 Storing and handing over the vehicle
Storage
To prevent any damage while vehicles are in storage,
Mercedes-Benz recommends that they be serviced and
stored in accordance with the manufacturer's specifi-
cations (→ page 51).
Handover
To prevent damage to the vehicle or to repair any
existing damage, Mercedes-Benz recommends that the
vehicle be subjected to a full function check and
a complete visual inspection before it is handed over.

6 Modifications to the basic vehicle
6.1 Suspension
6.1.1 General information on the suspension

⚠ WARNING
No additional detachable parts may be mounted to the
Modifications to suspension system components can
bolted connection points on the front axle.
result in impaired and unstable vehicle handling char-
acteristics. This could cause the driver to lose control
of the vehicle.
death if such systems no longer function correctly!
For this reason, no modifications whatsoever may be
made to components of the suspension system.
Front axle
1 Bolting points on the front axle

Arrow Direction of travel

In the front axle area, the following should be noted:

⑴ NOTE
• Specifications for steering in Chapter 4.2.6 Modifica-
tions to the steering (→ page 71) must be com- In order to prevent tire wear, a change in the stan-
plied with. dard wheel alignment values (camber, toe-in) at the
front axle can be economical in the case of vehicles
• Front transverse control arms: Changes to wheel
with increased curb weight due to upfit or equipment.
alignment settings are not permitted.
The information under 3.5 Dimensions and weights
• The front axle must not be changed in any way or
(→ page 37) on the vehicle curb weight and
used to mount additional assemblies and other mod-
corresponding axle loads before and after body
ifications.
mounting work, "Checking wheel alignment" under
• Rigid rear axle: Modifications are not permitted. 3.11.3 Work before handing over the modified
• Brakes: Modifications are not permitted. vehicle (→ page 53), 3.12 Special equipment
(→ page 55) and under 8.4.9 Interface overview
• Devices, sensors, line installation for ESP®/ABS:
(→ page 248) must be complied with.
Modifications are not permitted.
Examples of this are recovery vehicles, fire-fighting
• New bolts must be used when installing the front
vehicles, ambulances, semi-trailer tractors, workshop
axle. All bolts and threaded connections are to be
vehicles or motorhomes. For a planned change in
tightened in accordance with the Mercedes-Benz
the standard wheel alignment values, consulting a
tightening instructions. Information on this is avail-
Mercedes-Benz partner is recommended. Based on
able from your Mercedes-Benz Service Center.
the exact axle load conditions of the complete vehi-
• VDI (The association of German Engineers) guideline cle, the Mercedes-Benz partner can determine the
2862, in particular the section entitled “Threaded ideal camber and toe-in values based on the work-
connections with special safety relevance”, must be shop documents stored in the Workshop Information
implemented for all installations. System (WIS) (→ page 18).
• Any shortening of the free grip lengths, conversion to The same applies to fully laden vehicles as it can be
a stretch shank or the use of bolts with a shorter free assumed that the maximum permissible axle loads
thread cannot be approved. are mainly marginally utilized here as well.
• The settling properties of threaded connections must
ⓘ Information is available from any Mercedes-Benz

Service Center.
Additionally clamped component parts must exhibit an
identical or higher strength than the previous clamped
assembly.
The use of Mercedes-Benz tightening torques assumes
coefficients of friction for the bolts in the tolerance
range [= 0.08-0.14].
We recommend the use of standard Mercedes-Benz
parts.

6.1.2 Springs/shock absorbers/stabilizer bars 6.1.3 Brake system
General ⚠ WARNING
Several suspension variants are available from ex Work carried out incorrectly on the brake lines or
factory. A suitable suspension variant must be selected brake hoses may impair their function. This may
depending on the planned body, see 4.2 Limit values lead to the failure of components or safety-relevant
for the suspension (→ page 68) component parts. This could cause the driver to lose
Modifications to springs, shock absorbers and stabilizer control of the vehicle. There is a risk of accident,
bars can only be made in the combinations specified by personal injuries and death if such systems no longer
Mercedes-Benz on the front and rear axle. Any modifi- function correctly!
cations over and above this must be evaluated by the Work on brake lines or brake hoses may only be car-
relevant specialist department in each individual case. ried out by an authorized specialist workshop.
Please reach out to the Upfitter Portal for more infor-
mation, refer to 1.7 Contact (→ page 11). After completion of the work, check that the brake
• We recommend the use of Mercedes-Benz genuine system is working correctly. We recommend that the
springs. brake system be inspected and approved by a technical
• Do not damage the surface or anti-corrosion protec- inspection station.
tion of the spring leaves during installation work. If the routing has to be altered, avoid routing across
• Before carrying out welding work, springs must be sharp edges and through narrow cavities or near mov-
covered to protect them against welding spatter. ing components.
• Do not touch springs with welding electrodes or Hydraulic brake system

welding tongs.
Hydraulic brake lines must be replaced with-
• For modifications to springs, shock absorbers and out additional connecting points using Mer-
stabilizers as a part of the Mercedes-Benz AG cedes-Benz-approved double-walled wrapped tubes
approved combinations on the front and rear axle of 4.75 mm x 0.7 mm/0.19 in x 0.03 in or fully
assembled brake lines with connecting parts (genu-
on vehicles with front radar sensor, code BA3/
ine Mercedes-Benz replacement parts).
ET4 – for more detailed explanation see Chapter
8.9.3 Active Brake Assist/Active Distance Assist Brake lines between the master brake cylinder and
the hydraulic assembly must not be modified.
(DISTRONIC PLUS) (→ page 275) – where applica-
ble, the installation height of the front radar sensor The bending radius must be >18 mm/0.71 in.
must be compared against and adapted to the value Lines must only be shaped in a bending machine.
entered there, depending on the type of modifica- The cross-section must not be reduced.
tion involved. A service calibration of the front radar Attach nuts (part no. 000 997 66 34)
sensor must also be performed, as this modification or retaining screws (genuine Mercedes-Benz
replacement parts) to the ends of lines and make a
also causes the driving axis to change.
flange.
The inside of the lines must be cleaned before
installation.
⚠ WARNING
The brake fluid must be renewed regularly in accor-
On no account should springs or shock absorbers be dance with the Mercedes-Benz specifications, but
used if they are not standard Mercedes-Benz parts. at least every two years. If necessary, renew the
brake fluid before delivery to the customer.
Otherwise, the ESP and suspension system may no
longer work correctly and could ultimately fail. This If the change interval of the brake fluid has
could cause the driver to lose control of the vehicle. been exceeded or if the age of the brake fluid is
unknown, the brake fluid must be replaced.
death if such systems no longer function correctly! For routing between two components which move
in relation to each other, a high-pressure-resistant
flexible line (brake hose, genuine Mercedes-Benz
brake components if possible) must be used. Make
sure that the flexible lines are not placed under
stress in any operating statuses and cannot chafe
against other components.

Installation of lines Disk brakes

Cooling must not be impaired by attaching spoilers
⚠ WARNING
below the bumper, additional wheel trims or brake disk
A sufficient distance must be maintained between covers, etc.
brake lines and heat sources, sharp-edged or moving For fully integrated bodies (7.14 Bodies on chassis with
parts. Otherwise the brake system function could be base (F28) (→ page 209), it must be ensured that the
impaired or the brake system could suffer total failure ventilation of the wheel wells, for cooling the brakes,
as a result of bubbles forming in the brake fluid or exists to the same extend as in a corresponding BM
from chafe marks in the brake lines. 907 cargo van.
This could cause the driver to lose control of the vehi-
cle. There is a risk of accident, personal injuries and ⚠ WARNING
death if such systems no longer function correctly! On no account should modifications be made to the
Work on brake lines may only be carried out by an air inflow and air outflow of the brake system. Any
authorized specialist workshop. modifications to the steering and the brake system
may result in these systems malfunctioning and
• We recommend the use of genuine Mercedes-Benz ultimately failing. This could cause the driver to lose
brake line brackets for the attachment of the brake control of the vehicle.
lines. There is a risk of accident, personal injuries and
• The distance from bracket to bracket may not exceed
a maximum of 500 mm/19.7 in. For this reason, make sure that there is a sufficient
supply of cooling air at all times.
The brake lines must be routed without kinks.
Routing lines along the brake hoses and brake lines ⚠ WARNING
No other lines may be attached to brake hoses and Any modifications to brake components may result
brake lines. in these systems not functioning correctly and
ultimately failing. This could cause the driver to lose
Brake cable for the parking brake/modifying the control of the vehicle.
length of the brake cable There is a risk of accident, personal injuries and
If a new brake cable is required for the parking death if such systems no longer function correctly!
brake, the new length of the cable must be deter-
mined and a suitable new cable must be procured. Modifications to brake system components are not
permitted.
The brake cable retainers are moment-optimized; modi-
fications are not permitted.
The brake cables must be routed without kinks.
There must be no angle changes at the end pieces of
the brake cable conduit.
No other lines may be attached to brake lines, other
than those installed as standard.

Trailer Brake Control Preparation

The brake signal from the trailer control module is not
directly hardwired to the 7-way trailer tow connector.
Instead, the brake signal circuit is routed to the green
4-pin connector (pin 3) and from there a separate wire
(pin 4) is routed to the trailer tow 7-way connector.
The green connector has power, ground, and brake
signal input and output. Use the green connector for
aftermarket trailer brake control.
⚠ WARNING
All cables for fitting a trailer brake controller should
be routed using the green connector only. Maximum
circuit warning may not be exceeded.
Pin Color Size Description

1 Red/Yellow 2.5 mm2/0.004 in2, max 18 A 12 V Positive fused via F55/6 (max. 30 A) on
position 30
2 Brown 2.5 mm2/0.004 in2, max 18 A Ground (via Seatbase)
3 Blue 0.75 mm2/0.001 in2, max 7 A Brake Signal from vehicle (via Trailer Control Unit
Code E40) Output Only
4 Blue 2.5 mm2/0.004 in2, max 18 A Signal to 7-pin Connector at Trailer Hitch
Trailer brake control preparation driver seat box

Crimp pins to your wiring harness and attach to the Figure Part Number Description
plug connector making sure that your wires match
1 A0395453528 Plug Connector 4-pin
the female connector pin layout as outlined:
2 A0355457428 Flag plug terminal (male)
1.5 mm2 – 2.5 mm2/
0.002 in2 – 0.004 in2
3 A0465454028 Flag plug terminal (male)
2 1 0.75 mm2 – 1.0 mm2/
0.001 in2 – 0.002 in2
4 3
N42.70-2022-00
Plug Connector (completed)
N42.70-2026-00
N42.70-2023-00
Electric Brakes
Fig. 1: Plug Connector housing
N42.70-2024-00
Fig. 2: Flag plug terminal
N42.70-2027-00
Front view and insertion end connectors
N42.70-2025-00
Fig. 3: Flag plug terminal

6.1.4 Air suspension 6.1.5 Wheels/tires

For latest information on Mercedes-Benz air suspen-
sion option, please refer to the most current Dealer ⓘ Only fit wheels or tires of a type and size approved
Ordering Guide (DOG). by Mercedes-Benz for your vehicle model and
observe the tire load capacity required for your
Please note that retrofitting an air suspension to the
vehicle and the tire speed rating.
front axle is not permitted due to potential impairment
to the front crash structure. In particular, comply with national regulations
concerning the approval of tires. These regulations
may define a specific type of tire for the vehicle or
⚠ WARNING may forbid the use of certain tire types which are
approved in other countries.
If attachments are fitted to the front part of the
frame, this modified crash structure may cause the If you have other wheels or tires (not approved by
airbag units to function incorrectly on vehicles with Mercedes-Benz) fitted,
this equipment. This applies in particular to the - wheel brakes and components of the suspension
retrofitting of air suspension to the front axle. For this system may be damaged
reason, air suspension must not be retrofitted to the
front axle. - wheel and tire clearance can no longer be guaran-
teed
⚠ WARNING - wheel brakes or components of the suspension

system may no longer function correctly
On no account should springs and shock absorbers
The upfitter must ensure that:
be used if they do not correspond to the characteris-
tics of standard parts, certified components or parts • there is always sufficient space between the tire
obtainable as special equipment. This applies in par- and the fender or wheel arch, even when snow
ticular to the retrofitting of air suspension systems. or anti-skid chains are fitted and the suspension
Otherwise, if the vehicle is fitted with ESP®, this is fully compressed (also allowing for axle twist)
system may no longer work correctly and could ulti- (→ page 114) and that the relevant data in the 2D
mately fail. This could cause the driver to lose control chassis drawings (offer drawings) (→ page 18) are
of the vehicle. There is a risk of accident! observed.
• only wheels and tires approved by Mercedes-Benz
are used (see vehicle registration document, 2D
chassis drawings (offer drawings) (→ page 70) or
the table below).
ⓘ More information about tires and wheels is avail-

able from any Mercedes-Benz Service Center or
under 3.12 Special equipment (→ page 55).

Tire sizes
Gross mass Equipment Tire size Weight and speed rating

Reference: 1500/2500 LT245/75 R16 120/116Q
2 LT245/75 R16 120/116Q
Reference: 3500/3500XD 1 (on front axle) 225/75 R16 C 121/120R (122L)
Super Single 1 (on rear axle) 285/65 R16 C 131R See note
1 (as spare wheel) 225/75 R16 C 121/120R (122L)
Reference: LT215/85 R16 115/112Q
3500/3500XD/4500 2 LT215/85 R16 115/112Q
1 With super single tires special equipment, code R9A

2 All-wheel drive and rough-road code Z12
C Commercial = lightweight truck tires
ⓘ We recommend that you stay within one wheel size

⑴ NOTE
group when changing tires.
We explicitly remind you that the use of appropriate
• This avoids the need to recode control units.
tire sizes only applies in the context of the weight and
• If you change the wheel size of your vehicle,
speed ratings approved and intended for these.
e.g. when changing wheels for winter operation,
please check their assignment to the wheel size
For more information on the wheel size groups group. If the assignment to the wheel size group
and recoding of control units, please refer to chapter changes, you must have the control units of your
3.8 Tires (→ page 45). vehicle recoded at a qualified specialist work-
The determined speed information of the vehicle is shop.
displayed in the instrument cluster and is important for • The display accuracy of the speedometer and
controlling the driving assistance systems. The display the odometer will otherwise be outside the
accuracy of the speedometer and the odometer is gov- legally prescribed tolerance. It can also deviate
erned by law. The determination of the speed informa- downwards, i.e. the current vehicle speed is then
tion depends on the tire size and the rolling circumfer- higher than the speed indicated by the speedom-
ence of the wheels and thus on their rim diameter. The eter.
rim diameter is always given in inches. • Driving assistance systems may be impaired in
their function in the event of a deviation outside
Therefore, the control units of the vehicle can be coded
the tolerance range or may detect a fault and
for the following wheel size groups:
shut down.
Wheel size group Tires BR 907
Wheel size group 1: 195/75 R16C
205/75 R16C
235/65 R16C
235/60 R17C
Wheel size group 2: 225/75 R16C
Wheel size group 3: 225/75 R16C FA
285/65 R16C RA
or
205/75 R16C FA
285/65 R16C RA
Wheel size group 4: 245/65 R17XL

6.1.6 Spare wheel

As standard, the Sprinter BM 907 is equipped with a
spare wheel and tire (code R87).
For dual rear wheel cab-chassis, a temporary mounting
of the spare wheel on the longitudinal frame member is
also available as a standard (code R60).
When mounting an aftermarket spare wheel, observe
the following:
• Fixing is only permitted to frame or structural com-
ponents with sufficient strength and rigidity.
• For mounting systems on the rear or roof of the
vehicle, the maximum permissible loads in Chap
ter 6.2 Body in white/body (→ page 101) must be
observed.
• Observe local and national requirements
• The spare wheel must be easily accessible and the
fastening mechanism must be easy to operate.
• The spare wheel must be secured twice against
falling off.
⑴ NOTE
The temporary attachment is not permitted for opera
tion of the vehicle on public roads, therefore the
upfitter is responsible for attaching the spare wheel in
a suitable, alternative position for this variant before
driving on public road. Ensuring road safety in all
operating situations of the vehicle is the responsibility
of the upfitter.
6.2 Body in white/body
6.2.1 General information on the body in white/ then additional roof bows must be fitted. The overall
body design of the side, front and rear roof structure must
be retained, and sufficient rigidity of the modified
Modifications to the body must not have a negative
parts must be guaranteed. 6.2.10 Cutting the cab
effect on the function nor on the strength of the vehicle
roof and B-pillar roof bow (→ page 123))
equipment, controls, or load-bearing parts.
• Modifications in the roof area and to the rear portal
When converting vehicles and mounting bodies, it is
are permitted only when adequate equivalent rigidity
not permissible to make modifications that affect
can be provided. Modifications in these areas must
the function or freedom of movement of chassis parts
be coordinated with Mercedes-Benz. Upon comple-
(e.g. during maintenance and inspection work) or
tion of all work on the vehicle, you must comply with
accessibility to these parts.
the specified anti-corrosion protection measures
Observe the following: (→ page 86).
• Wheelbase modifications are not permitted on all • Mounting consoles (plug welds) must be used to
Sprinter vehicles. attach additional equipment to the longitudinal
• The Tire Pressure Management System (TPMS) frame members and cross members. These require
may malfunction if modifications are made in the a review by Mercedes-Benz. Please reach out via
immediate vicinity of the antennas and wheels technical inquiry on www.UpfitterPortal.com.
(→ page 288). • Trailer connections must be checked for correct
• On no account should modifications be made to the operation.
structure of the longitudinal members and cross • If a trailer hitch is installed, the necessary reinforce-
members from the front to 1 m (3.28 ft) behind the ments must be present.
B-pillar because this can disrupt the structure neces-
• If bodies are mounted on basic vehicle “chas-
sary for passive safety. See Chapter 4.3.1 Modifica-
sis”, a fuel level sensor shield may be necessary
tions to the body in white(→ page 72).
depending on the body type see 6.3.1 Fuel system
(→ page 126).
⑴ NOTE
As part of the eXpertUpfitter program please refer to
Longitudinal frame members are crash-relevant www.UpfitterPortal.com.
structures.
If work is performed in these areas, the structure ⑴ NOTE
necessary for passive safety can be disrupted.
The factory-fitted wooden or plastic floors, including
Ex-factory holes on the longitudinal frame member the integrated tie-down eyes, represent a certified
are not suitable for securing attachments, bodies, as-built configuration in the cargo van.
equipment, and conversions; there is a risk of dam-
If the wooden or plastic floor is removed from these
age to the frame.
vehicles, it must be ensured that an equivalent substi-
tute is restored for securing loads in accordance with
• The clearance for the fuel filler neck, fuel tank and the international requirements of ISO 27956.
fuel lines must be maintained (→ page 126).
• Changes to the rigidity in the area of the filler neck
can result in leakage of the fuel tank after a crash.
• Avoid sharp-edged corners.
• It is not permissible to make cuts in the A-pillar or
B-pillar, including the associated roof bows.
• It is not permissible to make cuts in the C-pillar or
D-pillar, including the associated roof bows.
• If the roof skin and roof bows are removed and it is
not possible to install a continuous sectional frame,
Section dimensions of longitudinal frame members
Dimensions of the upper flange and lower flange
1 Upper flange
2 Lower flange
Permissible gross mass [t] a b c d e f

3500, 3500XD, 4500 3 mm/ 3 mm/ 70 mm/ 80 mm/ 120 mm/ 126 mm/
Chassis 0.12 in 0.12 in 2.76 in 3.15 in 4.72 in 4.96 in
1001 mm/
3.93 in
1500, 2500 - 1.5 mm/ 70 mm/ - 120 mm/ 93 mm/
Cargo van/passenger van 0.06 in 2.76 in 4.72 in 3.66 in
851 mm/
3.35 in
3500, 3500XD, 4500 - 3 mm/ 70 mm/ - 120 mm/ 118 mm/
Cargo van/passenger van 0.12 in 2.76 in 4.72 in 4.65 in
1001 mm/
3.93 in
1 In the area of the rear axle
1500, 2500 longitudinal frame member Welding work on the body in white
Welding work may only be performed by trained per-
h h1 h2 h sonnel.
ⓘ For additional information on welding work, see

Chapters 3 Planning of bodies (→ page 29),
5 Damage prevention (→ page 83) and 6.2.1
General information on the body in white/body
(→ page 101) and the Mercedes-Benz Workshop
N31.00-2174-00
Information System (WIS).
Dimensions of the lower flange of the longitudinal frame
member
⑴ NOTE
h 120 mm/4.72 in On no account should welding work be carried out

h1 85 mm/3.35 in on the upper and lower flanges of the chassis frame
h2 110 mm/4.33 in (including the front end longitudinal members).
Plug welding is only permissible in the vertical webs
3500, 3500XD, 4500 longitudinal frame member of the longitudinal frame member.
Do not perform any welding work in bends.
h h1
⚠ WARNING
Drilling or welding in the vicinity of the restraint sys-
tems (airbag or belts) can cause these systems to no
longer function correctly.
If restraint systems no longer function correctly, the
N31.00-2175-00
occupants may be unprotected in the event of an
Dimensions of the lower flange of the longitudinal frame accident. There is a risk of accident, personal injuries
member
and death if such restraint systems no longer func-
tion correctly!
h 120 mm/4.72 in Drilling or welding is therefore not permitted in the
h1 100 mm/3.94 in vicinity of the restraint systems.
The handling, transportation and storage of airbag units

are subject to the hazardous materials law regulated
by FMCSA under 49 CFR Part 173 in the US, and to
the Transportation of Dangerous Goods Act (Transport
Canada) in Canada.
Drilling work on the frame

⑴ NOTE
⑴ NOTE Upon completion of all work on the vehicle, you must
comply with the specified anti-corrosion protection
Existing holes in the longitudinal frame member
measures (→ page 86).
result from the production process and must not be
used. As part of the eXpertUpfitter program, possi- Drilling must not take place:
ble deviations can be evaluated with the responsible • On the upper and lower flanges of the frame
department. (except if drill holes are at the rear end of the
frame).
Drilling in the longitudinal member web is only possi- • Areas with a load-bearing function for the rear axle
ble in accordance with the following illustration and if or parts fastened to the frame
spacer bushings welded to the longitudinal member are • At load application points (e.g. spring brackets,
used. The attachment of implements and body parts holders etc.)
must be calculated according to their load. An evalu-
• Any weakening of the system is not permissible!
tion with the responsible department is necessary.
Drilling work on the longitudinal frame members (at the rear

end only)
1 Chassis frame
2 Spacer bushings
a Distance of at least 20% of the frame height
b Distance between drill holes at least 50 mm/1.97 in
After drilling holes, deburr and ream all holes.

Remove chips from the frame and apply cavity
sealant through the holes
Restore the anti-corrosion protection in accordance
with Mercedes‑Benz guidelines.
6.2.2 Attachment to the frame

⚠ WARNING
Drilling in the vicinity of the restraint systems (airbag Attachment to the front frame section
or belts) can cause these systems to no longer func- On no account should modifications (holes, cuts, etc.)
tion correctly. be made to the structure of the longitudinal members
If restraint systems no longer function correctly, the and crossmembers from the front through to 1 m/
occupants may be unprotected in the event of an 39.4 in" behind the B-pillar (see picture), or to the
accident. There is a risk of accident, personal injuries mountings of implements, brackets, components etc.
and death if such restraint systems no longer func- in the area of the front-end assembly and front axle,
tion correctly! because this can disrupt the structure necessary for
Drilling is therefore not permitted in the vicinity of the passive safety.
restraint systems.

are subject to the hazardous materials law regulated
by FMCSA under 49 CFR Part 173 in the US, and to
Canada) in Canada.
N31.00-2260-00
Longitudinal member and crossmember structure in the area

of the front-end assembly (viewed from below)
⚠ WARNING
If attachments are mounted on the front frame sec-
tion, the function of the forward crash structure and
the airbag units may be impaired.
Attachments are therefore only permitted to be
mounted on the front section of the frame after evalu-
ation with the responsible department.
⑴ NOTE
The modifications must not hinder possible repair
work on the standard vehicle.
Attachment to the rear frame section

The reinforcement of the trailer hitch (Q11) in the rear
longitudinal member on the left/right is available as
standard for model designation 907 and can not be
deleted.
If this special equipment is not included, attachment
of a trailer coupling is not permissible (see warning
notice).
The attachment of additional assemblies or bodies
to the rear frame section must be analogous to the
attachment of the trailer hitch available as special
equipment.
For the application of greater forces and moments, an
additional support on the end frame crossmember is
required.
Inside view of end crossmember on right longitudinal frame
member
a Attachment of mounting plate to longitudinal frame

member
b Lower flange of longitudinal frame member
c Frame end crossmember
d Mounting plate for trailer hitch
An evalution with the responsible department is neces-

sary. As part of the eXpertUpfitter program please refer
to www.UpfitterPortal.com.
Attachment by means of body consoles

All the factory-installed body consoles must be used
for attaching bodies to the vehicle frame. The bodies
must rest on the body consoles and may also rest on
End crossmember on longitudinal frame member (right) the longitudinal frame members.
Mercedes-Benz recommends that the body should not
a Attachment of mounting plate to longitudinal frame
member rest on the end crossmember. Additional information
b Lower flange of longitudinal frame member can be found under 7.1.4 Attachment to the chassis
c Frame end crossmember bed (→ page 183).
d Mounting plate for trailer hitch
⚠ WARNING
Risk of accident due to the unapproved attachment
of a trailer hitch!
If a trailer hitch is retrofitted and you attach a trailer
hitch or other components, the longitudinal frame
member will be weakened and can break. In this
case, the trailer can detach from the vehicle.
death as a result of the improper attachment of a
trailer hitch!
Only retrofit a trailer hitch if this is permissible.
6.2.3 Material for the chassis frame dimension and the distance of the rear end radar
from the rear axle must be entered in both rear
If the frame is extended, the material of the extension radars (BSM) by new SCN coding with O-codes.
element must have the same quality and dimensions
If the frame overhang is extended, the function of
as the standard chassis frame (only permissible in the the Trailer Stability Assist (TSA) and the permissible
underfloor area). towing capacity specified in the vehicle registration
document must be checked and, if necessary, be
⑴ NOTE reduced or even omitted, see 4.1.3 Vehicle dimen-
sions (→ page 59).
Lengthening in the area of the front-end assembly is On no account may the original positions of the
not permissible (impact load path)! radar sensors in the bumpers be changed. This
adjustment must be performed by a Mercedes-
Benz Service Center. More information is given in
Material Yield strength Tensile strength Chapter 8.9.4 Blind Spot Assist/Rear Cross Traffic
CR240LA 260-340 N/mm2 ≥ 240 N/mm2 Alert (RCTA)/Exit Warning (→ page 277).
37700-49300 psi ≥ 34800 psi The frame overhang must be reinforced accordingly.
S235JRG2 ≥ 235 N/mm2 340-510 N/mm2
Make sure that you do not exceed the permissible
≥ 34075 psi 49300-73950 psi
axle loads. Ensure that you maintain the position of
Material specifications should comply with the DIN the center of gravity within the permissible limits.
Standard MBN11251. After the upfit, the upfitter must determine the
vehicle's centers of gravity according to the
explanations in Chapter 9.1 Center of gravity
(→ page 309).
6.2.4 Overhang extension

• The minimum front axle load must be complied with
Modifications to the vehicle overhang are possible and in all load states (→ page 58).
must always take the permissible axle loads and the
minimum front axle load into account. You can obtain more information from the department
responsible 1.7 Contact (→ page 11).
For crew, passenger, and cargo vans, an overhang
extension is only permitted to upfitters in the eXpertUp-
fitter program for whom the possible deviations can be
evaluated by the responsible department.
Frame extensions are possible for cab-chassis when
the following requirements are met:
A frame extension with enforcement is to be exe-
cuted according to the following schematic diagram
Fastening (in X-direction) a frame extension to the
mounting brackets at the end of the frame is not
permitted.
It is recommended to select the following codes for
bodies when a frame extension is planned:
Frame end without mounting brackets, code Q74
Omission of end crossmember, code Q72
For frame extension of over 350 mm/14 in, an
additional crossmember must be installed.
Any additional frame crossmembers must have the
same functionality as standard crossmembers.
Standard body consoles must be used at the end of
the frame.
The interval between the body consoles must not
exceed 500 mm/20 in.
If the overhang is lengthened, the new overhang
Maximum overhang lengths

If you stay within the limits of the following overhang
lengths and the maximum rear axle load, the original
towing capacity still applies and ESP® operation is not
affected when the trailer coupling point is not relo-
cated. If the trailer coupling point is to be relocated,
Chapter 4.1.3 Vehicle dimensions (→ page 59) must
be observed.
Maximum overhang lengths

Wheelbase I Overhang length X
3665 mm/144 in 1850 mm/73 in
4325 mm/170 in 2200 mm/87 in
ⓘ The vehicle overhang length is part of the total N60.00-2215-00
overhang from the rear axle, including the frame Maximum overhang lengths (using a lifting work platform
overhang extension as well as the body and attach- as illustration)
ments. X Vehicle overhang
If the lateral protection needs to be repositioned due

to the overhang extension, the attachment must be
the same as that of the original vehicle (→ page 152).
The illustration depicts the implementation of a frame
extension for an overhang extension.
The effects on permissible towing capacity and
functioning of the Trailer Stability Assist (TSA) must
be checked; see Chapter 4.1.3 Vehicle dimensions
(→ page 59)
Frame extension with overhang extension
1 Chassis frame longitudinal member a Bore holes, 3665 mm/144 in wheelbase

2 Frame extension b Bore holes, 4325 mm/170 in wheelbase
3 Outer reinforcement c 350 mm/13.8 in (3665 mm/144 in wheelbase),
4 Inner reinforcement 300 mm/11.8 in (4325 mm/170 in wheelbase)
(wall thickness 11030 lbs: 3 mm/0.12 in) d Dimension defined by upfitter
5 Body support extension
6 Chassis frame extension ⑴ NOTE
(wall thickness 11030 lbs: 3 mm/0.12 in)
7 Reinforcement plate min. 2 mm/0.08 in Comply with all applicable FMVSS/CMVSS guidelines
8 Spacer bushing, tube 24 x 4 and regulations.
M steel or St 35 NBK
A longitudinal member reinforcement (see 7 and 8) is ⑴ NOTE

required when attachments are fitted (e.g. trailer cou Upon completion of all work on the vehicle, observe
pling or underride guard). the specified anti-corrosion protection measures
(→ page 86).
6.2.5 Modifications to the cab Changes to cab roof, general

For modifications on the cab, an evalution with the ⚠ WARNING
responsible department is necessary.
As part of the eXpertUpfitter program please refer to If aftermarket modifications are made to the head-
www.UpfitterPortal.com. liner or the roof panel between the A-pillar and the
B-pillar, the deployment of the window airbag may no
Rigidly installed equipment or conversions must satisfy
the requirements of legislation relating to head-on
impact as specified in FMVSS/CMVSS 201. If window airbags no longer function correctly, the
⚠ WARNING accident. There is a risk of accident, personal injuries
and death if such systems no longer function cor-
Modifications to the cab must not impair the function
rectly!
of any components relevant to safety (e.g. airbag
units, sensors, pedals, gearshift lever, lines or others). On no account should any subsequent modifications
This may lead to the failure of components or safe- be made to the headliner or the roof panel between
ty-relevant component parts. the A-pillar and the B-pillar if the vehicle is equipped
with window airbags.
Modifications to the cab roof (e.g. lowering the roof
height) may only be undertaken after consulting the
⑴ NOTE
department responsible 1.7 Contact (→ page 11)
If the fuel filler cap is removed or parts are attached or as described under 6.2.10 Cutting the cab roof and
to the fuel filler cap, blocking may occur in the event B-pillar roof bow (→ page 123).
of an accident. Because of this, the protrusion space Plastic roofs are suitable for the installation of roof
in the B-pillar may no longer function correctly. On hatches only to a limited extent.
no account should the cap be covered with paneling
parts, and "blocking" parts must never be mounted The roof load-bearing capacity is limited (→ page 73).
on the B-pillar.
⑴ NOTE
The strength and rigidity of the cab structure must not Roof bows or supporting parts may not be removed
be impaired. or modified without being replaced.
The intake of air into the engine must not be hindered.

Modifications to the cab will cause a change in the cen-
ⓘ You will find information on over-cab attachments
ter of gravity. The permissible center of gravity limits
and wind deflectors in the chapter "Attachments"
and axle loads must be maintained.
(→ page 157).
⑴ NOTE Observe the permissible center of gravity; the permissi-

ble axle loads must be maintained.
Upon completion of all work on the vehicle, you must
Modifying the cab rear panel Windows

If it is necessary to cut through the cab rear panel, it Windows must be inserted with a stable frame.
is possible to do this in connection with a continuous The frame must then be joined by a non-positive
surrounding frame. The equivalent rigidity of the frame attachment to other body elements.
must be at least equal to the original rigidity. If modifications need to be carried out to the
Partitions may be totally or partially removed. Also supporting structure of the basic vehicle (pillars,
reinforcements, attachment of roof bows) in order
observe 7.4 Modifications to closed cargo vans to retrofit windows (panoramic glazing), the rigidity
(→ page 192). of the modified body must be equal to that of the
The statutory standards (ISO, etc.) and the relevant basic vehicle.
licensing regulations must be complied with. If the upfitter installs window panes on his or her own,
the code W94 "Window openings without glass " can be
⚠ WARNING used.
If aftermarket modifications are made to the head- Laminated glass is regulated under FMVSS/
liner or the roof panel between the A-pillar and the CMVSS 205 Glazing Materials.
longer function correctly. ⓘ Additional information on modifications to the side
If window airbags no longer function correctly, the wall can be found under 6.6.4 Shelf systems/vehi-
occupants may be unprotected in the event of an cle interior installations (→ page 158).
and death if such systems no longer function cor- ⑴ NOTE
rectly!
It is not permissible to install panoramic glazing on a
On no account should any subsequent modifications cargo van basic vehicle by cutting out the stamped
be made to the headliner or the roof panel between window shape without ensuring equivalent rigidity.
the A-pillar and the B-pillar if the vehicle is equipped Otherwise there is a risk of damage to the side wall.
6.2.6 Side wall, windows, doors and flaps
Side wall
If modifications are made to the side wall of the cargo
van or the passenger van, the rigidity of the modified
body must be equal to that of the basic vehicle.
The front of the roof frame, the roof bow at the B-pillar,
and the A-pillar and the B-pillar themselves must be
retained and their function may not be impaired in any
way.
Refer to 8.9.2 Crosswind Assist (→ page 273) for
⑴ NOTE
Doors and flaps

If modifications need to be carried out to the support-
ing structure of the basic vehicle (frame crossmem-
bers, pillars, reinforcements, attachment of roof bows)
in order to retrofit doors, the rigidity of the modified
body must be equal to that of the basic vehicle.
The upfitter must comply with all applicable FMVSS/
CMVSS and warranty responsibility for those modifica-
tions. The rigidity of the modified body must be equal
to that of the basic vehicle.
The trigger sensor of the occupant protection systems
Example for cargo van/passenger van side wall body in white
is located in the door body on vehicles with window
structure and glass area
airbags or thorax/pelvis side airbags. On no account
should modifications be made to the door body (see
ⓘ For modifications which involve cutting out the illustration).
stamped window shape and adding reinforcements,
an evalution with the responsible department is
necessary. As part of the eXpertUpfitter program
please refer to www.UpfitterPortal.com.
ⓘ A design proposal with reinforcement measures

can be provided by the department responsible 1
1.7 Contact (→ page 11).
Please also observe 7.4 Modifications to closed
cargo vans (→ page 192).
If the upfitter is going to install its own windows in the
hinged rear doors, the following should be noted in
N91.60-2202-00
connection with code W78 "Windshield wiper on hinged
rear door": Door body with sensor system
• To guarantee proper functioning of the rear window 1 Pressure sensor

wipers, the geometry of the windows supplied by the (trigger sensor of the occupant protection systems)
upfitter must match that of the windows available as
standard equipment. Seats in the living and passenger compartment must
be directly accessible from the outside by a door or
• The wiper blades of the rear window wipers must
from the cab.
make contact with the windows across the entire
swept area. It must be possible to open locked doors quickly and
easily from the inside.
• The rear windows must be 3 mm/0.1 in thick.
The doors must open wide enough and the door
• The rear windows must not protrude above the door
entrances must be shaped in such a way as to enable
paneling.
persons to get in and out of the vehicle safely and
comfortably.
The maximum permitted height of the bottom step • Laminated glass (code W17+F43): 15.43 lbs./ 7 kg
above the roadway is 400 mm/15.75 in. • Sliding window in side wall (code W18):
Installations must allow a sufficient clearance from the 14.33 lbs./ 6.5 kg
inside handles in all positions (anti-pinch protection). • Luxury door trim (code V21): 4.41 lbs./ 2 kg
Upon completion of all work on the vehicle, you must (only for RWD A2LH2 RE)
comply with the specified anti-corrosion protection • Speakers (code EL9): 4.41 lbs./ 2 kg
Hinged rear doors
⑴ NOTE
The system for the hinged rear doors was designed for
For all versions of vehicle doors (front doors, sliding a maximum weight of 83.78 lbs./ 38 kg per hinged
doors, hinged rear doors), modifications to the lock- rear door, and this must not be exceeded due to modi-
ing system, in the immediate vicinity of the door and fications.
in the area of pillars/crossmembers must be avoided. The ex-factory weight of the hinged rear door for each
The attachment of additional mechanical locks (e.g. vehicle model and roof height is listed in the table. The
latch locks/"slam-locks") is not permitted. delta weight, including special equipment, corresponds
to the maximum permissible additional weight on the
hinged rear door.
Sliding door to load compartment
The system for the load compartment sliding door was Maximum permissible additional weight
designed for a maximum door weight of 143.3 lbs./ (total weight of rear doors - basic equipment = additional
65 kg. Modifications must not cause this weight to be weight)
exceeded. Roof Hinged rear door
height Left [lbs], [kg] Right [lbs], [kg]
The ex-factory weight of the load compartment sliding
LH1 83.78 - 60.63 = 23.15, 83.78 - 57.32 = 26.46,
door for each vehicle model and wheelbase is listed 38 - 27.5 = 10.5 38 - 26 = 12
in the table. The delta corresponds to the maximum LH2 83.78 - 66.14 = 17.64, 83.78 - 61.73 = 22.05,
permissible additional weight on the sliding door to the 38 - 30 = 8 38 - 28 = 10
load compartment.
For the special equipment items with the codes listed
Maximum permissible additional weight below, the following weights must be added to the
(total weight of load compartment sliding door - basic
basic equipment (see table).
equipment = additional weight)
Roof height If items of equipment are removed, they must be taken
LH1 143.30 - 108.03 = 35.27 lbs, into account in the weight calculation.
65 - 49 = 16 kg
• Window (code W61/W78): 4.41 lbs./ 2 kg
LH2 143.30 - 119.05 = 24.25 lbs,
65 - 54 = 11 kg • Luxury interior trim (code V21): 3.31 lbs./ 1.5 kg
• Window washer system (code W78): 2.20 lbs./ 1 kg
For the special equipment items with the codes listed
below, the following weights must be added to the
basic equipment (see table).
If items of equipment are removed, they must be taken
into account in the weight calculation.
• Electric closing assist (code T50/T51): 6.61 lbs./ 3 kg
• Electric operation (code T55/T56): 13.23 lbs./ 6 kg
(including code T50/T51)
• Window at front of sliding door (code W17):
8.82 lbs./ 4 kg
⚠ WARNING
Modifications to
• door kinematics
• guidance systems (rails, sliding carriages etc.)
• locking systems (closing assists, anti-entrapment
strips, locks, arresters etc.)
• end stop systems (buffers etc.)
• bodyshell structure
may result in the door opening unintentionally.
There is a risk of accident!
No modifications may be made to any of these sys- Rear door opening
tems.
1 Non modifying areas
Furthermore, care must be taken to ensure an extensive
connection and CoG distribution at the doors.
6.2.7 Fenders and wheel wells
The upfitter is responsible for his/her conversions and
Ensure that there is sufficient space between the
modifications on the vehicle.
tire and the fender or wheel well even with snow or
anti-skid chains fitted and the suspension completely
⑴ NOTE compressed (allowing for axle twist). Pay attention to
the dimensional data in the 2D chassis drawings (offer
When selecting a carrier system for bicycles or other drawings).
transported items on the rear end, observe the spec-
ified restrictions on additional masses on the hinged ⚠ WARNING
rear doors. The mass of the carrier system including
the transported items, e.g. bicycles, must be taken If modifications are made to the mountings of seats
into account. on the wheel well or to lowered wheel wells, the vehi-
cle (e.g. the wheel well and tires) could be damaged.
If the additional mass restriction cannot be complied There is a risk of accident, personal injuries and
with, it is recommended to use a suitable carrier death if such systems no longer function correctly!
system supported by or attached to the ball head of
the trailer coupling. On no account may seats be mounted on the wheel
well.
Rear portal
Any modifications to the rear door opening including comply with the specified anti-corrosion protection
the roof area are only permitted in exceptional cases measures (→ page 86).
and an UIS must be requested online via the Upfitter
Portal (→ page 18). Reductions in the width of the wheel wells are not
permitted.
Rear door opening and roof area

Do not modify the rear door opening including the roof
area.
Wheel wells (side wall and substructure scope) ⓘ The minimum distance of the wheel well is mea-
It is possible to lower the wheel wells as long as the sured from the floor of the cargo van to the lowest
following preconditions and limit values are complied point of the wheel well contour. More information
with: can be found under "Modifications to the basic
vehicle" (→ page 114).
• No components or sharp edges (e.g. folded seams or
edges) may protrude into the wheel well.
• The maximum permitted lowering dimension may not
be exceeded by any component in the wheel well.
• Unrestricted use of snow chains is not possible: The
entry "Use of snow chains subject to limitations"
must be entered in the vehicle documents.
Wheel well lowering/clearance requirement
1
a
N40.10-2299-00
Clearance requirement
1 Contour of standard cargo van wheel well

a Clearance requirement
If the clearance is inadequate, the fitting of snow and

anti-skid chains is prohibited.
Permissible gross mass Tires Dimension a

Reference: 1500/2500 LT245/75 R16 120/116Q 260 mm/10.24 in
(single)
Reference: 3500, 3500XD 285/65 R16 131R 260 mm/10.24 in
(super single)
Reference: 3500, 3500XD/4500 LT215/85 R16 115/112Q 210 mm/8.23 in
(twin tires)
Reference: 1500/2500 LT245/75 R16 120/116Q 200 mm/7.87 in
(all-wheel drive)
Reference: 3500, 3500XD/4500 LT215/85 R16 115/112Q 190 mm/7.48 in
(all-wheel drive)
Wheel well of upfitter (chassis)

The following limit values must be complied with for the
design of wheel wells on chassis (e.g. for box bodies)
by the upfitter:
• No components or sharp edges (e.g. folded seams or
edges) may protrude into the wheel well.
Y1 Y2
5 t vehicle frame with taper
Limit values for chassis wheel wells
• The maximum permitted lowering dimension may not

be exceeded by any component in the wheel well.
• Unrestricted use of snow chains is not possible: The
entry "Use of snow chains subject to limitations"
must be entered in the vehicle documents.
The diagram below shows the reference edges for the

dimensions Y1 and Y2 on vehicles with tapering frame
section (twin tires).
Limit values for the vehicle frame (RWD)

Permissible Tires Dimensions [mm], [in]
gross mass [t] X1 X2 Y1 Y22) A3)
4.6 285/65 R16 C 445, 17.52 445, 17.52 245, 9.65 635, 25 260, 10.24
4.6 - 5.01) 2 x 195/75 R16 C 405, 15.94 405, 15.94 120, 4.72 630, 24.80 240, 9.45
2 x 205/75 R16 C 410, 16.14 410, 16.14 115, 4.53 635, 25 250, 9.84
5.0 (all-wheel 2 x 205/75 R16 C 410, 16.14 410, 16.14 115, 4.53 638, 25.12 205, 8.07
drive)1)
5.51) 2 x 205/75 R16 C 410, 16.14 410, 16.14 115, 4.53 635, 25 250, 9.84
1) On vehicles with twin tires, the inside of the inner wheel

was used for Y1 and the outside of the outer wheel for
Y2.
2) With maximum wheel well trim to wheel center
3) Minimum distance from frame flange to wheel well
contour
The minimum distance A of the wheel well is measured

from the flange between the upper and lower flanges of
the longitudinal frame member up to the lowest point
of the wheel well contour.
The dimensions Y1 and Y2 are measured from the outer
edge of the frame flange on the longitudinal frame
member.
ⓘ For more information on tires, see Chapter 4.2.3

Approved tire sizes (→ page 70)
ⓘ More information can be found under "Modifica-

tions to the basic vehicle" (→ page 114).
6.2.8 Frame end crossmember 6.2.9 Cargo Van/Passenger Van roof

If special bodies are mounted, the end panel cross- If modifications are made to the roof structure of Cargo
member acting as a rear underrun may be omitted at Vans/Passenger Vans, the following points must be
the factory (code Q72) (→ page 157). observed:
You will find more information on the underrun • If the roof skin and roof bows are removed and if no
protection in the chapter 6.6.2 Attachment above cab continuous sectional frame is possible, additional
(→ page 157) roof bows must be fitted. The overall design must be
retained, and sufficient rigidity of the modified parts
⑴ NOTE must be guaranteed.
Upon completion of all work on the vehicle, you must • In order to prevent function impairments, the body
comply with the specified anti-corrosion protection limits for camera-based support systems must be
measures (→ page 86). observed; see 8.9.5 Highbeam Assist, Lane Keeping
Assist and traffic sign recognition (→ page 286)
and 8.9.6 Rain sensor and Headlamp Assist
Comply with all applicable FMVSS/CMVSS guidelines (→ page 286).
and regulations.
• Refer to 8.9.2 Crosswind Assist (→ page 273) for
• Observe the limit values for the suspension
(→ page 68).
⑴ NOTE
The rigidity of the new roof structure must be equal
to that of the original standard roof.
rear portal including the roof area.
Attachment to the roof Roof height increase

Securing elements similar to roof racks are possible for Any modifications to the rear door opening including
retrofitting attachments (→ page 158). the roof area are only permitted in exceptional cases
For attachments to the roof skin and to roof bows, an and an evalution with the responsible department
evalution with the responsible department is necessary. is necessary. As part of the eXpertUpfitter program
As part of the eXpertUpfitter program please refer to please refer to www.UpfitterPortal.com.
www.UpfitterPortal.com. The rigidity of the new roof structure must be equal to
that of the original standard roof.
⚠ WARNING
Number of roof bows
If aftermarket modifications are made to the head-
liner or the roof panel between the A-pillar and the
Wheelbase Quantity required
3665 mm/144 in ≥ 5 bows
4325 mm/170 in ≥ 6 bows
If window airbags no longer function correctly, the
accident. There is a risk of accident, personal injuries Location of roof bows
rectly!
On no account should any subsequent modifications
be made to the headliner or the roof panel between
the A-pillar and the B-pillar if the vehicle is equipped
Cutouts in the roof

Cutouts in the roof are permissible when the following
specifications are observed: Cargo van roof bows
• A distance of at least 0.8 in (20 mm) must be main-
tained between structural components of the roof
(roof bows, side wall attachment) and the cut out.
• The roof structure may only be modified in accor-
dance with the above-mentioned specifications.
• The corners of the roof cutout must have a radius
of at least 75 mm.
• In the case of plastic roofs, particular attention must
be paid to the material properties due to possible
susceptibility to cracking.
• All edges must be deburred and sealed with anti-
corrosion protection.
• For deviating designs, an evalution with the
responsible department is necessary. As part of
the eXpertUpfitter program please refer to
• For cutouts in the cab roof, the specifications in
Chapter 6.2.10 Cutting the cab roof and B-pillar roof
bow (→ page 123) must be observed.
The maximum roof load of the high panel roof is

⑴ NOTE
150 kg/331 lbs if the load is evenly distributed over
The bows must be secured to the side walls in such the entire roof surface (→ page 158).
a way that a non-positive connection is guaranteed
(bend-resistant connection of bow and roof frame). ⚠ WARNING
If the maximum permissible center of gravity is
The roof bows must be reinforced in the event of any exceeded on vehicles with ESP®, this system may no
increase in the height of the roof. longer work correctly and could ultimately fail. This
could cause the driver to lose control of the vehicle.
The minimum moment of inertia required Ix per roof There is a risk of accident, personal injuries and
bow can be seen in the table below: death if such systems no longer function correctly!
Roof height increase Moment of inertia Ix per bow Make sure that the permissible height for the center
250/10 in ≥ 40,000 mm4/0.09 in4 of gravity is not exceeded.
400/16 in ≥ 65,000 mm4/0.15 in4
550/22 in ≥ 86,000 mm4/0.20 in4 Refer to 8.9.2 Crosswind Assist (→ page 273) for
modifications on the projected lateral face (increase in
If the roof height is either reduced or not modified, a the height of the roof).
minimum required moment of inertia per roof bow of
Ix = 33000 mm4 /0.08 in4 must be maintained.
60
57,5
55
52,5
H 50 20 mm 20 mm
[mm] 0.8 in 0.8 in
47,5
45
42,5
40
H
37,5 s
35
32,5 1 23 4 5
30
B
30000
35000
40000
45000
50000
55000
60000
65000
70000
75000
80000
85000
90000
95000
100000
I x [mm4]
N65.20-2101-00
Required moments of inertia for roof bows with 20 mm/0.8 in flange with the roof skin
1 B: 50 x s: 0.8
2 B: 40 x s: 1.0
3 B: 50 x s: 1.0
4 B: 60 x s: 1.0
5 B: 50 x s: 1.2
Retrofitting a lifting roof

⑴ NOTE
⚠ WARNING Roof bows or supporting parts may not be removed
If aftermarket modifications are made to the head- or damaged without being replaced (→ page 123).
liner or the roof panel between the A-pillar and the
longer function correctly. Maximum roof loads
If window airbags and thorax/pelvis side airbags Cargo van High-roof cargo van Cab
no longer function correctly, the occupants may be LH1 LH2
unprotected in the event of an accident. There is a 300 kg/661 lbs 150 kg/330 lbs 100 kg/220 lbs
risk of accident, personal injuries and death if such
systems no longer function correctly! The limit value of the vehicle's maximum center of
On no account should any subsequent modifications gravity must not be exceeded.
be made to the headliner or the roof panel between
the A-pillar and the B-pillar if the vehicle is equipped
The following points must be observed for the installa

tion of roof hatches/lifting roofs:
• The specifications regarding cutouts in the roof and
changes to the roof structure must be observed.
• Roof hatches should be positioned as centrally as
possible (symmetrically to the longitudinal axis of the
vehicle).
• The roof load limit values given below must be com
plied with, see table.
• Plastic roofs are suitable for the installation of roof
hatches only to a limited extent. The roof hatch
must be glued over the entire surface in the area of
the overlap to stiffen the roof section. The compo-
nent weight must not exceed 8 kg or 17.64 lbs. It
is recommended to use a suitable solution from the
camper van sector.
• If a lifting roof is fitted, at least 2/3 of the original
roof area must be retained.
• A seal between the installation and the roof surface
against water and dust ingress must be provided.
For any deviations to above points, an evalution with
the responsible department is necessary. As part of
the eXpertUpfitter program please refer to
Retrofitting of roof hatch To insert a roof hatch, it might be necessary to have a

If the GVWR of a bus exceeds 10,000 lbs, a roof hatch cutout in the roof (skin and arch) of the van.
installed with proper roof frame reinforcement is If you are cutting the roof, ensure corrosion protection.
required by FMVSS/CMVSS 217. 5.3 Anti-corrosion protection measures (→ page 86)
The roof is part of the body which forms a self-support- Reinforce the remaining body and consider the extra
ing unit. weight of the added parts to ensure a stable structure.
N65.00-2089-00
Roof hatch
Reinforcement brackets (1) must be installed at

both ends of the arches which are located next to
the cutout (see “Stress lines”).
Corner braces (3) connected to the arches next to
the cutout must be installed.
The sturdy frame (2) must be integrated without
deforming the arches next to the cutout. Avoid
tension or pressure.
Ensure sealing.
6.2.10 Cutting the cab roof and B-pillar roof bow Equivalent rigidity when cutting B-pillar roof bow
For semi-integrated bodies, e.g. RVs or integral box For the following variants, an evalution with the respon-
bodies, the cab roof including B-pillar roof bow can be sible department is necessary.
cut out in the indicated area (see illustration) where As part of the eXpertUpfitter program please refer to
necessary: www.UpfitterPortal.com.
Variant 1: Sandwich construction/wooden board

When the B-pillar roof bow is cut, the equivalent rigidity
requirements can be met by means of a wooden
board or sandwich construction bonded to the basic
vehicle over its entire surface (e.g. with Sikaflex 221).
The arched roof contour must be adapted to form
24 in
610 mm
a non-positive fit with the sandwich construction or

wooden board by means of an auxiliary construction.
Required bending resistance of sandwich construc-

1270 mm tion/wooden board
50 in y-axis El2 = 7 x 108 N/mm²; 1015 x 108 psi
N60.80-2473-00 z-axis El1 = 2 x 1011 N/mm²; 290 x 1011 psi
Permissible roof cut
⑴ NOTE
When cutting the B-pillar roof bow, it is essential to m
0m n
35 3.8 i
ensure equivalent rigidity in one of the ways listed 1
below. mm
70 0 in
12 5
For alternative methods of ensuring equivalent rigidity m

0m n
developed by the upfitter, an evalution with the 35 3.8 i
1
responsible department is necessary. As part of the N60.80-2474-00.

eXpertUpfitter program please refer to Simulating structure (sandwich construction/wooden board)
www.UpfitterPortal.com. bonded to cut roof structure over entire surface
Material characteristics
Sandwich construction Wooden board
Structure: Structure:
2.0 mm/0.08 in GRP 20.0 mm/0.8 in wood
26.0 mm/1 in foam
2.0 mm/0.08 in GRP
EGRP = 12000 N/mm²; EWood = 3000 N/mm²
1740000 psi 435000 psi
EFoam = 80 N/mm²;
11600 psi
Variant 2: Welded structure under cab roof

When the B-pillar roof bow is cut, the equivalent rigidity
requirements can be met by means of a welded struc-
ture installed in the basic vehicle under the cut cab
roof.
Required bending resistance for welded structures

y-axis El2 = 8.35 x 109 N/mm²
1.21 x 1012 psi
z-axis El1 = 2.36 x 1011 N/mm² Welded structure
3.42 x 1013 psi
4325 mm/170.3 in ≥ 6 bows 1 Plug weld
2 Overlap seam
3 Rectangular profile
4 End plate
Welded structure
1 Roof paneling
2 Rectangular profile
Material characteristics of subframe

Material At least DC01 or S235JRG2
Height 20 mm/0.8 in
Width 100 mm/3.9 in
Wall thickness 1.5 mm/0.06 in
E 210000 N/mm²; 3.045 x 107 psi
50 mm 100 mm
2.0 in 3.9 in
12 mm 20 mm
0.5 in 0.8 in
N60.80-2475-00
Cross-section of welded structure
1 Fillet weld 4 Plug weld

2 Rectangular profile (2 mm/0.08 in wall thickness) 5 End plate
3 Overlap seam
6.3 Engine peripherals/drivetrain
• If the box bodies are mounted on cab-chassis, a fuel

⑴ NOTE level sensor shield is necessary when the fuel level
Maintenance and repair of the vehicle must not be sensor is not protected by the box body. Fuel level
hindered by the body (→ page 51). sensor shield with part number A906 471 00 87 is
available. It is installed by means of the standard
weld screws with two M6-8 nut-and-washer assem-
blies (MBN10104).
Modifications to the engine timing/performance
enhancement
⑴ NOTE
⑴ NOTE If box bodies are mounted on the cab-chassis, the
fuel level sensor may have to be protected against
Any interference in the engine timing by customer
any falling cargo, depending on the box type. Oth-
and upfitter is not permitted.
erwise damage could occur, rendering the vehicle
Manipulations or modifications to the engine timing inoperative.
cause changes in the certified engine data and emis-
sion values and thus result in the immediate invalida-
tion of the operating permit.
6.3.1 Fuel system
General
Modifications to the fuel system may only be carried
out with the approval of the department responsible
1.7 Contact (→ page 11).
⚠ WARNING Fuel level sensor shield
Fuels are highly flammable. There is a risk of fire and

explosion if fuels are improperly handled!
Avoid all fire, open flames, smoking and sparks.
⑴ NOTE
Non-approved modifications to the fuel system (fuel
tank, lines, etc.) may lead to impaired performance
and engine limp-home mode.
N47.50-2008-00
Note the following when working on the fuel system: Fuel level sensor shield
• The attachment of heat-conducting components or

components which restrict installation space is not
permitted.
• Modifications to the fuel pump, fuel line length and
fuel line routing are not permitted. Any changes here
to components that are matched to each other may
impair engine operation.
• Modifications and attachments (e.g. additional eye-
lets) are not permitted in the vicinity of the fuel filler
neck in the area of the B-pillar.
Protection of the fuel system
⑴ NOTE
On no account may any load be placed on the fuel
tank, for example by using it as a step.
In the case of cab-chassis, it is necessary to protect
the system components on the top of the fuel tank
(fill level sensor and vent valve) from falling cargo or
objects as shown in the schematic diagram below.
Without such protection in the area illustrated, these
system components and the fuel tank can be dam-
aged, rendering the vehicle unusable. Position of fuel filter on OM654 engine (schematic, rear
wheel drive)
The planning and execution of the protection, taking
into account the specific body, are the duty of the 1 Fuel filter for OM654
upfitter and are his or her sole responsibility. Arrow Direction of travel
⑴ NOTE
Operation of additional external consumers
Any unapproved modifications to the fuel filter and
hindrance to the access of fuel filter may lead to func-
tional impairments or to component failure, and conse-
quently to the engine running in limp-home mode.
Fuel-powered heater booster

The following must be observed if fuel-powered heater
Protection of the fuel system boosters are retrofitted:
• No sharp edges permitted
Fuel filter
• The fuel tank must not be subjected to load in the
With the introduction of the new engine OM654, the event of an impact. Deflection plates must be fitted if
fuel filter for this vehicle configuration is now located necessary
at a new position in the substructure, in the direction
• Fuel lines must be designed safely
of travel, upstream of the fuel tank (see figure). The
position differs for the vehicles with rear wheel drive • Exhaust gases must not be directed into the vehicle
and with all-wheel drive in the x-direction. interior
For the previous engines OM651/OM642, the position When connecting the fuel supply for auxiliary heating,
of the fuel filter in the engine compartment remains the type approval procedure must be followed.
unchanged.
Connection of heater booster (code KL1)
More detailed information on the position and com-
ponent geometry will be available as CAD data to the Code KL1 is available as special equipment and con-
eXpertUpfitters on the Upfitter Portal. sists of the following components:
No modifications may be made to the fuel filter, its • 1 ea. transport protection with connector coupling
position and mounting, and the related detachable • 1 ea. auxiliary heater line
parts. Accessibility to the fuel filter for service and
This code is only available for Diesel engines.
repair work should be assured, and it should not be
hindered by any aftermarket detachable parts.
A fuel tap is standard equipment on Diesel engines.

⑴ NOTE
This fuel tap prevents the fuel tank from running empty.
Operation of additional external consumers
KL1 Auxiliary Diesel Fuel Tap (standard)
When the fuel level is at the reserve level, do not
tap fuel from externally operated consumers via the The fuel gauge sensor is fitted with an additional fuel
auxiliary heater line. connection to facilitate retrofitting of a fuel-powered
auxiliary heater. The fuel tank can be consumed down
to approximately 5 gallons.
⑴ NOTE
The picture shows a cap which can be removed. The
Tank fill level indicator connector piece is ø 7.89 mm/0.31in. Aftermarket
Modifications to the fuel tank are not permitted. If the quick connects have to be compatible with SAEJ2044
upfitter installs a tank of a different size, the fill level specified tube end forms.
will no longer be displayed correctly on the instru-
ment cluster.
When using externally operated consumers via the
auxiliary heater line in vehicles with code J51 "Fuel
gauge, adapted for additional fuel tapping", the indi-
cated range remaining varies from the series produc-
tion configuration.
ENVIRONMENTAL NOTE
Modifications carried out incorrectly to the fuel
system may have a detrimental effect on the environ-
ment. N47.00-2059-00
View from underneath without a fuel fired heater
N47.00-2060-00
Top view showing a fuel pump unit on a chassis cab
ENVIRONMENTAL NOTE
Modifications carried out incorrectly to the fuel
system may have a detrimental effect on the environ-
ment.
The male connector piece which is coming with KL1 is shown in detail below. The measurements are shown in metric (mm).
Male connector piece drawing
For connecting an aftermarket fuel line the upfitter can order the female connector from the supplier Rayconnect Incorporated
(https://catalog.araymond-automotive.com).
Female connector drawing
Example for a female connector for KL1
6.3.2 SCR system AdBlue®/DEF tank

The SCR system (Selective Catalytic Reduction, code The AdBlue®/DEF tank system is part of the SCR
KP6) is related to emission and certification. The SCR exhaust gas aftertreatment system.
system is an exhaust gas aftertreatment system which The AdBlue®/DEF tank system is designed for all com-
aims at reducing nitrogen oxide (NOx). mon AdBlue containers and delivery nozzles.
Modifying the components of the SCR system or The tank flange module (preheater package) with
changing their installation positions is not permitted. pumps, heating and sensors, which is part of the SCR
This includes the AdBlue® tank, the AdBlue® lines and system, is welded together with the AdBlue®/DEF
all other SCR system components. tank. The AdBlue®/DEF tank is located in the front-end
Apart from electronic control units and sensors, the assembly on the right side in front of the front axle, and
SCR system requires a catalytic converter and the is connected to the longitudinal frame member and the
additive AdBlue®/DEF. inside of the A-pillar.
AdBlue®/DEF On the series production vehicle, the components of
the AdBlue® tank and tank flange module, as well as
AdBlue®/DEF is a solution of urea (32.5%) and water.
the electrical and hydraulic connections, are protected
AdBlue®/DEF is a noncombustible, nontoxic, colorless,
against damage by the front apron, e.g. when driving
odorless and water-soluble liquid.
over low curbs or other obstacles.
AdBlue®/DEF has a limited shelf life, which is affected
If the factory-fitted front apron is omitted, measures
by the ambient temperature and air humidity. When
must be taken to protect the components on the under
filling it from containers, the following points must be
side of the SCR exhaust gas aftertreatment system.
observed.
The filler neck is located in an opening at the front of
Information on handling AdBlue® and its material char
the front module carrier under the hood.
acteristics can be found in ISO 22241.
Local and national laws and regulations for proper and
correct disposal and handling must be observed.
If AdBlue®/DEF comes into contact with painted sur-
faces or aluminum, the affected area must immediately
be cleaned with water.
Any AdBlue®/DEF pumped out of the SCR tank must
not be reused. As the AdBlue®/DEF that is pumped out
is not always pure, it must be properly disposed of.
ⓘ For further information, observe the operator's

manual of the vehicle.
Modifications to the tank flange module may only be The SCR systems of the vehicles with the previous
made with the consent of Mercedes-Benz. engines OM651/OM642 and the new engine OM654
The AdBlue®/DEF line connects the AdBlue®/DEF differ in terms of the number of AdBlue® injection
tank to the injection point at the engine. points on the exhaust system, and consequently the
number of injection valves and lines:
The AdBlue®/DEF line is electrically heated and
designed for this system in terms of its rigidity. • OM651/OM642: Single metering near engine
Modifications to the heat AdBlue®/DEF line may only • OM654: Double metering near engine and in
be made with the consent of Mercedes-Benz. substructure area
3
3
2
1 1
N14.40-2038-00
2
N14.40-2038-00 N14.40-2037-00
SCR system for engines OM651/ OM642
1 AdBlue®/DEF tank
2 AdBlue®/DEF line
3 AdBlue®/DEF filler neck
The newly designed AdBlue® tank for OM654 is located

at the same position in the engine compartment as in
the previous engines.

SCR system for engine OM654
1 AdBlue® tank
2 AdBlue® line for metering near engine
3 AdBlue® filler neck
4 AdBlue® line for metering in substructure area
6.3.3 Exhaust system Exhaust system geometry

Mercedes-Benz AG recommends that you refrain from The following dimensions must be observed when mod-
modifying the exhaust system of Sprinter vehicles. The ifying the geometry of the exhaust system:
upfit scope should be planned according to the avail-
able special equipment of exhaust system variants.
If a vehicle's exhaust system is replaced, we rec-
ommend the use of Mercedes-Benz genuine parts.
When selecting a different exhaust system as special
equipment, ensure that it is also available for the same
engine variant and emissions rating from the produc-
tion plant of Mercedes-Benz AG. This guarantees that
the planned special exhaust system has been certified
1,
in this vehicle configuration. Further information
5
can be obtained from the local Mercedes-Benz Service
N49.10-2054-00
Center.
Example of a pipe bend design
Comply with all local and national guidelines and
regulations. • Maximum pipe bend 90°
General • Avoid the use of additional pipe bends
It is important to note that modifications to the geom- • Bending radii >1.5 d

etry of the exhaust system and its piping are only per-
Minimum clearances to lines
mitted under the boundary conditions described below.
When the vehicle is in operation, the temperature
As part of such modifications, measurements of the
between the exhaust system (diesel particulate filter,
exhaust gas back pressure must be taken (before/
catalytic converter or main muffler) and the floor panel
after) to ensure that it has not increased in compar-
may rise above 80°C/ 176°F depending on the loca-
ison to the unmodified exhaust system. The upfitter
tion. During regeneration, the diesel particulate filter
concerned must be able to provide evidence of these
can reach a surface temperature in excess of 500°C/
measurements to Mercedes-Benz AG on request.
932°F. For this reason, shielding or insulation must be
All modifications above and beyond these constitute an mounted on the substructure to reduce the effects of
alteration of a certified state in terms of emissions and radiated heat.
noise levels.
Specification for minimum clearances for fuel lines,
plastic lines, electrical cables and spare wheels, and for
⑴ NOTE
all components made of non-heat-resistant materials:
Upon completion of all work on the vehicle, you must • 200 mm/ 7.87 in. for exhaust systems without
comply with the specified anti-corrosion protection shielding
• 80 mm/ 3.15 in. in areas with sheet metal shielding
• 40 mm/ 1.57 in. in areas with sheet metal shielding
with additional insulation
⚠ WARNING
If the minimum distances to fuel lines, plastic lines
and electrical cables are not maintained, severe heat
can result in a fire.
There is a risk of fire and explosion!
Always comply with the specified minimum clear-
ances.
It is important to not only consider the radiant heat Exhaust system without SCR system (gas engine)
emitted by the exhaust system, but also the jet of The length and installation position of the flexible metal
exhaust emitted behind the exhaust pipe outlet under hose between the exhaust manifold and the exhaust
all operating conditions. pipe must not be changed.
The free cross-section of the exhaust pipe behind the
⑴ NOTE
main muffler must not be reduced.
When using the power take-off, refer to the informa-
tion and notes in the operator's manual of the vehicle ⚠ WARNING
regarding regeneration of the diesel particulate filter The lengths and routings, e.g. between the diesel
in the exhaust system. particulate filter and the main muffler, are optimized
with regards to temperature characteristics. Modifi-
cations could lead to higher or extreme temperatures
Additional shielding is required in the exhaust system and surrounding components
• Near control panels (propeller shafts, fuel tank, floor panel, etc.). There is
a risk of fire!
• Near major assemblies, attachments and equipment,
unless they are made of heat-resistant material. Modifications to the exhaust system as far as the
muffler are not permitted.
Exhaust emission
It must be ensured that the exhaust gases emitted from
the tailpipe cannot enter the passenger compartment.
Particular attention must be paid to this in the layout of
accesses and doors.
Ex-factory exhaust system variants

The following exhaust system versions are available
from the factory as special equipment:
Code Description
K63 Exhaust, to the side behind the rear axle
KA3 Exhaust, to the side in front of the rear axle
ⓘ Additional information on special equipment can be

obtained from your Mercedes-Benz Service Center,
under 1.7 Contact (→ page 11) or under 3.12
Special equipment (→ page 55).
Exhaust system with SCR system It is the upfitter's sole responsibility to guarantee
Modifications to the exhaust system with SCR sys- adequate clearance between the exhaust system and
tem are only allowed at a minimum distance of all the components relative to its body scopes. The
100 mm/3.94 in behind the last sensor (NOx sensor). above-mentioned minimum distances to the exhaust
The positions and installation positions of the sensors system components must be observed.
and the throttle valve as well as the spatial geometry
of the overall system or other components may not be
modified.
.

100 mm /
3.94 in
PP
Schematic illustration of exhaust system OM651/ OM642
1 NOx sensor
2 SCR catalytic converter
3 Area in which modifications are not permitted
4 Particulate matter sensor
Schematic diagram of exhaust system OM654
1 NOx sensor
2 SCR catalytic converter
3 Area in which modifications are not permitted
4 Throttle valve
6.3.4 Engine cooling 6.3.5 Engine air intake
a) Vehicles with engine OM651/ OM642

It is not permissible to modify the cooling system
(cooler, radiator grille, air ducts, coolant circuit,
etc.) because a sufficient flow of cooling air must be
assured.
1
The flow areas of the cooling air intake areas are to be
kept free. This means:
• at least 11 dm²/170.5 in² for the front grille (radiator
and condenser)
N14.40-2040-00
• at least 7 dm²/108.5 in² for the opening in the Engine air intake opening for OM651/ OM642
bumper (charge air cooler flow)
1 Area of engine air intake

Engine cooling, flow areas directives
1 Front grill radiator: 11 dm²/170.5 in²

Engine air intake opening for OM654
2 Front grill charge air cooler: 7 dm²/108.5 in²
1 Area of engine air intake

For vehicles with a modified front end (e.g.fully inte
grated RVs), the further specifications in Chapter
4.4.2 Engine cooling system (→ page 74) must be ⑴ NOTE
observed.
On no account should modifications be made in the
b) Vehicles with engine OM654 area of engine air intake (see illustration).
The new information and specifications for engine
OM654 cooling is available in Chapter 4.4.2 Engine The engine air intake for engines OM651/ OM642 is
cooling (→ page 74)). located in the left area of the front grill.
The engine air intake for the new engine OM654 is
integrated into the area of the upper cross-member of
the new front module.
The air filter is secured by two rubber mounted brack-
ets in the front module. The design of the attachment
of the air filter must be retained in the event of any
modification to the front module.
Warm air 6.3.7 Propeller shafts

The intake of warm air will lead to a loss of engine The correct layout of the propeller shaft drive prevents
power. A bulkhead between the engine compartment, noise and the development of vibrations. We recommend
the vehicle interior and the intake point is therefore the use of genuine Mercedes-Benz parts.
essential. The intake temperature should not exceed
the outside temperature by more than 10 °C/50 °F. Working angles
If necessary, use several propeller shafts with interme
Water
diate bearings.
When being drained off, water, splash water or car
The working angles must be identical at both universal
wash water must not flow directly past the intake area
joints (β1 ≠ β2). The working angles must generally
from the body. Make sure that water cannot reach the
not exceed 4.5° and in exceptional cases must be no
intake points through any fresh air supply inlets. The
greater than 6° (proper functioning of the universal
flow velocity at the intake points must not be increased
joints must be assured). The angular difference should
by modifications to the opening of the intake points.
not exceed 1°.
Dust/dirt
⑴ NOTE
Increased dust intake will lead to shorter maintenance
intervals for the air filter. Working angles greater than 6° and angle errors
(β1 ≠ β2) lead to vibrations on the drivetrain.
6.3.6 Clearance for major assemblies They shorten the service life of major assemblies and
may cause damage.
To guarantee proper functioning and operational safety of In addition, problems due to noise and vibrations
the major assemblies, sufficient clearance must be main- should be expected.
tained (in particular to electrical, brake and fuel lines).
The dimensional data in the 2D chassis drawings (offer
drawings) must be observed (→ page 18).
The distance between the cab and the body must be at
least 50 mm/2.0 in.
N41.00-2014-00
Types of angular offset
b1 = b2
Angle in one plane (two-dimensional offset):

“W” or “Z” layout
Angles in two planes (three-dimensional offset):
With three-dimensional offset, the input and
output shafts intersect in different planes (com-
bined W and Zoffset).
In order to compensate for any irregularities, the inner
joint forks can be offset. This fork offset must be
designed and secured by a company qualified in propel
ler shaft engineering.
Propeller shafts must be balanced before installation.
Modifications should not exceed the limit values.
⑴ NOTE
Any temporary dismantling of the rebound straps
during the upfit must be returned to the Mer-
cedes-Benz specification before returning to use.
The Mercedes-Benz screws must be bolted at the
designated points with a tightening torque of 70 Nm
+/- 7 Nm (52 ft lb +/- 5 ft lb). The number of rebound
straps varies depending on the length of the body.
All Mercedes-Benz passenger vans come standard
withthe option code AP2 (protection bar for drivesh-
aft). The option code AP2 ensures compliance with
all federal regulations for driveshaft protection
regarding passenger vans and bus conversions. If any
conversion of a non-passenger van to a passenger
van is carried out, the upfitter is obligated to ensure
that the van is compliant with all relevant driveshaft
protection regulations and may order the option code
AP2.
The driveshaft underneath the cab must be secured
with at least one bracket.
Rebound straps
6.4 Interior
6.4.1 General information

⚠ WARNING
⚠ WARNING If paint or surface treatment is applied to the instru-
ment panel, the window airbags, the steering wheel
Any modifications to restraint systems or their wiring
impact absorber and the airbag tear seams, chemical
could result in these restraint systems not functioning
reactions can occur on the treated surfaces. This
correctly. A restraint system can fail or unintention-
could weaken or damage the materials meaning that
ally activate. There is a risk of accident, personal
the restraint systems no longer operate properly.
injuries and death if such systems no longer function
correctly!
Modifications to restraint systems or their wiring are
Painting or surface treatment is not permissible on
therefore not permitted.
the instrument panel, the window airbags, the steer-
ing wheel impact absorber and the airbag tear seams.
This includes modifications to the belt mounting points
and their positioning on the B-pillar and any modi
The permissible center of gravity and maximum permis-
fication of genuine Mercedes-Benz belt system compo-
sible axle loads must not be exceeded.
nents.
Information on camper conversions can be found under
The driver and front passenger airbag units, the window
7.15 RV – Recreational vehicles (→ page 219).
airbags and thorax/pelvis side airbags and the seat
belt tensioners are pyrotechnical components. The interior must be designed with soft edges and
surfaces.
are subject to the hazardous materials law regulated Fittings must be made of flame-resistant materials and
by FMCSA under 49 CFR Part 173 in the US, and to be fitted securely.
the Transportation of Dangerous Goods Act (Transport Unimpeded access to the seats must be ensured.
Canada) in Canada. There must not be any protruding parts, edges or cor-
The purchase, transportation, storage, fitting, removal ners which could cause injury in the area of the seats.
and disposal of potentially explosive substances may
only be carried out by trained personnel and in accor- ⑴ NOTE
dance with the relevant safety regulations.
Attachments with rigid connections to the front, side
Modifications in the cockpit area and above the belt and rear of the vehicle at the height of possible acci-
trail line must fulfill the criteria associated with the dent zones could modify the characteristics of the
head impact tests as per FMVSS/CMVSS 201. vehicle's passive safety.
In the area of the airbag deployment zones, modifica-
tions to the surface of the cockpit, interior trim and ⚠ WARNING
seats (wooden trim, additional fixtures, mobile phone
cradle, bottle holder, etc.) are not permitted. For more Modifications to or work incorrectly carried out on
information, see the schematic diagrams for the airbag a restraint system (seat belt and seat belt anchor-
deployment areas (→ page 143). ings, seat belt tensioners or airbags) or its wiring
could cause the restraint systems to stop functioning
Painting or surface treatment is not permissible on the
correctly. There is a risk of accident, personal injuries
instrument panel, steering wheel impact absorber or
airbag tear seams.
rectly!
This also applies for restraint systems integrated in the
On no account may any modifications be made to the
seats (e.g. flush-mounted modules).
airbag system or the seat belt tensioner system.
Protective covers could interfere with the functioning
of the thorax/pelvis side airbag and the seat mat
detection system.
6.4.2 Safety equipment

⚠ WARNING
If, for example, the following alterations are made to Airbag control unit and sensors
the structure of the vehicle, the safe function of the It is not permitted to modify the installation location,
front airbag, window airbag, thorax/pelvis side airbag installation position, and attachment of airbag control
and seat belt tensioners is no longer guaranteed: units and satellite sensors by comparison with the stan
• modifications to the seats and thus changes in dard vehicle on vehicles equipped with window airbags
the kinematics of the occupants in the event of an and thorax/pelvis side airbags. Any changes to the
impact lines of these components are also not permitted.
• modifications to the front-end assembly Other vehicle components must not be secured to the
• installation of parts in the vicinity of airbag inflation airbag control unit, the satellite sensors, their lines or
points or in airbag deployment areas the attachment points. When installing components in
the vicinity of these components, a minimum distance
• installation of non-MB seats of 6 mm/ 0.236 in must be maintained.
• modifications to the A-pillar and B-pillar, the roof When components (e.g. the airbag control unit) have
frame and its lining been removed, all the components must be reinstalled
• modifications to the doors and door trim with the appropriate tightening torques in accordance
• modification or replacement of the seat cover in with the repair instructions when reassembling.
case of integrated Thorax-Pelvis-Airbag
⚠ WARNING
These modifications are therefore not permitted.
When, for example, the following alterations are made
No systems or components which influence passive to the structure of the vehicle, the safe operation of
safety may be modified. This could otherwise result in restraint systems is no longer guaranteed:
personal injury.
• modifications to the front-end assembly
• installation of parts in the vicinity of airbag inflation
points or in airbag deployment areas
• modifications to the A-pillar and B-pillar, the roof
frame and its lining
• modifications to the doors
These modifications are therefore not permitted.
No systems or components which influence passive
safety may be modified. This could otherwise result in
personal injury.
In the case of the following interventions in the struc-

ture of the vehicle, pay attention to the particular
provisions of Mercedes-Benz in Chapter 6.4.3:
• Modifications to the seats
• Installation of non-Mercedes-Benz seats
⑴ NOTE
Attachments with rigid connections to the front, side
and rear of the vehicle at the height of possible acci-
dent zones could modify the characteristics of the
vehicle's passive safety.
⚠ WARNING
Any modifications to the components of the restraint
systems (airbag control unit, satellite sensors,
airbags, seat belt tensioners, etc.), their lines and
attachments are not permitted.
Vehicle parts that generate vibrations may not be
mounted in the proximity of the airbag control unit or
1
the sensor installation locations. Nor may modifica-
tions be made to the floor structure in the proximity
of the airbag control unit or the satellite sensors.
Otherwise, reliable operation of the restraint systems
is no longer guaranteed, and there is a risk of injury.
N91.60-2202-00
Front pressure sensor

The airbag control unit is located on the center tunnel
under the center console. 1 Pressure sensor
(trigger sensor of the occupant protection systems)
N91.60-2204-00
Location of airbag control unit
1 Airbag control unit

In vehicles equipped with window airbags and/or

thorax/pelvis side airbags, the satellite sensors are
located towards the bottom of the B-pillar behind the
door sill trim in the driver's and front passenger's
entrance boxes.
The pressure sensors are located in the driver and/or
front passenger door.
Seat belts and seat belt tensioners
⚠ WARNING
Parts relevant to safety such as seat belts or belt
anchorages and seat belt tensioners must not be
damaged or soiled when work is carried out on the
vehicle. Otherwise these restraint systems may no
longer function properly, and in the event of an acci-
1 dent they would fail to provide sufficient protection.
⑴ NOTE
Only the original seat belts may be fitted, otherwise
the general operating permit of the vehicle would be
invalidated.
For seat belts, seat belt tensioners and seat belt

anchoring points, the specifications of the FMVSS/
N91.60-2205-00
CMVSS, plus the national regulations concerning seat
Sectional view of left entrance box at B-pillar
belts must be complied with and verified insofar as the
FMVSS/CMVSS do not completely cover the national
1 Satellite sensor regulations or have priority over them.
(trigger sensor of the occupant protection systems)
Vehicles must be equipped with seat belts.
The anchoring of the seat belts must be tested as per
FMVSS/CMVSS 210.
All vehicles, except vehicles without front airbags and
with special attachments (e.g. snowplow), are fitted
with pyrotechnical seat belt tensioners in the retractors
on the front seats.
The retractors are located in the B-pillars. There is an
additional retractor in the seat backrest of the bench
seat on vehicles with two-seater front passenger bench
seat.
1
N91.60-2207-00
Retractor with pyrotechnical seat belt tensioner

N91.60-2208-00
1 Connector
Front passenger bench seat with retractor
⚠ WARNING 1 Retractor
When installing an aftermarket partition do not drill or

attach any fasteners in the area between the bottom ⑴ NOTE
of the seat belt retractor and the bottom of the seat
Please ensure to comply with local and federal
belt height adjustment.
regulations.
N91.60-2209-00
Securing point for seat belt end fitting in B-pillar
1 Seat belt end fitting

N91.40-2195-00
Location of seat belt retractor between 620-770 mm/

24.25–30.5 in above floor
Front airbag
All airbag units are labeled "Airbag":
• The driver's airbag unit is identified by the "Airbag"
inscription on the steering wheel boss.
• If the vehicle is equipped with a front passenger
airbag, this unit is also identified by the "Airbag"
inscription.
• If the vehicle is equipped with window airbags, they
are identified by the "Airbag" inscription on the cover.
• If the vehicle is equipped with thorax/pelvis side air-
bags, these are identified by the "Airbag" inscription
on the seat backrest.
The indicator lamp signals a malfunction in the restraint
system, which includes functions of the seat belt warn-
ing and the ESP® sensor system.
Schematic diagram of deployment area of driver's airbag
• Because ESP® is standard equipment, the lamp is
present in every instrument cluster and is active in
the lamp check even when no restraint equipment is
installed.
• The seat belt reminder warning is also triggered by
the restraint system, even when no restraint equip-
ment is installed.
The following illustrations show the location and
deployment areas of the driver’s and front passenger
airbags as well as that of window airbag and thorax/
pelvis side airbag. The deployment areas shown are
greater than the actual volume of the airbag because
space is required for airbag rebound as it deploys. Schematic diagram of deployment area of front passenger
airbag
Sidebags
B-pillar, door bodies, trim and seat covers.
Schematic diagram of deployment area of thorax/pelvis side

airbag on left side of vehicle
Schematic diagram of deployment area of window airbag on

right side of vehicle
The preceding illustrations of the airbag deployment

areas show the approximate maximum schematic
deployment states (for illustration purposes only; no
responsibility is accepted for the correctness of the
information).
⚠ WARNING
Working on the A-pillar can cause damage to the
window airbag. This can result in the window airbag
no longer functioning properly and it may not provide
adequate protection in the event of an accident.
N91.60-2210-00
Window airbag installation position
1 Cover
2 Window airbag in protective sleeve
3 Gas generator in window airbag
Working with airbag and seat belt tensioner units Transporting and storing airbag units and seat belt
tensioner units
⚠ WARNING
Transportation should always be carried out using the
Removed airbag units must always be stored in such replacement part packaging in the vehicle trunk or load
a way that the padded side faces upwards. If the compartment and in observance of the below warning
padded side faces downwards, the airbag unit will be notice.
catapulted through the air if it is triggered acciden-
tally. ⑴ NOTE
Do not transport any airbag and seat belt tensioner
Observe the following specifications when handling units in the passenger compartment.
airbag and seat belt tensioner components:
• Only qualified personnel may work with removed
components and perform testing and assembly The airbag units fitted to the Sprinter BM 907 include
operations. the driver and front passenger airbags as well as the
window airbag and thorax/pelvis side airbag.
• Electrical inspection is to be conducted in installed
condition only, using specified test equipment. We The handling, transportation and storage of airbag units
recommend that tests be carried out at a Mer- are subject to the hazardous materials law regulated
cedes-Benz Service Center. by FMCSA under 49 CFR Part 173 in the US, and to
• Assembly and disassembly are to be conducted only Canada) in Canada.
when the battery is disconnected, with covered up
negative terminal or covered up negative clamp, and The weights of the individual components are:
disconnected test coupling/ connector.
Driver's airbag 1.5 kg/3.3 lbs
• After disassembling, components must be stored in Front passenger airbag 3.3 kg/7.3 lbs
a suitable storeroom only and must only be removed Window airbag 2.1 kg/4.6 lbs
just before they are to be assembled. Thorax/pelvis side airbag 0.7 kg/1.5 lbs
• If work has to be interrupted, store components Seat belt 1.4 kg/3.1 lbs
involved under lock and key.
• Do not treat with grease, cleaning agents or similar
agents.
• Do not expose components to temperatures over
100°C/ 212°F.
• Replace any airbag and seat belt tensioner compo-
nents that have been dropped to the floor.
• The airbag and seat belt tensioner units may only be
electrically tested in the installed condition with the
prescribed test equipment. For safety reasons, the
test should only be performed at a Mercedes-Benz
Service Center or at a specialist workshop that
has been specially trained to service these safety
systems.
Disposing of airbag and seat belt tensioner units 6.4.3 Seats

Dispose of airbag and seat belt tensioner units in Proof of the strength of the seats delivered from the
accordance with the local and country specific laws factory is only valid if the seats are secured in original
and guidelines. mountings.
If seat belt tensioners that have not been triggered As part of the eXpertUpfitter program, possible
require detonation for disposal purposes, place deviations can be evaluated with the responsible
them in the footwell of a vehicle which has been
sent for scrapping, and connect them directly using (→ page 11).
a 2-pin connector coupling. The test reports in relation to FMVSS 202a /CMVSS
If the bolster plates on the airbag units have not 202, FMVSS/CMVSS 207, FMVSS/CMVSS 209
been destroyed, the airbag units must be detonated and FMVSS/CMVSS 210 are a requirement to be an
by trained personnel using the 2-pin connector eXpertUpfitter.
coupling.
It is essential to observe the H-point for each seat. The
These safety measures are necessary because seats installed ex factory (driver/front passenger) must
flammability materials could cause injury if activated not be secured directly to the low seat base when the
incorrectly. vehicle is delivered to the end customer. The H-point
on seats available ex factory (driver/front passenger)
ⓘ Airbag and seat belt tensioner units must be in combination with the low seat base can be achieved
disposed of by personnel who have undergone using the swivel console available ex factory.
special training for this task. Accident prevention
A rear seat system with 2- or 3-point seat belts that
regulations must be observed.
deviates from the standard seating arrangement must
Hazards arise from disposal using cutting torches, meet the requirements of the FMVSS/CMVSS 207
by smelting, or if primed parts are disposed of on open (seating systems) and the FMVSS/CMVSS 210 (seat
fires or smoldering fires on waste disposal sites. belt assembly anchorages) standard. Furthermore,
In order to ensure that no additional work arises due the standard FMVSS/CMVSS 209 (Seat belt assem-
to these safety measures, we recommend that you blies) must be adhered to. For the headrests, proof of
entrust the disposal of pyrotechnical substances to an compliance with the FMVSS 202a/CMVSS 202 (Head
external waste disposal company, which will implement restraints) standard is required. Always comply with
the required safety measures (incl. 10 m/39.4 in safe local and national regulations.
distance, special ignition equipment). Seats without belts are not permitted.
When the materials are handed over, the waste dis- When seat belts and seats (including seat bases) are
posal company must sign a declaration containing the reinstalled, new bolts must be tightened, tested, and
obligation to dispose of the pyrotechnical materials documented to the specified torque, including tolerance.
in accordance with accident prevention regulations.
In the case of vehicle orders where the driver's seat
Agreements of this kind must ensure that it is not pos-
(Code S90) or front passenger seat (Code S91) is
sible to extract pyrotechnical materials after disposal
deleted, it is not possible to retrofit standard seats in
and to pass them on for repairs.
the body-in-white, as there are no reinforcements or
suitable connection points. However, retrofitting after-
market seats is possible, see Chapter 7.3 Modifications
to the interior (→ page 190).
Test certificates for seats on a rigid plate are not per-
missible. Mercedes-Benz reserves the right to request
these test certificates at any time as part of its product
monitoring processes.
ⓘ Information on retrofitting seats can be found

under Retrofitting additional seats (→ page 190).
6.4.4 Reducing interior noise

⚠ WARNING
Soundproofing material can be installed in order to
Unsuitable seat covers could hinder, or even prevent, reduce the noise level in the vehicle interior. It must not
the deployment of the airbags integrated in the seats. be flammable.
The airbags would then not protect the vehicle occu-
pants as intended. There is a heightened risk of injury Floor area
or even of death!
A structure as shown in the illustration is advisable for
insulation and soundproofing. An additional covering
It is strongly recommended that the upfitter does not with heavy-duty insulating foil may be provided in the
modify the seat cover in any way. It is the upfitter’s area of the wheel wells.
responsibility to ensure that all applicable technical and
regulatory requirements are met.
⑴ NOTE
⚠ WARNING Insulating foils, e.g. bituminous felt, have limited
On no account may seats be mounted on the wheel temperature resistance. They should therefore not
well. This also applies for lowered wheel wells. Other- be installed in the immediate vicinity of the engine or
wise the vehicle could be damaged (e.g. wheel wells exhaust system.
and tires), resulting in accidents.
1 Carpet (rubberized underside)

2 Wooden floor (12 mm/0.47 in plywood)
3 Heavy-duty insulating foil (weight per unit area
8-10 kg/m2 ; 1.636–2.045 lbs/ft2)
4 Load-bearing construction
Roof and side walls 6.4.5 Ventilation

Apart from providing insulation, the materials used for The living compartment and the driver area must have
insulation should exhibit the following properties: adequate ventilation with provision for air to enter and
• Not hygroscopic exit.
• Not water-retaining The windshield and side window defrosting function
must remain operational, especially if the driver area is
• Not water-absorbing
integrated into the living compartment or if the layout
• Not water-attracting and design of the interior does not correspond to that
• Water-repellent of the standard equipment.
Arrangements are to be made for the rapid and unhin- When modifying/removing the standard windshield,
dered drainage of accumulated moisture or condensa- adequate defrosting/deicing must be provided and
tion in order to avoid conditions that promote corrosion. the solar sensor must be reinstalled (standard with
HH4 Front automatic air conditioning). An incorrectly
The standard drain holes must be preserved intact. If
installed solar sensor or a different inclination of the
necessary, additional drain holes must be created with
windshield results in deviations in the climate control
the responsible department. As part of the eXpertUpfit-
with HH4 (Front automatic air conditioning).
ter program please refer to www.UpfitterPortal.com.
New vehicles can be delivered from the factory with the
The inside must be covered with a sound-transmitting
special equipment code HH9 (Manual front air condition-
material (perforated card, plastic, fabric cover).
ing), code HH4 (Front automatic air conditioning), code
⚠ WARNING HH9+HH7 (Manual front air conditioning + roof-mounted
air conditioning system), code HH9/ HH4+H08 (Front
On no account should any subsequent modifications air conditioning + roof-mounted air conditioning system)
be made to the headliner or the roof panel between and code HH9/HH4+HK4 (Front air conditioning + roof-
the A-pillar and the B-pillar if the vehicle is equipped mounted air conditioning system).
with window airbags. Otherwise the window airbag
Observe 6.5 Additional assemblies (→ page 152)
may no longer function correctly (e.g. window airbag
when retrofitting major assemblies.
deployment is delayed or incomplete).
Seals
Openings, gaps and slots between the engine compart-
ment or the vehicle underside or the firewall and the
vehicle interior must be carefully sealed with elastic
material. Vent openings must not be fitted in the imme-
diate vicinity of sources of noise.
In addition, manufacturers or suppliers of soundproof-
ing materials should be consulted.
They will be able to provide you with suggestions on
how to design optimum noise insulation for your modi-
fied vehicle body.
6.4.6 Attachment points for load compartment • The specifications in these Body/Equipment Mount-
trim parts on the side wall/roof ing Directives for the work to be performed must be
observed, see Chapter 3.9.1 Threaded connections
To line the load compartment in cargo van model des-
(→ page 46), Chapter 4.1.5 Drilling must not
ignations, it is recommended to use the load compart-
take place (→ page 63), Chapter 5.3 Anti-cor-
ment trim parts available from Mercedes-Benz AG ex
rosion protection measures (→ page 86),
factory.
Chapter 5.4 Painting work/preservation work
If the upfitter installs specific load compartment trim (→ page 88) and Chapter 6.2.1 General informa-
parts, the following specifications must be observed: tion on the body in white/body (→ page 101).
• Load compartment trim parts in the lower area of the For any questions, please reach out to the
side wall and on the roof are to be fastened at exist- Upfitter Portal:
ing mounting holes in the body-in-white (for clips,
expansion rivets or similar fasteners) for the inner
parts of the side wall and the cross bows of the roof,
see schematic diagram.
• In places where there are no existing mounting
holes (e.g. the upper part of the side wall), additional
mounting holes are permissible only in the marked
areas of the side wall inner parts, see schematic
diagram.
• To prevent cracks from occurring when drilling extra
mounting holes, a distance of at least 15 mm/
0.59 in. must be maintained from the edge of the
hole to all cuts and joints, openings, other holes and
panel edges of the body-in-white.
• Proper execution of the drilled holes must be
assured, with the avoidance of shavings, the
deburring of holes and subsequent anti-corrosion
protection.
• On completion of the body mounting work, all
shavings must be entirely eliminated from joints,
profiles and cavities.
Cargo van model designation, inside of right side wall: Permissible areas for the attachment of load compartment trim parts
(dark markings, schematic diagram)
Cargo van model designation, inside of left side wall: Permissible areas for the attachment of load compartment trim parts
(dark markings, schematic diagram)
Cargol van model designation, inside of roof: Permissible areas for the attachment of load compartment trim parts at the
cross bows (dark markings, schematic diagram)
6.5 Additional assemblies
If additional assemblies are fitted, the factory-fit- • Ensure that all lines (→ page 84) and electrical
ted power take-offs or auxiliary drives must be used lines (→ page 239) are routed correctly.
(→ page 132). • There should be no impairment of the accessibility or
easy maintenance of installed equipment.
6.5.1 Retrofitting an air conditioning system
• The operating instructions and the maintenance
⚠ WARNING manual for the additional assemblies must be sup-
plied on handing over the vehicle.
Prior to all mechanical and electrical work, the vehi-
• The air supply and cooling required for the engine
cle must be rendered free of voltage/current (discon-
must not be impaired (→ page 135).
necting the battery is absolutely essential).
• If compact systems are mounted on the cab roof
(evaporator, condenser and blower), the permissible
All electrical equipment fitted must be tested in accor-
roof loads must not be exceeded (→ page 121).
dance with FCC, CE and UL in the US, and with CSA
and ULC in Canada. • For attachments to the roof, an evalution with the
The installation of additional air conditioning compo-
nents (compressor, evaporator, lines etc.) on the air
conditioning systems available as special equipment ex
factory is not permissible.
Air conditioning system special equipment options ⑴ NOTE

• HH9 (Manual front air conditioning) When using refrigeration systems/components in
• HH4 (Front automatic air conditioning) combination with the refrigerant R1234yf, all applica-
ble laws, regulations and safety specifications must
• HH9+HH7 (Manual front air conditioning + roof-
be observed.
mounted air conditioning system)
In particular, compliance with the safety regulations
• HH9/HH4+H08 (Front air conditioning + roof-
according to ISO 13043 at both the component and
mounted air conditioning system)
overall system level (FMEA, leaktightness require-
• HH9/HH4+HK4 (Front air conditioning + roof- ments, concentration measurements etc.) must be
mounted air conditioning system) guaranteed.
If other air conditioning systems are installed, the Along with this, also observe the safety requirements
equipment manufacturer's guidelines must be with regard to inflammability and risk of combustibil-
observed. ity in combination with R1234yf (maintain best-pos-
sible packaging or largest-possible distance to hot
The following points must be observed with regard to
parts, if necessary, install additional devices for
compatibility with the base model vehicle:
assuring the required safety).
• On no account should the installation of an air condi-
If R1234yf is used, a specific information label with
tioning system impair vehicle parts or their function.
details of the quantity and combustion risk must be
• The battery must have sufficient capacity and considered or installed in a visible location.
the alternator must generate sufficient power
(→ page 242).
• Additional fuse protection for the air conditioning
power circuit (→ page 239).
• Air conditioning compressors must be attached using
the major assembly carrier provided (→ page 155).
• The additional pulley for driving air conditioning
compressors is available from the factory as special
equipment under code N63 (maximum output 8 kW)
(→ page 154).
Optimum belt tensioner position on OM651

If a different belt pulley diameter is used, it is important
to ensure that the belt length for the main belt drive is
adapted accordingly.
N83.30-3189-00
Position of belt tensioner in engine compartment

Note on belt tension on engine OM654
1 Belt tensioner
The specified marking on the engine-mounted belt
To ensure that all engine functions work properly, the tensioner of the main belt drive is only present in
marking on the belt tensioner indicated by the arrow engine OM651. Engine OM654 no longer bears this
must be in area 1. The marking indicated by the arrow marking and therefore the following specification must
must NEVER be in area 2. be observed:
⑴ NOTE
Modifications may not be made to the belt pulley
diameter in the main belt drive (primary drive) on
engine OM654.
The belt tensioning method for the engine-mounted

power take-off is specified in Chapter 6.5.3 Engine
power take-off (→ page 154).
1 2
N83.30-3190-00
Belt tensioner position
1 Correct belt tensioner position

2 Incorrect belt tensioner position
6.5.2 Auxiliary heating 6.5.3 Engine power take-off

If auxiliary heaters and their operating units are retrofit- Additional assemblies (e.g. an A/C compressor or an
ted, make sure that no exhaust gases enter the vehicle additional alternator) can be driven by an additional
interior during operation. pulley on the front of the crankshaft, see also 6.5 Addi-
The following auxiliary heating system is available from tional assemblies (→ page 152).
the factory as serial equipment: The following codes are available for power take-offs:
Description Code Code N62 Front engine bracket for

Hot-air auxiliary heater HH2 additional alternator
electric (PTC) Code N63 Front engine bracket for
auxiliary A/C compressor
The following auxiliary heating systems are available
from the factory as special equipment: These power take-offs can be obtained from the factory
as special equipment.
Description Code
For the power take-off with code N62, an alternator
Hot-water auxiliary heater H12 with freewheeling belt pulley must be used.
(stationary heater)
Hot-water auxiliary heater HZ9 These are available only for Diesel.
(only as heater booster) The maximum transferable torques for each of the
Additional heat exchanger on sub- H13 power take-offs are guide values for shock-free and
structure vibration-free operation.
These figures are based on a highly durable gearing
Code H88 (Preparation for additional heat exchanger),
design and a service life calculated in compliance with
available as special equipment ex factory, allows an
the German standard DIN 622. The additional inertia
aftermarket auxiliary heat exchanger to be connected
forces of the driven major assemblies are not taken
to the existing heater circuit (including the stationary
into account.
heater). The mechanical and electrical requirements,
including adjustment of the coolant quantity for reliable The ratio chosen should ensure that a minimum engine
engine operation, must be taken into account. speed of 1200 rpm with a power output of P = 28 kW
is maintained. The power output should be within the
Additional information can be found under 3.12 Special
range of the maximum engine torque.
equipment (→ page 55).
For further information regarding the code H88, please ⑴ NOTE
refer to the bulletin on the Upfitter Portal, Sprinter
MY2019+ Auxiliary Heat Exchanger Prep (H88). Mercedes-Benz does not provide any power take-off
options (e.g. auxiliary alternator or AC compressor)
for gas engines (engine type M274).
Mercedes-Benz does not permit any after-market
power take-off options for gas engines (engine type
M274).
Maximum transferable output
Code N62 8.5 kW

Code N63 8.0 kW
Required belt pulley for additional assemblies

• V-ribbed belt pulley, 6-groove
• Outside diameter
- Code N62: 50 mm/ 1.97 in
- Code N63: 119 mm/ 4.69 in
The following Mercedes-Benz genuine parts must Additional assembly on engine-mounted major assembly
be used as belts: carrier
OM642 1 Additional refrigerant compressor

Code N62 A001 993 47 96 2 Major assembly carrier
Code N63 A001 993 37 96
Maximum weight of additional assemblies
OM651
Code N62 7.3 kg/16.1 lbs
Code N62 A001 993 95 96 Stretch fit
Code N63 7.3 kg/16.1 lbs
OM654
ⓘ Please consult your Mercedes-Benz Service Partner

for advice regarding successor item numbers if the
above item number is unavailable.
Additional assemblies can be mounted on a major
assembly carrier fixed to the engine.
Setting of belt tension on engine power take-off After fitting the stretch fit belt and checking if the belt
OM654 is correctly positioned, the eccentric belt tensioner is
The tension of the stretch fit belt on the engine- rotated clockwise using the internal Torx bolt (T55) up
mounted power take-off can be adjusted using the to the lower end stop, which is just after the dead cen-
eccentric pulley, which is known as an eccentric belt ter position, so that the eccentric belt tensioner then
tensioner (eccentric RSP) (see following figure). remains in this position (see following figure).
After fixing the eccentric belt tensioner in place by
tightening the external Torx bolt (E12) to a torque of
30 Nm, the stretch fit belt then has the required pre-
load force.

Belt tensioner on engine OM654 in as-delivered state (with

code N63)

1 Engine-mounted belt pulley
2 Eccentric belt tensioner in as-delivered state Belt tensioner in final state after assembly and tensioning of
3 Internal Torx bolt (T55) belt (with code N63)
4 External Torx bolt (E12)
5 Guide pulley only with power take-off, code N63 (not 1 Engine-mounted belt pulley
available with code N62) 2 Eccentric belt tensioner in final state
3 Internal Torx bolt (T55)
In the as-delivered state (still without belt), the eccen- 4 External Torx bolt (E12)
tric belt tensioner is in a position in which the stretch 5 Guide pulley only with power take-off, code N63 (not
fit belt can be easily placed over the guide pulley and available with code N62)
the belt pulley of the power take-off and auxiliary 6 Stretch fit belt in tensioned assembly state
assembly. In this assembly state, the internal Torx bolt 7 Auxiliary assembly (example here of refrigerant compres-
sor with power take-off, code N63)
(T55) of the eccentric belt tensioner is set to an 11
o'clock position, which is the upper end stop, and the
eccentric belt tensioner is preset at this position. 6.5.4 Retrofitting an alternator
For the subsequent drive of an additional alternator,
the power take-off special equipment with code N62
must be used. Only alternators with a freewheel alter-
nator pulley are permitted.
More detailed information on additional alternators
can be found under 8.4.7 Retrofitting an alternator
(→ page 242).
6.6 Attachments
For attachments to the frame, an evalution with the

Make sure that you adhere to the permissible axle
loads in all cases.
Attachments must not impair the function of vehicle
parts.
Comply with local and national legal requirements. Area for applying adhesive when fitting wind deflectors
Winch
⑴ NOTE
If winches are attached behind the cab, they must be
mounted on an assembly frame of sufficient size and Additional holes for mounting in the cab roof are not
strength. permitted.
⑴ NOTE For other roof attachments, an evalution with the

On no account should a winch be attached to the responsible department is necessary.
front section of the frame. As part of the eXpertUpfitter program please refer to
6.6.2 Attachment above cab

6.6.1 Wind deflectors
• The permissible center of gravity location and the
Wind deflectors may only be fitted onto the cab roof
front axle load must be observed (→ page 58).
by applying high-strength adhesive to the whole area
around the lateral roof frame, the front roof frame and • The roof attachment must be designed as per 6.2.9
the 1st roof bow (level with the B-pillar). Cargo Van/Passenger Van roof (→ page 118).
The load applied by air resistance or contact pressure • If the conversion causes vibrations or noise, the
must be taken into consideration. The deflectors must assembly frame must be extended through the
only be fitted in such a way that the basic vehicle is not cab rear panel to underneath the seat bases and
damaged. secured. Auxiliary battery under code E2I (located in
the front passenger's seat base) is not possible with
Note that this may interfere with driving assis-
this design.
tance systems, see 8.9 Driving assistance systems
(→ page 271). Note that this may interfere with driving assis-
tance systems, see 8.9 Driving assistance systems
(→ page 271).
6.6.3 Roof racks 6.6.4 Shelf systems/vehicle interior installations

Shelf systems must not collapse in the event of a
Sprinter cargo and passenger vans
crash. Shelf systems must have no negative influences
• Make sure that the load is distributed evenly across on the base model vehicle and its functions (passive
the entire roof area. safety in particular).
• Support feet must be spaced at regular intervals.
50 kg/110 lbs per pair of feet and strut is recom- General
mended as a basic rule. Shelf systems must:
• With shorter roof racks, the load must be reduced • be sufficiently strong and self-supporting
proportionally. • rest on the crossmembers and longitudinal members
of the vehicle floor
Limit values for roof rack (laden)
Max. roof load Minimum num- • distribute forces evenly
ber of support • be attached to the load rails and tie-down eyes or to
feet pairs the entire contact surface on the body-in-white in
Low roof 300 kg/661 lbs 6 the same way as the standard rails or to the pre-in-
High roof 150 kg/331 lbs 3 stallation for shelf systems (code ZE6)
Cab 100 kg/220 lbs 2 • be installed free of mechanical stresses (including
the installations with the shelving preparations (code
To make it possible to fit roof rack systems, the
ZE6) as well as without this pre-installation. The gap
Sprinter BM 907 can be equipped with C-rails (special
between the roof bow bracket and the longitudinal
equipment code D13).
tube of the shelving must be reduced and must not
Note: C-rails, code D13, are not available ex factory for exceed 1 mm/ 0.04 in, before fastening the shelf
cabs. system onto the vehicle body.
1 ⑴ NOTE
Fastenings with side wall applications of the vehicle
or in the roof structure, as well as selective force
application to the vehicle wall must be avoided.
Otherwise there is a risk of damage to the side wall
and the roof.
N31.20-2110-00
We recommend the load rails available as a special
Mounting of roof racks
equipment option for mounting and attaching shelves
1 C-rail (roof rack) (code VC4 or code V42).
Note that there may be interference with driving assis-
tance systems due to large objects on the roof rack; ⓘ For further information about the side wall
see 8.9 Driving assistance systems (→ page 271). (→ page 111).
Load rails ex factory Maximum tensile forces of genuine Mercedes-Benz

Load rails are available ex factory in two heights on the load rails
vehicle Permissible
• Code VC4 - Load rails on roof frame rated tensile force
Upper load rail 150 daN/337 lb f
• Code V42 - Load rails on belt rail (underneath the
Code VC4
window stamping)
Lower load rail 250 daN/562 lb f
Code V42
The stated values only apply if the following conditions

are met:
• The load must be standing on the floor.
• The load must be secured at two tie-down points of
the rail.
• The distance to the next load securing point on the
same rail may be max. 1 m/3.3 ft.
ⓘ Observe the operator's manual supplied with the

load rails available ex factory.
Load rails in the cargo van
1 Load rails
Retrofitting load rails/tie-down rails
⑴ NOTE
Load rails or tie-down rails may only be retrofitted to
the areas of the vehicle side wall designed for this
purpose in the same way as the load rails available ex
factory.
The maximum tensile forces (see table) must be com-
plied with in all driving conditions. Otherwise there is
a risk of damage to the side wall.
Position for retrofitting tie-down rails to vehicle side wall
Center of load rail Dimension

Based on standard wooden floor a = 718 mm/28 in b = 1552 mm/61 in
Based on vehicle floor (upper rib- a = 729 mm/29 in b = 1563 mm/62 in
bing)
The following points must be observed with respect to • The maximum tensile forces (see table) must be
retrofitting load rails to the vehicle side wall: clearly indicated in the area of the load rails (e.g.
• The instructions of the load rail manufacturer must using adhesive labels) and enclosed in a suitable
be observed. form with the operator's manual in the vehicle.
Connection to vehicle side wall though riveting plus Requirements of rivets

adhesive bonding When retrofitting load rails on the vehicle side walls
Permissible rated tensile with rivets, the following values must be complied with:
force • Cross-tension strength min. 3800 N
Upper load rail (in area of 120 daN/270 lb f
• Shear strength min. 3300 N
roof frame)
Lower load rail (in area of 200 daN/450 lb f • Rivet diameter = 4.8 mm/0.19 in
belt rail) • Head diameter = 9.3 mm/0.37 in
• Clamping range = 3.5 mm/0.14 in to
Connection to vehicle side wall through riveting 6.0 mm/0.24 in
Permissible rated tensile Recommended process adhesives

force
Upper load rail (in area of 60 daN/135 lb f Körapur 140
roof frame) Use Adhesive
Lower load rail (in area of 100 daN/225 lb f Supplier Kömmerling,
belt rail) Suppl. no. 110/75074
Part no. A 009 989 17 71
The stated values only apply if the following conditions Chemical base 1K-PU that hardens in air
are met: humidity
• The load must be standing on the floor. Use-by date 6 months,
date specified on container
• The load must be secured at two tie-down points of
the rail.
Köracur 110
• The distance to the next load securing point on the Use Accelerator paste
same rail may be max. 1 m/ 3.28 ft. Supplier Kömmerling,
Suppl. no. 110/75074
Part no. A 009 989 18 71
Chemical base Water-based gel paste
Use-by date 9 months,
date specified on container
Körabond HG81
Use Activator
Supplier Kömmerling,
Suppl. no. 110/75074
Part no. A 001 986 90 71
Chemical base Silane, artificial resin
Use-by date 12 months
Recommended process steps for adhesive bonding • Adhesive application

• Roughen load rail - Bead geometry:
The entire length of the bonding surface at the rear Round bead
of the mounting rail must be roughened with a wire - Bead diameter:
brush. Roughened rails must be activated immedi-
Approx. 6 mm/0.24 in
ately.
- Dwell time of adhesive in static mixer:
• Activate bonding surface
Max. 15 minutes
The entire roughened bonding surface must be
activated with a PE bottle with a felt insert. Straight - Time between adhesive application and joining:
afterwards, the activator that has not yet evapo- Max. 15 minutes
rated must be completely wiped off with a cleaning
cloth (wipe on/wipe off procedure). - Dwell time of adhesive on rail:
Max. 15 minutes
- Flash-off time:
At least 10 minutes - Time until load may be applied (curing time)
Approx. 7 days
- Time until application of adhesive:
Max. 24 hours ⑴ NOTE
- Replacement cycle for felt insert:
The handling instructions of the adhesive manu-
When no longer functional
facturer must be followed. If the specified bonding
- Replacement cycle of PE bottle: instructions are not followed, the bond will not be of
At least once daily the required quality.
• Bonding mounting rail The mounting rail with adhesive must be bonded to
The adhesive must be applied to the entire length the inside of the vehicle within 15 minutes. Otherwise
of the activated bonding surface as a straight, excessive forces may result, causing damage to the
round bead. There must be a gap in the adhesive side wall.
bead of approx. 10 mm/0.39 in at the rivet holes
to prevent adhesive from being squeezed out in the
visible area.
Rivet distances for load rails retrofitted to vehicle

side wall
⑴ NOTE
The maximum rivet distances (see table) must be
complied with in all driving conditions. Otherwise
excessive forces may result, causing damage to the
side wall.
Rivet distances for load rails retrofitted to vehicle side wall
Rivet distance Dimension x max. Dimension y max.

Riveting plus adhesive bonding 75 mm/3 in 450 mm/18 in
Riveting (without adhesive bonding) 25 mm/1 in 225 mm/9 in
Pre-installation for fitted shelving

Code ZE6 "Pre-installation for fitted shelving" is available
from the factory to facilitate the retrofitting of shelves.
The package includes angles attached to the roof bows
and body consoles mounted on the vehicle floor.
Bolting the mounting consoles to the floor

ZE6 package contents in shaded areas
To fix the wooden floor, 2 angles per support must
Arrow Direction of travel be mounted at the bolt connection between the
support and the mounting console (contact surface
The following must be observed when using the shelf per angle at least 1200 mm²/1.9 in², dimensions
pre-installation: 60 mm x 20 mm/2.4 in x 0.8 in).
A steel tube with a rectangular profile measuring
• Shelves must not be wider than 450 mm/17.7 in.
60 mm x 40 mm x 3 mm/2.4 in x 1.6 in x 0.1 in
• The max. load-bearing capacity is 80 kg/m; is bolted onto the brackets on the roof bows. The
53.7 lbs/ft. shelf supports are bolted to this rectangular profile
at the top.
• The shelf supports must be made of steel (at least
ST235JO according to DIN EN 10025) complying
with the US SAE/ASTM standards can be used
with a minimum cross-section of 60 mm x 40 mm x
3 mm/2.4 in x 1.6 in x 0.1 in
(length x width x thickness).
The shelf supports are bolted to the floor with the
mounting consoles.
In addition to fixing the shelf supports to the floor

or to the roof bows, it is necessary to fix them to
the belt rail by means of a mounting console.
The connection must be made by bonding and
riveting. A minimum bonding surface area of
7000 mm2/10.85 in2 is required.
⚠ WARNING
Improper shelf attachment may result in mechanical
stress and may affect vehicle durability.
In the case of an accident, this could increase the
risk of personal injuries. Please refer to the General
subsection on section 6.6.4 Shelf systems/ vehicle
interior installations (→ page 158).
Connecting the shelf longitudinal tube to the roof bow
bracket
Connecting the longitudinal tube to the support
• The longitudinal tube must not be connected with the

partition wall or the rear door frame.
Suggested design for mounting console on belt rail
6.6.5 Loading cranes

The size of the crane must be selected in accordance
with the chassis size.
Loading cranes must be secured on an assembly frame
to relieve the load acting on the frame (→ page 180).
The permissible axle loads must be verified by calculat-
ing a weight balance.
The vehicle's stability must be ensured by the upfit-
ter. The slewing range of the crane must be limited
accordingly.
Comply with local and national legal requirements.
The mounting instructions of the crane manufacturer
Additional connection of the longitudinal tubes must be observed.
1 Connecting rail ⓘ If additional platform or dump trucks are mounted,

2 Longitudinal tube the dimensions of the assembly frame longitu-
3 Support brace dinal members must be taken from the table for
If the first or last support is more than platform bodies (→ page 196) or dump trucks
300 mm/11.8 in away from the roof bow, the longi-
tudinal tubes must be connected together. (→ page 200).
⑴ NOTE
Outriggers must be provided for every loading crane.
We recommend using hydraulic outriggers.
The vehicle must not be raised using the outriggers,
as this would damage the frame.
Suggested shelf attachment with ZE6
Loading crane mounted behind the cab • If a stronger assembly frame is required than for the
Loading cranes and outriggers must not impair the body when a loading crane is mounted behind the
function of other equipment. For connecting the cab, the loading crane can be secured on a shorter
assembly frame to the vehicle frame Mercedes-Benz assembly frame (see illustration below). The short
recommends a shear-resistant connection. chamfered assembly frame must have a length lM
corresponding to 35% of the wheelbase.
Assembly frame • For this type of attachment, an evalution with the
• Maximum crane load moment (kN x l): responsible department is necessary.
25 kNm/5175 ft lb As part of the eXpertUpfitter program please refer to
• Section moduli (Wx) and material properties can be
found under 7.1 Assembly frame (→ page 180).
• Assembly frame longitudinal member section dimen-
sions (→ page 180).
• While the crane is in operation, vehicle stability must
be ensured by extending support feet.
Indicate supports that protrude beyond the vehicle
when the vehicle is stationary by means of conspic-
uous colors, rear reflectors and warning lights.
Determine the platform length according to the
position and weight of the loading crane, complying
with the permissible axle loads.
• If the maximum crane load moments are exceeded,
an evalution with the responsible department is nec-
essary. As part of the eXpertUpfitter program, please
refer to www.UpfitterPortal.com.
• The vehicle may only be used on flat, paved roads.
• A frame extension may become necessary as a result
of the load distribution.
Loading crane
1 Loading crane assembly frame

2 Body consoles
3 Loading crane attachment
4 Outrigger
lM Length of loading crane assembly frame
Loading crane mounted at end of frame Mounting a lifting platform on cargo vans
Please consult with Mercedes-Benz if you intend to
⚠ WARNING
retrofit a lifting platform to a cargo van 1.7 Contact
The minimum front axle load (→ page 58) must be (→ page 11).
complied with in all load states. Otherwise adequate
driving stability is no longer guaranteed. Preconditions for mounting a lifting platform
• Loading cranes must be secured to an assembly ⑴ NOTE

frame made of steel. The assembly frame is to be An alternator and a battery with higher capacity as
joined to the vehicle frame by a shear-resistant well as an auxiliary battery must be fitted if an elec-
connection. trohydraulic lifting platform is fitted.
• Maximum crane load moment (kN x l):
25 kNm/5175 ft lb
• The permissible rear axle load must not be exceeded.
• The minimum front axle load must be complied with
in all load states (→ page 58).
• For the section dimensions of assembly frame longi-
• Vehicle stability must be ensured by the upfitter in all
tudinal members, see (→ page 180).
operating statuses.
• While the crane is in operation, vehicle stability must
• Loading platforms must comply with the local and
be ensured by extending support feet, which must be
national regulations.
designed as described on (→ page 167).
6.6.6 Lifting platform (cargo liftgate)
General
Before installing a cargo liftgate, the available installa-
tion space must be checked by the upfitter. Note the
limitations in the installation space due to the installed
exhaust system and tank system.
⑴ NOTE
The reinforcement of the trailer hitch (Q11) in the
rear longitudinal member on the left/right is available
as standard for model designation 907 and cannot be
deleted.
Use calculations to determine the load distribution. Lifting platform attachment

Take all special equipment into account when doing
so. The lifting platform must be attached as per Attach-
ment to the rear frame section (→ page 106).
If necessary, shorten the body length and the rear
chassis overhang accordingly (chassis). Additional torque support must be provided by means
of at least two bolted connections fitted with spacer
• We recommend using hydraulic outriggers.
bushes (e.g. on the assembly frame).
• Maximum load clearance 600 mm/23.6 in, relative to
Extend the assembly frame as far forwards as pos-
the standard rear portal/standard rear crossmember. sible and attach it with a non-positive connection to
• The legal requirements in various countries relating the chassis frame.
to "Underride guard" and "Lighting system" must be • No assembly frame is required on vehicles with a
observed when a lifting platform is mounted. standard cargo van body.
• Cuts in the end crossmember are only permitted At the least, all the factory-installed body consoles, and
after consultation with the department responsible in particular those at the rear end of the frame, must
1.7 Contact (→ page 11). be used to connect the assembly frame (body and
• Vehicle stability when loading and unloading the lifting platform) to the vehicle frame.
vehicle must be ensured by the user. Attention must also be paid to the need for reinforce
ments in the left and right rear longitudinal members in
⑴ NOTE vehicles with trailer coupling or the pre-installation for a
trailer coupling, see note in Chapter 6.6.7 Trailer hitch
The permissible nominal live load on the lifting
(→ page 172).
platform used must not be exceeded and the load
clearance must be observed. If modifications are required to the rear underrun
protection due to the attachment of a lifting platform,
the strength and bending resistance of the rear under-
⑴ NOTE
run protection must not be changed (→ page 176).
The standard tail lamps of chassis vehicles may only
be installed in the approved horizontal installation ⚠ WARNING
position as in the original condition.
The vehicle must not be raised using the outriggers,
For other installation positions, alternative tail as this would damage the frame.
lamps are available from the manufacturer of the
standard tail lamps, see Chapter 8.5.3 Tail lamps
(→ page 255).
Permissible lifting force of lifting platform
Type Wheelbase Maximum lifting force [kN]2 Minimum dimension

Chassis Cargo van1 of assembly frame
1500, 2500 144” 5 5 None
3500, 3500XD, 4500 170” 5 5
144” 7.5 5 80 x 45 x 3 mm (3.15 x 1.77 x 0.12 in)
170” 7.5 5 or factory platform, code P02
144” 10 5 120 x 50 x 4 mm (4.72 x 1.97 x 0.16 in)
170” 10 5
1 Without assembly frame

2 For rated load distance of 600 mm/23.5 in
6.6.7 Trailer hitch

⑴ NOTE
⑴ NOTE Never attach a trailer hitch to the end crossmember

of the frame.
as standard for model designation 907 and cannot be ⚠ WARNING
deleted. Risk of accident due to the impermissible attachment
of a trailer hitch!
• We recommend only using trailer hitches which are If a trailer hitch is retrofitted and you attach a trailer
approved by Mercedes-Benz or equivalently safe hitch or other components, the longitudinal frame
trailer hitches which are attached to the special member will be weakened and can break. In this
mounting points on the body in white (rear longitudi- case, the trailer can detach from the vehicle.
nal member) (→ page 322). There is a risk of accident, personal injuries and
• Access to the spare wheel must be guaranteed if a death as a result of the improper attachment of a
trailer hitch with a non-detachable ball head is fitted trailer hitch!
(especially with a fully laden vehicle). Only retrofit a trailer hitch if this is permissible.
• The trailer hitch attachment and clearance dimen-
sions must comply with FMVSS/CMVSS 110 for
the Sprinters below 10,000 lbs GVWR (model 1500,
2500, 3500).
• There is no technical problem retrofitting a trailer
hitch when special equipment code E40 Trailer plug
socket 7-poles is already fitted.
ⓘ For information on the relationships between

towing capacity, vehicle overhang and Trailer
Stability Assist (TSA), see 4.1.3 Vehicle dimensions
(→ page 59).
Dimensioning the trailer hitch Clearance dimensions of trailer hitch

The size of the trailer hitch is defined by the drawbar Clearance dimensions of FMVSS/CMVSS 110 must be
ratio. taken into account.
m k × ma The height of the trailer hitch above the ground must be
D=g× (kN )
m k + ma between 350 mm and 420 mm/12 in and 18 in when
D = Drawbar ratio the vehicle is laden to the permissible gross mass.
mk = Permissible gross mass of tractor unit (vehicle) in t The reliable operation of the hitch must not be
ma = Permissible gross mass of trailer in t impaired. Do not install an open-jaw hitch fitted to the
g = 9.80665 m/s2 ; 386 in/s2 front of the vehicle. The specified clearances must be
In order to allow the trailer to be exchanged when used maintained.
in international transport, the clearance between the
center of the trailer hitch and the end of the towing
vehicle must be no more than 300 mm/11.8 in.
Please refer to FMVSS/CMVSS 110.
Trailer hitch
In the USA and Canada, the following trailer hitch is
used:
N31.10-2335-00
Trailer hitch
Interior view
The ball neck (orange) for the specific trailers can be
purchased in the accessories trade. a Attachment of mounting plate to longitudinal frame
member
b Lower flange of longitudinal frame member
c Frame end crossmember
⚠ WARNING d Mounting plate for trailer hitch
If the towing vehicle is unladen, only an unladen
trailer may be towed. Otherwise, the vehicle may • No attachment may be made to the rear underrun
become unstable. protection.
• If the frame needs extending, spacer bushes must
be fitted to the frame to attach the mounting plate or
⑴ NOTE the rear crossmember (→ page 104). They may lead
If trailer hitches have removable ball heads, the oper- to a reduction in the towing weight or the tongue
ating instructions must be supplied in the vehicle and weight.
they must refer to the special features and operation Hole patterns with dimensions for attaching trailer
of the hitch. hitches can be found under 10.3 Trailer hitch hole pat-
terns (→ page 322).
⚠ WARNING
Attachment of the trailer hitch Risk of accident due to the impermissible attachment
Only secure trailer hitches/trailer brackets to the spe- of a trailer hitch!
cial mounting points on the body in white (rear longitu- If a trailer hitch is retrofitted and you attach a trailer
dinal member) (→ page 322). hitch or other components, the longitudinal frame
In addition, cargo vans require an additional attach- member will be weakened and can break. In this
ment as support on the rear cross member of the case, the trailer can detach from the vehicle.
vehicle frame. There is a risk of accident, personal injuries and
death as a result of the improper attachment of a
trailer hitch!
Depending on the model series, the following special

equipment is available as an option code from the fac-
tory to retrofit trailer hitches:
Code Description
E40 Trailer Plug Socket 7-pin
Provides power for trailer lightning systems (tail lights, brake lights, direction indicators, rear fog lights
and reversing light) and allows electrical operation. It is installed with the corresponding wire harness
and trailer control unit.
Required for: trailer couplings (QA2/Q24)
QA9 Cross Member with Integral Step
Step (on right sight of the trailer hitch) consisting of a tubular steel frame with welded-on anti-slip
tread surface is bolted onto the right-hand side of the trailer coupling cross member
Step dimensions: 520 mm x 190 mm/20.5 in x 7.5 in
Q24 Trailer Cross Member (towing capacity 2268 kg/5000 lbs)
Enables retrofit of a trailer coupling. Trailer socket (E40) is included.
Max. permissible tongue weight is 500 lbs (227 kg)
Max. towing capacity is 5000 lbs (2268 kg)
Not for 170EXT cargo van. Available in combination with QA9.
QA2 Trailer Cross Member (towing capacity 3402 kg/7500 lbs)
Enables retrofit of a trailer coupling. Trailer socket (E40) is included.
Max. permissible tongue weight is 750 lbs (340 kg)
Max. towing capacity is 7500 lbs (3402 kg)
Not for cargo van with length 170EXT. Available in combination with QA9.
⑴ NOTE
as standard for model designation 907 and can not
be deleted.
6.6.8 Underrun protection Dimensions of the rear underrun protection

• Maximum height of rear underrun protection
Rear underrun protection (unladen vehicle) above roadway: 550 mm/22 in.
The rear underrun protection fitted at the factory • Width:
(except on cargo vans and passenger vans) complies
with the regulation UN R 58. -  Maximum = Width of the rear axle (outer tire
edges).
Rear underrun protections are based on state level
regulations. -  Minimum = Width of rear axle minus
100 mm/4 in on each side. The decisive factor is
the widest axle.
• The crossmember must have a section height of at
least 100 mm/4 in.
• Edge radius at least 2.5 mm/0.1 in.
3.9 in
min.
100 mm
max.
21.7 in
550 mm
max.
400 mm
15.7 in
N31.30-2336-00
Side view of the rear underrun protection location

underrun protection.
The regulation UN R 58 stipulates a underrun protec-
tion when:
• with the vehicle in its unladen condition, the dis-
tance between the roadway and the chassis or main
parts of the body in the area between the insides
of the tires -100 mm/4 in per side, is more than
550 mm/22 in
Exceptions to this regulation are semitrailer trucks,
working machines and vehicles whose purpose cannot
be fulfilled if an rear underrun protection is fitted.
The underride guard must be mounted as far back as
possible.
Front underrun protection Modifications to the underrun protection

Front underrun protections are based on state level If the underrun protection needs to be repositioned due
regulations. Please refer to CMVSS 215/US 49 CFR to the overhang extension, the attachment must be the
Part 581. same as that of the original vehicle.
If modifications are required to the underrun protec-
tion (e.g. due to the attachment of a lifting platform),
the strength and bending resistance of the underrun
protection must not be modified.
Any modifications to the underrun protection must
comply with local and national regulations and laws.
⑴ NOTE
On cab-chassis, the reinforcement of the trailer
coupling in the left/right rear longitudinal member for
BR 907 is installed in the vehicle as standard. If this
is not required, it must be deleted when the vehicle is
ordered (code QW1). For cargo, crew, and passenger
vans, the longitudinal member reinforcement must be
N31.30-2337-00
ordered at the same time (code Q11).
Side view of the front underrun protection location
Dimensions of the front underrun protection:

Lateral protections
• Height of front underrun protection above roadway:
406 mm/16 in.
• The crossmember must have a section height of at
13.8 in
least 100 mm/4 in. 350 mm
21.7 in
550 mm
• In case of code ZG1/ZG3 (4x4), the front underrun

protection lies 74 mm/2.9 in lower.
37.4 in
950 mm
Torques for remounting:
N31.30-2339-00
Side view of the lateral protection location
N31.30-2338-00
Torques for remounting ront underrun protections
Protective equipment on the sides has to comply with 6.6.9 Positioning placard holders
applicable legal regulations.
This chapter provides information about positioning and
Components may be mounted within the lateral pro- fastening methods to add aftermarket placard holders
tections, e.g. battery box, air tank, fuel tank, lamps, to the Sprinter vehicle.
reflectors, spare wheel and tool box, provided that the
specified clearances are maintained. ⑴ NOTE
Brake, air or hydraulic lines and other parts must not be
It is the upfitter’s responsibility to adhere to all appli-
fastened to the lateral protection.
cable rules and regulations, particularly Canadian
The function and accessibility of all equipment on the laws mandated by Transport Canada regarding the
vehicle must not be impaired. Transportation of Dangerous Goods.
If lateral protections are retrofitted: The upfitter may choose the below mentioned posi-
• The dimensions specified in the illustration may not tions. For fastening the placard holders, it is recom-
be exceeded. mended to use a gluing method to reduce the risk of
corrosion due to drilling through the body shell. If the
• Protective equipment must comply with applicable upfitter fastens the placard holders by drilling holes and
legal regulations. using bolts, please refer to Chapter 5.3 Anti-corrosion
• The lateral protections must extend continuously protection measures (→ page 86). The upfitter needs
from the front to the rear wherever possible. to ensure enough clearance between the sliding door
Adjacent parts may overlap. The overlapping edge must and the placard holder. The upfitter needs to ensure
point to the rear or downwards. The maximum permis- that the equipment installed to the exterior of the
sible width of any gap between segments is 25 mm / vehicle must not become loose and be lost during the
0.98 in, provided the rear part does not protrude signifi- vehicle operation.
cantly beyond the front part. The following picture indicates the Mercedes-Benz
The lateral protection may consist of a continuous recommended left, right, and rear position of the
level surface. The outer surface must be smooth and placard holders. For positioning the placard holder to
generally flat. The lateral protection parts must be rigid the front-bumper of the vehicle, it needs to be ensured
and permanently fixed into place. They must be made that no sensors are covered or impaired if the vehicle
of metal or another suitable material. The distance is equipped with Parktronic or Collision Prevent Assist/
between the outer surface of the lateral protection Active Brake Assist - code BA3/Active Distance Assist
and the outer edge of the vehicle must not be more – ET4. The sensor positions are described in chapter
than 120 mm/4.7 in. The edge radius must be at least 5.4 Painting work/preservation work (→ page 88),
2.5 mm/0.1 in. chapter 8.9.3 Active Brake Assist/Active Distance
Assist (DISTRONIC PLUS) (→ page 275) and chapter
8.9.10 Parktronic sensors (→ page 295).
144” 170” 170”EXT

x1 450 mm / 450 mm / 450 mm /
17.7 in 17.7 in 17.7 in
Y1 584 mm / 584 mm / 584 mm /
23 in 23 in 23 in
x2 485 mm / 485 mm / 485 mm /
19 in 19 in 19 in
y2 584 mm / 584 mm / 584 mm /
23 in 23 in 23 in
x3 289 mm / 289 mm / 289 mm /
11.3 in 11.3 in 11.3 in
y3 181 mm / 181 mm / 181 mm /
7.1 in 7.1 in 7.1 in
Positioning of placard holders (left, right, and rear position
7 Design of bodies
7.1 Assembly frame
This chapter contains information concerning the upfit

Minimum section modulus required for assembly
made by the upfitter.
frame Wx1
All upfits require a continuous assembly frame or a Version Platform/ Dumper/ Loading
substructure that acts as a continuous assembly frame box body lifting work crane
in order to ensure a flawless connection between the platform
chassis and upfit, see 7.1.5 Assembly frame as floor All weight 17 cm /
[2] 3 30 cm3/ 40 cm3/
assembly (→ page 188) and 7.2 Self-supporting bod- variants 1.0 in 3 1.8 in 3 1.0 in3
ies (→ page 189).
1 The minimum section modulus required for assembly
The attachment to the frame must run along the
frames is relevant to the material characteristics speci-
frame using the body consoles attached to the frame fied in the table of materials above, and each individual
at the factory, see 7.1.2 Design (→ page 181) and assembly frame longitudinal member must have this
7.1.4 Attachment to the chassis bed (→ page 183). section modulus.
Exception: On vehicles with a dropped frame (model 2 Up to the maximum standard wheelbase; above that:
designation 907.x5x) (7.1.2 Design (→ page 181)), the +10%.
assembly frame longitudinal members can run continu-
ously in a straight line. • If high-strength steel is used for the assembly
frames, their strength must be at least equivalent to
7.1.1 Material quality, general that of steel assembly frames.
• When using an assembly frame made of aluminum,
Material quality of specified assembly frame made of
for example, it must have at least the bending
steel:
strength (E x I) of a steel assembly frame. Observe
• Assembly frame mounted with mounting consoles the specifications of the manufacturer.
(non-positive) = CR240LA or S235JRG2.
• For CR240LA or S235JRG2 steels complying with Guideline values for modulus of elasticity:
the DIN EN standard, analogous materials complying • Aluminum: 70000 N/mm2; 1015000 psi
with the US SAE/ASTM J403/J412/J413 standards,
• Steel: 210000 N/mm2; 3045000 psi
the Japanese JIS G3445 standards or the UK BS 970
standards can be used. .
If a lifting platform (cargo liftgate) is being fitted,
Material Yield strength Tensile strength observe the relevant chapter and refer to the overview
CR240LA 260-340 N/mm2; ≥ 240 N/mm2; (→ page 169).
37700 psi- ≥ 34800 psi
49300 psi ⓘ Observe any deviations in the specifications in this
S235JRG2 ≥ 235 N/mm2; 340-510 N/mm2; chapter, see 7.5 Platform bodies (→ page 196)
≥ 34075 psi 49300 psi- and 7.9 Dump trucks (→ page 200).
73950 psi
Material specifications should correspond to DIN stan

dard MBN11251
7 Design of bodies
7.1.2 Design
If very high longitudinal members are required, or if
General low overall frame heights are achieved, the following
On model designations 907.X2X, 907.X3X and non-positive connections are possible for U-sections:
907.X4X, the mounting frame longitudinal members
must be arranged above the straight chassis frame • Closed as a box
longitudinal members. • Nested
On model designation 907.X5X, the mounting • Overlapping
frame longitudinal members can be straight
through, see note on offset frames at the end of This increases the section modulus and torsional
this chapter. stability.
At the position of the double body brackets (see
2 in illustration Chapter 6.2.2 Attachment to
the frame (→ page 105)), the mounting frame
cross-members must be positioned about the chas-
sis frame cross-members.
For the other mounting frame cross-members, an
arrangement above the chassis frame cross-mem-
bers is recommended.
The assembly frame longitudinal members must
extend as far towards the front of the vehicle as
possible, to reinforce the point behind the cab
which is critical with regard to bending stress, as
well as to prevent vibration problems.
The body must have a torsion-free attachment to the
body consoles on the longitudinal frame member.
Place the vehicle on a flat, horizontal surface
before mounting the body.
Frame sections
A Open U-section Assembly frame with dropped frame

B Closed U-section
C Nested U-section On vehicles with a dropped frame (permissible gross
D Overlapping U-section mass ≥ 4.6 t/10141 lbs), the assembly frame longitudi-
nal members can run continuously in a straight line.
7 Design of bodies
7.1.3 Section dimensions/dimensioning Please refer to the table below for the section dimen-
sions of assembly frame longitudinal members (open
Folded U sections or commercially available U sections
section).
for vehicle construction (not rolled steel sections) are
to be used for the longitudinal members. Box sections The assembly frame and the chassis frame should have
are also permitted as longitudinal member sections. approximately the same flange width.
The dimensions of the longitudinal members are a func-
tion of the section modulus (Wx) required for the body ⑴ NOTE
and the chassis (→ page 180). If more than one body is mounted on the same
The specified section moduli and section dimensions chassis (e.g. platform and lifting platform), the larger
refer to longitudinal frame members subjected to iden- of the specified section moduli must be taken to
tical loads on both sides. determine the assembly frame.
Longitudinal member dimensioning
h: Section height in mm
Wx: Section modulus in cm3
7 Design of bodies
7.1.4 Attachment to the chassis bed The bodies must rest on the body consoles and may
also rest on the frame crossmembers. It is recom-
At the least, all the factory-installed body consoles
mended that the body should not rest on the end
must be used for attaching bodies to the vehicle frame.
crossmember. If prefabricated assembly frames are
The consoles are located on the longitudinal frame
used, the production tolerances of the chassis frame
members and additional body consoles may be fitted
width (maximum +6/–3 mm; +0.2/-0.1 in) must be
to the longitudinal frame members as required. All the
taken into consideration.
body consoles, in particular those at the rear end of the
frame, must be used to attach a lifting platform (cargo
liftgate) and the body. ⓘ The positions for the body consoles are indicated in
the 2D chassis drawings (offer drawings) depending
on the model series (→ page 18).
⑴ NOTE
The minimum distance between the body and the cab
must be > 50 mm/2 in.
1 2
60 mm
18 mm
0.71 in
13 mm
0.51in
1 2.36 in 2
180 mm 134 mm 70 mm 118 mm 70 mm 25 mm

2.76 in 195 mm
7.09 in 5.28 in 2.76 in 4.65 in 0.98 in 7.68 in
18 mm 18 mm
0.71 in 0.71 in
23 mm
66 mm 0.91 in
13 mm 120 mm
2.60 in 0.51in 4.72 in
N60.00-2228-00
N60.00-2506-00
Designs of attachment points on the frame
7 Design of bodies
Additional body consoles

If it is necessary to fit additional body consoles, make
sure that you comply with the welding directives
(→ page 85).
• Do not perform any welding work in bends.
The body consoles must be attached using two bolts
for each body console.
Attachment of the body consoles

If a mounted box body is rigid, then it is recommended
to ensure that there is a large contact area between
the mounting consoles and the body. If possible, the
mounting consoles of the subframe should have identical
Example of a body console design
dimensions to the body consoles on the vehicle.
The force at these threaded connections must be I Box section
distributed across the maximum possible surface area II U-section
using washers with a diameter of approximately 35-40 1 Chassis frame
mm (1.37-1.57 in) or square shims with a length along 2 Assembly frame
3 Standard mounting console
each edge of approximately 35-40 mm (1.37-1.57 in)
4 Mounting console
Body consoles (dimensions in mm/in)
Attachment to a longitudinal member
7 Design of bodies
Shear-resistant connection
ⓘ Also refer to 7.10 Light duty truck (→ page 201).

For a shear-resistant connection, the assembly frame
longitudinal members must be secured in both longitu-
dinal and transverse directions. This will allow move-
ment of the assembly frame longitudinal member only
under specific conditions.
The body can be secured to the sides of the upper flan-
ges on the longitudinal frame member. Spacer bushes
welded to the frame must be used for reinforcement.
For shear-resistant connections, a double support is
required for each longitudinal frame member as depicted
in the figure below. The shear-resistant connection is
required e.g. for "Loading crane at frame end" and is
Attachment to a crossmember recommended for "Loading crane behind the cab".
Double support (shear-resistant connection)

Attachment to a crossmember
a Shear-resistant connection at frame end
1 Body console b Standard holes at frame end
Select the number of attachments to ensure adequate

transfer of all longitudinal and lateral forces.
Correct attachment is a decisive factor for:
• vehicle handling and operating safety
• the durability of the chassis frame and the body
7 Design of bodies
Chassis connection for rigid body upfits

For fully integrated bodies (continuous connection
between the upfit and the rear of the B-pillar):
It is recommended to utilize standard bolted or rigid
connections with maximized grip length between all
mounting consoles and the mounting frame (the upfit-
ter’s frame connecting to the chassis frame).
For non-fully integrated bodies (no connection
between the upfit and the rear of the B-pillar) and upfits
with a rigid mounting frame, please follow the out-
lined recommendations below.
The upfitter needs to ensure that the equipment Elastomer bearings/ bushings"
installed to the vehicle must not become loose and be
lost during the vehicle operation. • A rigid connection with maximized grip length should
be used at the last connecting console of the chassis
⑴ NOTE frame, and if necessary, place the rigid connections
with maximized grip length from the third console
Definition of rigid body upfits: Mounting frames or to the mounting console immediately behind the
box upfits connected to the longitudinal members of rear axle. The spacer sleeve is used to maximize the
the cab chassis frame which substantially modify the grip length to prevent connection from loosening.
torsional rigidity and bending behavior of the vehicle The dimensions of the spacer sleeves must be thick
frame particularly in the area behind the B-Pillar. enough to ensure they do not deform. These rigid con-
nections should also be used for attaching bodies such
The following mounting concept is recommended to
as garbage presses or box bodies ≥ 1000 mm/39.8
decrease potential stress peaks directly behind the
in (measured from behind the B-pillar) in combination
B-Pillar (transition between rear of cab and longitudi-
with a dump bed or platform on the chassis frame
nal members) by using a combination of elastic and
rigid connections:
• An elastic connection should be used for the first and
second mounting consoles to prevent stress peaks in
the transition area between the rear of the cab and the
longitudinal members (see pictures on following page).
The picture below shows an example using multiple disc
springs. As an alternative, an elastic element out of elas-
tomer material (e.g. rubber) may be used as well.
Rigid connection with maximized grip length
• A standard bolted should be used from the third con-

sole to the mounting console immediately behind the
rear axle. Also a rigid connection with maximized grip
length (described in B) may be used in this area.
Elastic connection with spring discs

a Flanged bolt M12 x 90, strength 10.9
b Spacer sleeve 22-13 x 50
c Washer DIN 7349-13-ST
d Nut with flange M12, strength 10.9
e Elastic element (e.g. multiple disc springs or
polymer springs)
7 Design of bodies
Standard bolted connection

If there are additional loads on the chassis frame
besides the body upfit, then it may be required to
reinforce the rear end of the mounting frame by fitting
a diagonal cross.
Please also observe Chapter 8.4.6 Retrofitting electri-
cal equipment (→ page 242)
ⓘ If additional information is required, please refer to

Mounting concept for body upfits with rigidity:
Sprinter cab chassis with 144” wheelbase – recommended attachment to the chassis frame/longitudinal members
Sprinter cab chassis with 144” wheelbase – recommended attachment to the chassis frame/longitudinal members
7 Design of bodies
7.1.5 Assembly frame as floor assembly

An assembly frame with continuous longitudinal mem-
bers is not required if the body floor assembly can take
on the function of the assembly frame.
The longitudinal members can also be integrated in
the body. If the assembly frame longitudinal members
are intersected by the crossmembers, the connection
between the longitudinal and crossmembers must be
rigid and resistant to torsion and bending.
Example of a floor assembly design
7 Design of bodies
7.2 Self-supporting bodies
An assembly frame with continuous longitudinal mem-

bers is not required if the body's floor assembly can
assume the functions of the assembly frame.
Self-supporting bodies must comply with the proper-
ties of the specified assembly frame. The body's floor
assembly must have equivalent rigidity and a section
modulus similar to the assembly frame. The floor
assembly of the self-supporting body must be attached
to the vehicle frame in the same way as a body frame/
assembly frame by means of a stretch bolt connection
locked to prevent loosening (→ page 188).
mm
00 in
x. 6 23.6
ma
N31.20-2200-00
Example of a body design
7 Design of bodies
7.3 Modifications to the interior
Retrofitting additional seats For modifications to the seat attachments (including

The strength of the seats delivered from the factory is only seat bases) and seat belt anchorages or for the instal-
valid if the seats are secured in their original mountings lation of seats other than those available from the
factory, an evalution with the responsible department
When retrofitting seats, it is absolutely essential to is necessary. As part of the eXpertUpfitter program
keep to the H-point. The seat adjustment range must please refer to www.UpfitterPortal.com.
not be enlarged. For up to date documentation, see 1.7
Contact (→ page 11). ⚠ WARNING
If a rear bench seat with 2 or 3-point seat belts devi- If seats other than those fitted at the factory are
ates from the standard seat design, it must comply fitted in conjunction with seat belts available from the
with the requirements from chapters 6.4.1 General factory, only seat belt buckles that are compatible
information (→ page 138), 6.4.2 Safety equipment with the belt tongues of the factory-supplied seat
(→ page 139) and 6.4.3 Seats (→ page 147). belts may be used. Otherwise the seat belt cannot
A rear seat system with 2- or 3-point seat belts that be locked in the seat belt buckle as intended. Pas-
deviates from the standard seating arrangement must sengers will not be protected as intended. There is a
meet the requirements of the FMVSS/CMVSS 207 risk of accident, personal injuries and death if such
(seating systems) and the FMVSS/CMVSS 210 (seat systems no longer function correctly!
belt assembly anchorages) standard. Furthermore, the Only use latch plates which are approved for the
standard FMVSS/CMVSS 209 (Seat belt assemblies) factory-fitted seat belts.
must be adhered to. For the headrests, proof of compli-
ance with the FMVSS/CMVSS 202a (Head restraints)
standard is required. The test reports in relation to Only the components of the series production supplier
FMVSS/CMVSS 202a, FMVSS/CMVSS 207, FMVSS/ may be used for the installation of seat belts and seat
CMVSS 209 and FMVSS/CMVSS 210 must be submit- belt buckles:
ted for approval by Mercedes-Benz. Contact details
When reinstalling seat belts, the specified bolts must Postal address: Autoliv B.V. and Co. KG
be replaced and tightened to the original torque with Postfach 109
the tolerances for connecting and fastening elements D-25333 Elmshorn, Germany
including the classification (A/B/C) as per VDI 2862 Telephone: +49 (0)4121 - 797-0
(The Association of German Engineers).
All regulations relevant to approval (e.g. seat belt
⚠ WARNING buckle position) must be observed when fitting seat
belts and seat belt buckles other than those available
It is not permitted to mount seats on the wheel well,
from the factory.
partitions or other sheets metal parts of the vehicle
as they could become detached from their anchor-
ages in the event of an accident. Passengers will not
be protected as intended. There is a risk of accident,
personal injuries and death if such systems no longer
function correctly.
In the case of vehicle orders where the driver's seat

(code S90) or front passenger seat (code S91) is omit
ted, subsequent installation of standard seats (driver's
or front passenger seat) in the body-in-white is not
permitted, as no reinforcements or suitable connection
points are available. However retrofitting of aftermarket
seats is possible.
7 Design of bodies
Rear seats in the passenger compartment/cargo

area
On cargo vans of model series BR 907, the body-in-
white floor assembly is available from the factory as
special equipment under code V40 (Crewbus floor 1
assembly) for retrofitting bench seats. The number
of mounting options for the crewbus floor assembly
depends on the model series and the equipment or
registration variants (the mounting shells for the bench
seats are not included in the scope of delivery). N91.12-2191-00
Right load compartment sliding door from outside without

paneling
⑴ NOTE
The upfitter is responsible for ensuring compliance 1 Assembly part "impact protection reinforcement"
with the legal requirements for transporting passen-
The reinforcement is required when installing rear seats
gers in the rear.
in the cargo van and crewbus in the following coun-
tries:
Additional information on special equipment code V40 • Mexico, USA, Canada
can be obtained from your Mercedes-Benz Service
Center, the relevant department (→ page 14) or • GCC Arab States of the Gulf (Kuwait, Bahrain, Saudi
under 3.12 Special equipment (→ page 55). Arabia, Qatar, United Arab Emirates, Oman)
GCC = Gulf Cooperation Council
If rear seats with 2 or 3-point seat belts deviate from
the standard seat design, they must comply with the If the upfitter retrofits of rear seating for these coun-
requirements of the regulations UN-R 14 (seat belt tries, it must be ensured that the impact protection
anchoring), UN-R 16 (seat belts) and UN-R 17 (seats reinforcement is installed.
and head restraints). In combination with the special equipment crewbus
floor assembly (code V40), the impact protection rein-
⚠ WARNING forcement is already installed at the factory.
If seats other than those fitted at the factory are For retrofit installation, the assembly part is available
fitted in conjunction with seat belts available from the from your Mercedes-Benz Service partner under the
factory, only seat belt buckles that are compatible following item numbers:
with the belt tongues of the factory-supplied seat • A 910 730 47 00 left reinforcement
belts may be used. Otherwise the seat belt cannot be
locked in the seat belt buckle as intended. Passen- • A 910 730 48 00 right reinforcement
gers cannot be protected as intended. There is a risk The fasteners and tightening torques documented in
of injury! WIS (see Chapter 2.3.2 Workshop Information System
Only use latch plates which are approved for the (WIS) (→ page 18)) must be used for installation.
factory-fitted seat belts.
⑴ NOTE
The upfitter must check and comply with all national
Reinforcement of sliding door to load compartment
laws, directives and registration regulations.
with rear seats
For the Sprinter BR 907 the impact protection rein-
forcement is added automatically as required for vehi-
cles with a long sliding door to the load compartment
(vehicle length A2 and over, not for A1) and vehicles
with crewbus floor assembly (code V40) for countries
with appropriate legislation which requires the installa-
tion of this reinforcement.
7 Design of bodies
7.4 Modifications to closed cargo vans
Floor assembly/side walls

On cargo vans, the body and the chassis frame form a
self-supporting unit. If body parts are modified or fitted,
they must only be welded if a bonded connection is not
possible.
For this reason, windows, roof hatches and vent open-
ings must be mounted in a sturdy frame. The frame
must then be joined by a non-positive attachment to
other body elements.
Underbody Supporting Structure Depending on the coding, there is an underbody sup-

porting structure (A 906 312 16 61) in the cargo van
and passenger van integrated. The amount of installed
structures at the different positions for different config-
urations is shown in the following table:
Tonnage Wheelbase
170 170 EXT
Support- Support- Support- Support-
ing struc- ing struc- ing struc- ing struc-
ture 1 ture 2 ture 1 ture 2
2500 1 1 1 3
3500, 1 1 1 1
3500 EXT
N61.00-2035-00
Underbody Supporting Structure
The underbody supporting structure may have parts

installed, if the following codes are used:
Code Description Supporting Structure 1 Supporting Structure 2

UT1 Seat Attachment Fond, Fixing Point No Yes
V39 Artificial Surface No No
People Mover
V43 Wooden Floor No No
ZE6 Structure for the Installation of No No
Shelves
7 Design of bodies
Cab rear panel Partitions in the BM 907

If an opening is made in the cab rear panel, it must be Vehicles upfitted as commercial vehicles without a
surrounded by a sectional frame. partition do not satisfy the requirements of ISO 27956,
The remaining braces and pillars must be reinforced which describes the fixtures for the proper securing of
by additional gussets and connected to the sectional cargo in delivery vans. If the vehicle is used to trans-
frame (e.g. by bonding). port goods, the installation of a ISO 27956 compliant
partition is recommended.
Also please refer to 6.2.5 Modifications to the cab
(→ page 110). If retrofits, modifications, or attachments of any kind
are performed on the partition, compliance with ISO
27956 is recommended.
If the partition is removed, the vehicle will no longer
comply with ISO 27956. In this case, the tie-down eyes
must be installed. If the partition/divider is modified or
removed or has parts attached to the partition wall, the
functionality of safety equipment (e.g. the deployment
areas of airbags) must not be affected (see Chapter
6.4.2 Safety equipment (→ page 139)).
In these cases the upfitter must ensure that the prod-
uct satisfies the requirements of a safe product, if nec-
essary by means of other measures as he or she sees
fit. In this respect, the ISO standard represents only the
technical minimum standard.
The following partition walls are available as special
equipment from the factory:
Code Description
D50 Full-width partition wall (standard)
D51 Full-width partition wall with window
D56* Full-width partition wall at C-pillar
D64 Partition wall with sliding door
D93 Omission of partition wall
* Only available in Canada
Additional information on special equipment can be

obtained from your Mercedes-Benz Service Center or
under 3.12 Special equipment (→ page 55).
7 Design of bodies
Head Impact
⑴ NOTE
Certain precautionary measures are necessary to
ensure the safety of all passengers. Following FMVSS 201 requirements, all Mercedes-
Benz Vans ≤10,000 lbs and without a partition wall are
Mercedes-Benz offers two different solutions:
fitted with foam pads (see picture). Vehicles >10,000
1. Mercedes-Benz partition wall meeting the FMVSS lbs with and without a partition wall are fitted without
201 requirements. foam pads.
2. If there is no Mercedes-Benz partition wall installed, It is not recommended to modify the foam pads
foam pads are provided in order to meet FMVSS 201. and their surrounding area in order to comply with
FMVSS 201.
ⓘ In the case you are installing an aftermarket
partition wall, please ensure to meet FMVSS 201
requirements.
It is upfitter’s ultimate responsibility to review and com-
ply with FMVSS 201 as it relates to its installation of
Mercedes-Benz partition walls and foam pads, as well
as its decision to use and install non-Mercedes-Benz
partition walls and parts.
• If the vehicle has no partition wall installed and has
a GVWR ≤ 10,000 lbs, it is fitted with foam pads (see
pictures below)
High roof Standard roof
• If the vehicle has a partition wall installed, it is not

fitted with foam pads (see pictures below)
7 Design of bodies
• If the vehicle has no partition wall installed and has

a GVWR ≥ 10,000 lbs, it is not fitted with foam pads
(see pictures below)
7 Design of bodies
7.5 Platform bodies
To ensure the uniform loading of the chassis frame, the

body must be attached to the chassis frame by means
of an assembly frame (U-section longitudinal members)
(→ page 180).
must be used for attaching platforms to the vehicle
frame.
If the standard platform is subjected to point loads (e.g.
for the transportation of cable drums, coils, etc.), the
substructure and the platform floor must be reinforced
to support the load.
Before start of installation:
Weigh the chassis and establish body length.
• For the section dimensions of the assembly
frame longitudinal members, see the diagram
(→ page 182).
⑴ NOTE
Where bodies include detachable parts which move
independently, ensure that there is adequate clear-
ance between the detachable parts and the basic
vehicle, otherwise they may collide with the basic
vehicle, resulting in damage.
7 Design of bodies
7.6 Box bodies
To ensure the uniform loading of the chassis frame,

the box body must be attached to the chassis frame
by means of an assembly frame (U-section longitudinal
members) (→ page 180). In the case of self-support-
ing box bodies, its function and the equivalent rigidity
of the floor assembly of the box body must be guaran-
teed. Refer to the chapters 7.1.5 Assembly frame as
floor assembly (→ page 188) and 7.2 Self-supporting
bodies (→ page 189).
must be used for attaching box bodies to the vehicle
frame. The information on mounting on the vehicle
frame in chapters 6.2.2 Attachment to the frame
(→ page 105) and 7.1.4 Attachment to the chassis
bed (→ page 183) must be implemented.
The floor assembly, see Chapter 7.1.5 Assembly frame
as floor assembly (→ page 188), and a self-support-
ing body, see Chapter 7.2 Self-supporting bodies
(→ page 189), must be attached to the vehicle frame
in the same way as a body assembly frame is mounted
on the vehicle frame.
On self-supporting or box bodies with assembly frames,
stretch bolt connections locked to prevent loosening
and spacer sleeves must be provided behind the cab
at the first and second body consoles. The dimensions
of the spacer sleeves must be adequate to ensure that
they cannot become deformed (→ page 188).
Section moduli (Wx) and material properties can be
⑴ NOTE
The minimum distance between the cab and a sepa-
rate body must be > 50 mm or 1.97 in.
ⓘ For integral box bodies (→ page 226).
7 Design of bodies
7.7 Refrigerated vehicles/temperature-con-

trolled vehicles
Refer also to the following chapters:

⑴ NOTE
• 6.5.1 Retrofitting an air conditioning system
(→ page 152). People working inside the vehicle may inadvertently
• 6.5.3 Engine power take-off (→ page 154) become trapped by doors closing by themselves or
being closed by other persons.
• 6.2.9 Cargo Van/Passenger Van roof (→ page 118).
The bodies of refrigerated/temperature-controlled
• 8.4.6 Retrofitting electrical equipment vehicles must be designed so that any persons shut
(→ page 242). inside can open the door outwards from the inside in
• The requirements for reducing noise in the vehicle every situation.
interior must be met, based on the cargo van, by We recommended fitting the doors of refrigerated
means of insulation material for refrigerated vehicles, bodies with an emergency release so that they can
see 6.4.4 Reducing interior noise (→ page 148). be opened easily from the inside at any time even
With cargo vans, easy access to the components of the when locked.
door mechanism (e.g. guide rails and hinges) must be
retained so as not to hinder possible repair work.
⑴ NOTE
⑴ NOTE When using refrigeration systems/components in
combination with the refrigerant R1234yf, all applica
On cargo vans, the insulation increases the weight
ble laws, regulations and safety specifications must
of the doors and therefore the load on the hinges,
be observed.
carriages and locking systems.
In particular, compliance with the safety regulations
according to ISO 13043 at both the component and
These requirements and notes are also applicable for overall system level (FMEA, leaktightness require
vehicles used to transport loads under constant condi- ments, concentration measurements etc.) must be
tions within the load compartment, for example with a guaranteed.
constant temperature higher than 0 °C/32 °F.
Along with this, also observe the safety requirements
with regard to inflammability and risk of combustibil
ity in combination with R1234yf (maintain best-pos
sible packaging or largest-possible distance to hot
parts, if necessary, install additional devices for
assuring the required safety).
If R1234yf is used, a specific information label with
details of the quantity and combustion risk must be
considered or installed in a visible location.
7 Design of bodies
7.8 Vehicles for transportation

of technical gases
Vehicles for transporting technical gases with tanks

and lines for liquefied gases must be equipped with
adequate heat insulation from the rest of the vehicle.
This is even more important for lines that are passed
through the vehicle chassis or the body in white. To
allow venting of supercooled liquefied gases, a dis-
tance of at least three meters is required between the
vent opening and the vehicle. If venting is necessary,
make sure that the vent opening points away from the
vehicle. Any escaping condensation must be caught in
a suitable container.
Transport of gases is subject to the hazardous materi-
als law regulated by FMCSA under 49 CFR Part 173 in
the US, and to the Transportation of Dangerous Goods
Act (Transport Canada) in Canada.
7 Design of bodies
7.9 Dump trucks
Vehicles with dump trucks are subject to local and Tilting ram
countryspecific directives and laws. The press carrier is attached to crossmembers in
Vehicles with dump bodies can only be used under nor- the assembly frame.
mal operating conditions. As part of the eXpertUpfitter The crossmembers of the assembly frame and the
program, possible deviations can be evaluated with the chassis must be placed on top of each other as far
responsible department. as possible.
On three-way dump trucks, the application point
Make sure that you do not exceed the permissible axle of the lifting press must be in front of the center of
loads. gravity of the body and the payload.
ⓘ Also see Chapter 6.6.8 Underrun protection Assembly frame

(→ page 176) and see subsection Lateral protec- If chassis are provided with dump trucks, the assembly
tions (→ page 177) frame must have the correct dimensions to support the
high loads to which the vehicle will be subjected.
ⓘ Tilt support
Pay attention to the following points:
The rear tilt support for three-way and rear-end Attach assembly frames to body consoles
dump trucks should be mounted as close as possi- as per 7.1.4 Attachment to the chassis bed
ble to the rear axle. (→ page 183).
The dropside must not impact the frame end, the Make sure that the steel longitudinal and cross-
lighting equipment or the trailer hitch when folded members have the correct dimensions.
down.
Close off the rear area of the assembly frame
Provide guide brackets for the front pivots, so towards the cargo van and, if necessary, reinforce
that the pivots are guided when the dump body is the assembly frame by installing a diagonal cross or
lowered. by taking other appropriate measures.
Restraining facilities At the least, all the factory-installed body consoles

must be used for attaching dump trucks to the
Local and country-specific directives and laws must vehicle frame.
be observed.
Vehicles with dump trucks can only be used under
Install a support (fold-out support) to prevent the normal operating conditions. As part of the eXpert-
dump body from dropping. Upfitter program, possible deviations can be evalu-
Secure operating devices against accidental operated with the responsible department.
ation. Section moduli (Wx) and material properties can be
Connect a "Dump truck" indicator lamp to provide found under 7.1 Assembly frame (→ page 180).
a visual warning that the dump truck has not folded
back completely (in driving position).
7 Design of bodies
7.10 Light duty truck
Chassis may generally be converted into light duty Consult your local licensing authority/office if you are
truck vehicles provided that this conversion com- unsure whether a semitrailer without ABS can continue
plies with national regulations and laws. The different to be used in your registration area.
regional and national vehicle registration requirements It is not permitted to combine the Sprinter BR 907.xxx
are too diverse to be covered here, so please obtain with a semitrailer without ABS.
comprehensive details from your local licensing author-
ity or office before ordering and modifying the vehicle. For vehicles of these classes which are not equipped
with ESP® ex factory, no CoC documents will be
Among others, the specific registration requirements provided from now on (code XC1 or code XC9). These
in terms of the Electronic Stability Program (ESP®) and affect the following:
tire pressure loss detection system must be obtained
and complied with. • Code O27 - Brake control system retrofitted for ABS
with MSR
The Sprinter (BM: 907.133, 907.233, 907.153,
907.253) may be operated as a light duty truck with Please note that this applies to all vehicles if they are
ESP® under the following condition: to be registered with a gross mass of no more than
12000 kg/26455 lbs. This also applies, for example, to
1. Combining the Sprinter with a semi-trailer without light duty trucks with the codes XP6 and XP7.
ABS is not permitted. To convert a chassis to a light duty truck, an evalution
However, in order to achieve optimum handling char- with the responsible department is necessary. As part
acteristics, we recommend the use of an RSC system of the eXpertUpfitter program please refer to www.
(Roll Stability Control) in the light duty truck which will UpfitterPortal.com.
automatically intervene whenever the light duty truck The longitudinal frame members must be reinforced by
becomes unstable. These systems are available e.g. a subframe or a semitrailer bracket.
from the manufacturers Knorr-Bremse (TEBS) or Wabco
The vehicle must be equipped with stabilizer bars on
(EBS).
the front and rear axles.
Since the RSC of the light duty truck acts autono-
mously, no provision is made for signal transmission
from the towing vehicle, and no additional electrical
connections are necessary. The manufacturer of the
semitrailer brake system must be consulted to ascer-
tain whether it is possible to retrofit an RSC system on
a semitrailer with ABS.
7 Design of bodies
Recommended special equipment (option codes) Electrical connection for the light duty truck
for conversion to light duty truck All additional electrical consumers must be connected
Code E57: Electronic trailer socket as per 8.4 Interfaces (→ page 239) and 8.4.6 Retrofit-
Code E2I: Auxiliary battery for retrofit consumers, ting electrical equipment (→ page 242).
vehicle interior • The connection lines must not chafe against body
Code E2M: Auxiliary battery for retrofit consumers, components.
engine compartment • The upfitter must ensure freedom of movement when
Code EK1: Terminal strip for auxiliary consumers cornering.
For information regarding the available code combina- • Connection lines must not get caught on the light
tions, please refer to 1.7 Contact (→ page 11). duty truck or pull on the trailer socket.
We also recommend the use of additional stabilizer • When the tractor is driven without a light duty truck,
bars as special equipment to optimize handling charac- the connection lines must be secured correctly.
teristics, depending on the type of semitrailer used.
For information on recommended special equipment,
Brake system
please refer to 1.7 Contact (→ page 11).
The light duty truck brake system must be connected
Assembly frame for light duty truck to the light duty truck vehicle. On no account should
If the vehicle is used as a light duty truck vehicle, inertia-activated brakes be fitted.
a steel assembly frame made of rectangular tubes, An evalution with the responsible department is nec-
100 mm x 60 mm x 3 mm (or s = 4 mm)/ essary. (As part of the eXpertUpfitter program please
3.94 in x 2.36 in x 0.12 in (or s = 0.16 in) with a sec- refer to www.UpfitterPortal.com.)
tion modulus Wx of at least 25 cm3 is required. Therefore, the upfitter must ensure:
The assembly frame must extend rearwards as far as • The brake system of the light duty truck and light
the standard chassis end and, towards the front, as far duty truck, the compressed-air supply system and
as the first body console behind the cab. the compressed air reservoir must be designed in
The assembly frame must be mounted according to accordance with national guidelines and legislation.
7.1.4 Attachment to the chassis bed (→ page 183) • A hydraulic-pneumatic control valve must be installed
using, at the least, all the factory-installed body con- in the vehicle brake system for actuation of the light
soles. duty truck brake. Two valves manufactured by Beka
In addition, the connection between the frame and the are approved by Mercedes-Benz.
assembly frame must be shear-resistant at the frame
end. The attachment must be made to the upper flange
of the longitudinal frame members on the model desig-
nations 907.1 and 907.2 (→ page 183).
An additional shear-resistant connection must be made
at the front end of the longitudinal frame members.
7 Design of bodies
⑴ NOTE
The light duty truck brake system must be designed
with a sufficient supply of energy in accordance with
national guidelines and legislation.
The light duty truck manufacturer and the upfitter are
responsible for the correct functioning of the semi-
trailer brake.
Mounting plate and fifth wheel coupling

The upfitter must ensure that the mounting plate and
fifth wheel coupling are adequately dimensioned.
Comply with all national directives and laws.
The mounting plate and the fifth wheel coupling must
be mounted in compliance with the manufacturer's
specifications and mounting instructions.
7 Design of bodies
7.11 Recovery vehicles
Vehicles with bodies for rescue or recovery equipment

must be attached with assembly frames of adequate
dimensions (→ page 183).
In addition, the bodies must be fitted with two shear-re-
sistant connections for each longitudinal frame mem-
ber.
For bodies for recovery and towing vehicles, an evalu-
tion with the responsible department is necessary.
National/Country-specific regulations, as well as
accident prevention regulations and general machin-
ery directives must be observed. Lateral protec-
tions (→ page 177) and 6.6.8 Underrun protection
(→ page 176)
7 Design of bodies
7.12 Torsionally stiff body types
The bodies and assembly frames for torsionally rigid

bodies (e.g. municipal vehicles, refuse presses or
closed box bodies ≥ 1000 mm/39.4 in long behind the
cab in combination with a dump body or platform and
firetruck cargo vans or street-cleaning vehicles) must
be attached by means of threaded connections locked
to prevent loosening with spacer sleeves and stretch
bolts at the front of the frame (→ page 188). At the
least, all the factory-installed body consoles must be
used.
If required, the assembly frame must be additionally
reinforced at the rear by fitting a diagonal cross.
Please also observe 8.4.6 Retrofitting electrical equip-
ment (→ page 242).
7 Design of bodies
7.13 Lifting work platform
General If chassis are equipped with lifting work platforms, the

following points must be observed due to high loads:
⑴ NOTE • Retrofitting of lifting work platforms, an evalution
Where bodies include detachable parts which move with the responsible department is necessary. As
independently, ensure that there is adequate clear- part of the eXpertUpfitter program please refer to
ance between the detachable parts and the basic www.UpfitterPortal.com.
vehicle, otherwise they may collide with the basic • The stability of the lifting work platform must be
vehicle, resulting in damage. ensured by the upfitter.
• The outriggers must comply with the information
⑴ NOTE (→ page 166) on outriggers for loading cranes.
• The upfitter must produce additional operating
The lifting work platform may only be used when the
instructions for the lifting facility, which are to be
vehicle is fully raised on its outriggers. When the
supplied with the vehicle. The operating instructions
platform is raised, there must be no additional loads
must contain the warning that no persons or loads
in or on the cab. There is otherwise a risk of damage
are permitted in the cab when the vehicle is in the
to the frame. The vehicle must not be moved with
raised state.
the lifting work platform extended. The frame may
be damaged if the vehicle is moved with the lifting • To ensure the uniform loading of the chassis frame,
work platform extended. The upfitter must implement the body must be attached to the chassis frame by
a safety facility to prevent the vehicle from being means of an assembly frame.
moved with the lifting work platform extended. This • At the least, all the factory-installed body consoles
may be done through the control system of the lifting must be fastened to the assembly frame.
work platform, for example, or in conjunction with
• An additional body console must be installed for
the parameterizable special module (PSM, Code ED5)
each longitudinal frame member in the area behind
(→ page 296).
the cab (see example illustration).
• The attachment of the first and additional mount-
ing consoles must be with threaded connections
locked to prevent loosening and spacer sleeves
(→ page 188).
• The introduction of force onto the supports must be
exactly halfway between the two standard double
bracket pairs behind the cab on the assembly frame.
In addition, the assembly frame must be sufficiently
protected against torsion in the area of force intro-
duction by means of a crossmember.
7 Design of bodies
Required additional body console The body consoles must be of at least the same quality
To ensure a uniform introduction of force onto the as the standard material CR240LA and have a wall
chassis frame, one additional body console is required thickness of 3 mm/0.19 in.
for each longitudinal frame member in the area behind The hole spacing of the additional body console to the
the cab. next adjacent hole in the existing body console must
measure 100 mm/3.94 in.
Body consoles
1 Additional body consoles
When installing additional body consoles, we recom-

mend the use of genuine Mercedes-Benz parts.
For more detailed information on the standard posi-
tions and dimensions of the body consoles, see 2.3.1
Upfitter Portal (→ page 18) and 7.1.4 Attachment to
the chassis bed (→ page 183).
7 Design of bodies
Assembly frame The assembly frame must be attached in the same way
The installation of lifting work platforms on a chassis to all body consoles. The attachment of the assembly
requires an assembly frame of sufficient size. frame at the first and additional mounting consoles
must be with threaded connections locked to prevent
Section moduli (Wx) and material properties can be loosening and spacer sleeves (→ page 296). The
found under 7.1 Assembly frame (→ page 180). introduction of force onto the assembly frame by the
outriggers must take place exactly halfway between the
two double bracket pairs installed behind the cab as
standard.
In the area of the introduction of force onto the assem-
bly frame by the outriggers, a rigid crossmember (front
and rear) must be installed to protect the assembly
frame against torsion.
Attachment of assembly frame to body consoles
a Area of additional mounting consoles

b Required crossmembers for assembly frame in area of
force introduction from outriggers
c Outriggers
7 Design of bodies
7.14 Bodies on chassis with base (F28)
7.14.1 Base/windshield support structure and Base with doors F28

base with doors F28 On vehicles with cab base and doors, the cab rear
panel and cab roof are omitted ex factory. In addition,
Note regarding registration eligibility of base an auxiliary roof bow is fitted above the B-pillars to
vehicles (F28) stiffen the cab.
On leaving the factory, the base vehicles (F28) initially
only have incomplete vehicle documents. The upfit-
ter must ensure that the vehicle has complete type
approval.
Please refer to the information on requirements for the
approval and registration eligibility of vehicles given in
Chapter 2.3 Product and vehicle information for upfit-
ters (→ page 18).
Modifications or conversions to standard vehicles
(e.g. the installation of a lifting roof) may invalidate
the operating permit. Please refer to country and/or
state-specific legal regulations. For US operating per-
mits, the approval conditions and requirements of the
Department of Motor Vehicles (DMV) must be met. For
N60.80-2415-00
Canadian operating permits, please refer to provincial
Base with doors F28
transportation ministries.
Omission/cutting of B-pillar auxiliary roof bow

If the B-pillar auxiliary roof bows are cut or omitted,
reinforcement measures (→ page 123) are necessary.
⑴ NOTE
For alternative methods of ensuring equivalent rigidity
developed by the upfitter, an evalution with the
For the design of the measures ensuring equivalent
rigidity, an evalution with the responsible department
is necessary. As part of the eXpertUpfitter program
please refer to www.UpfitterPortal.com.
7 Design of bodies
7.14.2 Mechanical equipment

The following information is relevant to all upfitters
who use base vehicles (F28) as a basis, even if the text
addresses specific upfitters, e.g. RV manufacturers.
Reinforced seat base for seat with integrated

three-point seat belt (code S86)
1
The seat with integrated 3-point seat belt is not
included in the package supplied by Mercedes-Benz.
1 N60.80-2466-00
Side view of reinforced seat base

1 Swivel console
Pre-installation in seat (driver/front passenger)

for mounting second armrest
Function description
The seats (driver and front passenger) of the Sprinter
N60.80-2465-00
can be ordered by the upfitter with an additional mount
Schematic diagram of reinforced seat base for a second armrest.
1 Reinforced seat base Boundary conditions:

• The geometry of the connection element of the
Function description Sprinter’s armrest must be adopted.
The reinforced seat base is designed to absorb • The second armrest is a retrofit.
increased forces (caused by the seat with integrated
three-point seat belt). 2
Boundary conditions:
• Certification takes place in the system (seat + seat
base + body) and must be performed by the upfitter.
• The assumed point of load application on the seat
(when designing the reinforced seat base) must be
considered when selecting the seat.
1
N60.80-2467-00
Schematic diagram of seat

1 Swivel console
2 Armrest
For further information on the seat/seat load, see Chap-

ter 4.5 Limit values for the interior (→ page 77) and
Chapter 6.4 Interior (→ page 138) in these guidelines.
7 Design of bodies
7.14.3 Wiring harness connecting points
Overviews of wiring harness connecting points

The connecting points shown below, divided into series
production packages and special equipment options,
mainly concern the chassis versions with base (F28).
Certain connecting points are only relevant in the case
of conversion to RVs.
Other connecting points are specific to the traction
head. They are shown in the overview, but are not
described in further detail.
13 13 8
4 8

12 12 110
9 9 10
2
3 11 6
1 11 67 7
N60.80-2469-00
N60.80-2468-00
Overview of connecting points for series production

packages
7
Series production packages:
1 Wiring harness for connecting point for Headlamp Assist 8 9
(LA2) and rain sensor (JF1 option) with omission of wind-
shield
2 Wiring harness for driver’s seat connecting point / with
omission of seat (front passenger in mirror reverse) for
seat belt warning system and seat belt buckle pre-instal-
lation.
3 Wiring harness for door connecting point for driver and 10
front passenger with omission of door (front passenger
in mirror reverse) Overview of connecting points for special equipment options
4 Wiring harness for connecting point for headlamps,
(front passenger in mirror reverse)
5 Wiring harness connecting point for pre-installation for
Special equipment:
Blind Spot Assist (code J1V), for electrics of rear speak- 7 Body manufacturer interface H (code E2A); for traction
ers (code EP7) and for reversing camera (code FR7) head-specific details, see Body/Equipment Mounting
Directives for BR 910, chap. 7.15
6 Wiring harness connecting point for antenna box/GPS
interface 8 Body manufacturer interface M (code E5M); for traction
head-specific details, see Body/Equipment Mounting
Directives for BR 910, chap. 7.15
9 Wiring harness seat connecting point for driver with
omission of seat (front passenger in mirror reverse) for
seat heating pre-installation
10 Additional fuses for camper vans (code E1R and E1Y)
7 Design of bodies
7.14.4 Headlamp Assist (code LA2)
Relevance Boundary conditions/completion

• On base vehicles (code F28) with windshield: When If a superstructure is fitted (e.g. on alcove vehicles),
the vehicle leaves the factory, this system is fully this can have a negative effect on the Headlamp Assist.
functional. For the superstructure, an evaluation with the responsi-
ble department is necessary as part of the eXpertUpfit-
Function description of Headlamp Assist ter program.
If the ambient brightness drops below a certain value,
the Headlamp Assist switches on the driving lights
automatically. If the value measured by the light sensor
increases to a certain level, the Headlamp Assist
switches the driving lights off again.
Weather-related visibility impediments such as fog,
snow or rain are automatically taken into account by
the Headlamp Assist.
The Headlamp Assist increases visibility and safety in
road traffic.
N60.80-2470-00
Example of sensor on windshield
For detailed information on the Headlamp Assist and

rain sensor, see Chapter 8.9.6 Rain sensor and Head-
lamp Assist (→ page 286) in this guideline.
7 Design of bodies
7.14.5 Rain sensor (code JF1) 7.14.6 Driver’s and front passenger’s doors
connection point
Relevance
• On base vehicles (code F28) with windshield: When Relevance
the vehicle leaves the factory, this system is fully • Base vehicles (code F28) with omission of left cab
functional. door (code FW8) and right cab door (code FW9)
Function description of rain sensor Function description of door connecting point

When the windshield wiper lever is set to the appropri- The two vehicle doors ensure reliable operation of a
ate position, the windshield wipers are activated. wide variety of functions which can or must be imple-
The rain sensor transmits infrared light at a certain mented in combination with the door control unit.
angle into the windshield which then reflects the light The door control unit is connected to the body CAN
differently depending on how wet it is. An electronics and sends or receives necessary vehicle information
system uses the amount of light detected to control the via this CAN.
wiping cycle from a single wipe to continuous wiping. The installation and commissioning of both door control
This means relaxed driving even under unfavorable units is also necessary if only a side panel without
weather conditions by doing away with manual actua- access is implemented instead of the driver's or front
tion of the wiping interval. passenger door.
Boundary conditions/completion The door connecting point is an interface used for com-
pleting the following scopes.
If a superstructure is fitted (e.g. on alcove vehicles),
this can have a negative effect on the Headlamp Assist. • Door control unit and functions implemented by the
door control unit
For detailed information on the Headlamp Assist and
rain sensor, see Chapter 8.9.6 Rain sensor and Head- • Speaker connection (special equipment, added via
lamp Assist (→ page 286) in this guideline. radio)
Functions which are implemented by the door

control unit
• Exterior light functions: Entrance lamp, exit warning
lamp (only with code JB6)
• Exterior mirror functions: Turn signals, Blind Spot
Assist display (only with code JA7/JV1+OB2), heater,
motors
• Actuators: Power window motor, central locking
system
• Rotary tumbler door contact
• Actuation: Window lifter, seat heating, central lock-
ing, mirror adjustment
• Front side turn signal lamps with code L44 (instead
of mirror indicators, pin assignment must be
observed)
7 Design of bodies
Boundary conditions/information on installation 7.14.7 Headlamp connecting point - series

1. The door control unit must be connected and put production packages and special
into operation. The current coding must be observed. equipment options
Without the door control unit, the vehicle is not
operational. Relevance
2. A door connecting point (right and left) is provided • Chassis vehicles

ex factory. The door control unit is supplied with the
vehicle.
The headlamp connecting point is an interface used for
3. The code FX3 can be used to additionally order the
completing the following scopes.
door wiring harness from the door connecting point
to the door control unit and to the optional special • Series production packages: Headlamps and turn
equipment. signals
4. The listed functions only function in combination with • Special equipment option: Front fog lamps (code
the door control units. L13)
5. Further components such as switches and electric It is possible to use own halogen or LED headlamps if
motors can be provided on request. the performance data (table) given in chapter 10.2 Bulb
ratings of exterior lights (→ page 317) is complied
6. The door control unit and the other components
with.
must be installed and put into operation by the
upfitter. The provision of Mercedes-Benz series production
headlamps can be requested.
The vehicle can be registered on completion of the
series production packages.
N60.80-2471-00
Example of Sprinter light sources
Boundary conditions/completion
Power output data specified for light sources by
Mercedes-Benz must be complied with. This is neces-
sary to ensure that the lamp failure indicator functions
correctly.
For power output data, see Chapter 8.5 Illumination
(→ page 254) and Chapter 10.2 Bulb ratings of exte-
rior lights (→ page 317) in this guideline.
7 Design of bodies
7.14.8 Connecting point for antenna switchover 7.14.9 Pre-installation for upfitter interface H
box for third-party antennas (code E4A) (code E2A) and upfitter interface M (code
E5M)
Relevance
• All vehicles without roof ex factory including cab Pre-installation for upfitter interfaces H and M
chassis with doors with code F28 The pre-installation for upfitter interface H (tapping of
upfitter special signals in cockpit, code E2A) and for
Function description of antenna switchover box upfitter interface M (expansion of MPM (PSM) standard
With the special equipment option “Antenna interface contact, code E5M) allows the upfitter to tap the follow-
for radio, navigation and mobile radio (code E4A)”, ing signals in the cockpit.
Mercedes-Benz provides an interface for connecting a • Battery network
third-party antenna with AM/FM and DAB. This inter-
• Exterior lights
face is located in the driver’s seat box.
• Instrument lighting
An antenna box is connected downstream of this
connecting point ex factory. This box splits the incom- • Signal lines routed through from interface H. In
ing AM/FM and DAB signal into two signals and feeds combination with the MPM/PSM (code ED5), vehicle
them to the head unit. signals can also be supplied.
A 12 V power supply for the third-party antenna is pro-

vided at this connecting point.
For the upfitter, the connecting point enables simple
connection of a third-party to the Mercedes-Benz head
unit by means of a defined interface.
Boundary conditions/completion 2
The antenna switchover box must be supplied with the 1
following signals.
• FM (87 MHz – 108 MHz)/AM (531 kHz – 1720 kHz)
• DAB band III (174–240 MHz)
• Impedance 50 ohms N60.80-2444-00
Upfitter interfaces
The connection of the navigation system must be
supplied with the following signal: 1 Upfitter interface H
• GNSS 1575 MHz – 1606 MHz 2 Upfitter interface M
• RHC (right-hand circulation) polarization

• Impedance 50 ohms
• Operating voltage 4.5 V – 5.5 V
• Power consumption 20 mA ±3 mA
For further information on the upfitter antenna inter-
face, see Chapter 8.13.2 Antennas (→ page 303).
7 Design of bodies
Function description of upfitter interface H Function description of upfitter interface M

Upfitter interface H (code E2A) provides an additional Upfitter interface M (code E5M) allows the signals from
interface in the area of the A-pillar on the driver’s side. the MPM/PSM to be tapped more easily without the
Upfitter interface H allows the signals described below need for complex cable routing.
to be tapped more easily. Upfitter interface M provides an additional interface
In addition, 5 signals are routed from interface H in the driver’s seat box. The signals from the MPM/
through to interface M. These signals are freely avail- PSM are routed out from this interface. In addition, 5
able to the upfitter. They can be used to, for example, signals can be routed from upfitter interface M through
send signals from the MPM/PSM (code ED5) to inter- to upfitter interface H. These signals are freely available
face M (code E5M). to the upfitter.
See section 8.10.2 (→ page 298) for more information
Boundary conditions/completion
on the upfitter interface M plugs
The plug can be fitted with a wiring harness from the
Details on the following interfaces can be obtained
upfitter according to requirements.
from the respective specialist unit.
The following lines/signals are provided:
Body manufacturer interface M - plug 1
• Five signal lines
• Left and right turn signal indicators and one revers-
ing light
• Tml. 58d dimmable instrument lighting Requirements
• Tml. 15, tml. 30T (shutoff on weak battery) and • The fuse ratings can be found in the “Supplement -
tml. 31. Fuse assignments”.
The max. performance data and parameters of the • Access to the signals from the exterior lights is only
connections must be complied with. permitted in combination with the additional turn
signal module.
• Access to the reversing light signal is only permit-
ted in combination with the additional turn signal
module.
• Tml. 58d driver module requests (battery voltage):
Maximum current ≤1 A
7 Design of bodies
7.14.10 Pre-installation for rear speakers (code 7.14.11 E-call on base vehicles
EP7)
The Mercedes-Benz emergency call system can help
The electrical pre-installation for rear speakers, code to decisively reduce the time between an accident and
EP7, provides an additional electrical interface. the arrival of emergency services at the site of the acci-
This interface enables the upfitter to install his or her dent. The data is relayed via the communications mod-
own rear speakers. ule for Mercedes PRO in the vehicle. The emergency
call is thus not dependent on whether a mobile phone
Completion is switched on, but requires a GSM connection and the
ability to locate the vehicle via GPS. It can be triggered
The pre-installation provides a plug which is connected
automatically by the crash sensors or manually by the
to the speakers.
driver pressing the SOS button. The emergency call will
then be directed to the Mercedes-Benz emergency call
Requirements
number or to a local emergency call center.
In combination with the telematics and infotainment
system of Mercedes-Benz, the speakers must satisfy
certain requirements. For this, see Chapter 8.13.3
Speakers (→ page 307).
N60.80-2447-00
SOS push button switch
Completion
On F28 base vehicles (cab without roof and rear panel),
the SOS button and the associated microphone are
integrated in the overhead control panel. This is sup-
plied ex factory. For integration in the body, particular
attention must be paid to the accessibility of the push
Electrical interface
button switch for the driver and front passenger.
1 Connectors for additional rear speakers.
For more information, please use bulletin, Sprinter

MY2019+ Additional Speaker (code EP7), on Upfitter
Portal.
7 Design of bodies
1
N60.80-2448-00
Position of SOS button in overhead control panel
1 Position of SOS push button switch
Boundary conditions
In emergency call mode the center speaker is actuated
for voice output. It is located centrally at y=0 (in the
center of the vehicle) at the front of the cockpit shell
directly behind the windshield (F28 and standard).
The upfitter must take particular care to ensure that
the acoustics of the center speaker are not altered by
installations mounted over it, because this is a certi-
fied system. Likewise the center speaker must not be
replaced or modified in any vehicles with MB emer-
gency call system (code EY5).
N60.80-2449-00
Position of center speaker
7 Design of bodies
7.15 RV – Recreational vehicles
General 7.15.1 Body in white of RVs

Prior to conversion into an RV, please note:
Boundary conditions/notes
• The legal requirements must be complied with.
• Easy access to the engine, drivetrain, suspension,
• The legal requirements for interior design and equip- door mechanism (e.g. guide rails and hinges) must
ment for RVs must be fulfilled. be ensured so as not to hinder possible repair
work, see Chapter 3.11 Maintenance and repairs
Information on registration eligibility of RVs
(→ page 51).
On leaving the factory, the base vehicles (F28) initially
• The standard fuel filler cap must not be removed or
only have incomplete vehicle documents.
covered with any "blocking" parts.
The upfitter must ensure that the vehicle has complete
type approval. ⑴ NOTE
Modifications or conversions to standard vehicles
If the fuel cap is removed or parts are attached to
(e.g. the installation of a lifting roof) may invalidate
the fuel cap, blocking may occur in the event of an
the operating permit. Please refer to country and/or
accident. Because of this, the protrusion space in
state-specific legal regulations. For US operating per-
the B-pillar may no longer function correctly. On no
mits, the approval conditions and requirements of the
account should the cap be covered with paneling
Department of Motor Vehicles (DMV) must be met. For
parts, and “blocking” parts must never be mounted
Canadian operating permits, please refer to provincial
on the B-pillar.
transportation ministries.
The vehicle registration documents must be presented.
After the modifications have been entered, the vehi- Attachment to the frame
cle registration documents must be submitted to the
• Chassis must be attached to the basic vehicle using
relevant registration office so that a new type approval
at the least all of the factory-fitted body consoles
can be issued.
(→ page 183). These permissible body mounting
points are located only on the longitudinal frame
members and may be supplemented as required by
additional body consoles on the longitudinal frame
members.
• The body brackets must be secured using two bolts
for each body bracket.
• For information on integrated RVs, see Chapter 7.17
Semi-integrated bodies and optional mounting of
free-standing bodies (→ page 226).
7 Design of bodies
Particular attention must be paid to the following sec-

⑴ NOTE
tions of the Body and Equipment Guidelines:
The minimum distance between the rear edge • 3.5 Dimensions and weights (→ page 37)
of the door and an integrated body must be
• 4.2 Limit values for the suspension (→ page 68)
> 20 mm/0.79 in.
• 4.2.2 Permissible axle loads (→ page 69)
Otherwise, the rear edge of the door may come into
contact with the body in the event of an accident, • 6 Modifications to the basic vehicle (→ page 92)
and in extreme cases the door may be jammed. • 6.2.7 Fenders and wheel wells (→ page 114)
• 6.4.3 Seats (→ page 147)
• 7.4 Modifications to closed cargo vans
min. 20 mm (→ page 192): ensure compliance with FMVSS/
0.8 in
CMVSS for head impact
• 8 Electrics/electronics (→ page 233)
• 8.9.2 Crosswind Assist (→ page 273)
• 8.9.5 Highbeam Assist, Lane Keeping Assist and
traffic sign recognition (→ page 286)
• 8.9.6 Rain sensor and Headlamp Assist
(→ page 286)
7.15.2 Suspension of RVs

Detailed information on the suspension of RVs can be
found under Chapter 4.2 Limit values for the suspen-
sion (→ page 68).
Special considerations for RVs

N40.00-2053-00
Minimum distance between rear edge of door and For upfitters who build a RV on the Sprinter chassis,
integrated body the option code X2R - Conversion to RV requirement
must be ordered. When the code X2R is ordered, the
code B01 (Vehicle version for high center of gravity) will
be automatically added.
Please pay attention to the correct variant when order-
ing the vehicle. For more information please review
Chapter 9.1.2 Determination of the center of gravity in
the z-direction (→ page 311).
ⓘ Detailed information on base vehicles can be

found in 7.14 Bodies on chassis with base (F28)
(→ page 209).
⑴ NOTE
Mercedes-Benz recommends a reinforcement of
the front axle using an option code A50 (Front axle
reinforced)
7 Design of bodies
7.15.3 Electrics/electronics of RVs 7.15.4 Additional main fuses for RVs (codes E1R
and E1Y)
Overviews of wiring harness connecting points for
series production packages and special equipment
options.
The main fuse box contains 4 additional fuses that are
A detailed presentation of all connecting points can
not used by the basic vehicle. These are available to
be found in Chapter 7.14.3 Wiring harness connecting
the upfitter with code E1R and E1Y with different fuse
points (→ page 211) for cab base vehicles
ratings at fuse slot F9 (see table at the end of the chap-
Particular attention must be paid to the following chapter) in order to connect defined consumers.
ters of the Body and Equipment Guideline:
Three 30 A output fuses are provided in the seat base,
• 6.5 Additional assemblies (→ page 152) which are connected to F8 via a line (see illustration
• 8 Electrics/electronics (→ page 233) "Additional fuse for camper vans").
• 8.3 Battery (→ page 235) This facilitates the connection of electrical consumers
to terminal 30T.
• 8.4 Interfaces (→ page 239)
Fuse location F10 is occupied if the special equipment
• 8.9.2 Crosswind Assist (→ page 273)
rear air conditioning system with code HH7, HK4 or
• 8.9.3 Active Brake Assist/Active Distance Assist H08 is used, and is therefore no longer available.
(DISTRONIC PLUS) (→ page 275)
Fuse location F12 is occupied if the special equipment
• 8.9.4 Blind Spot Assist/Rear Cross Traffic Alert air spring (code CB2) is used, and is therefore no lon-
(RCTA)/Exit Warning (→ page 277) ger available.
• 8.9.5 Highbeam Assist, Lane Keeping Assist and
traffic sign recognition (→ page 286)
• 8.9.6 Rain sensor and Headlamp Assist
(→ page 286)
• 8.9.7 Tire pressure loss detection system
(→ page 288)
• 10.2 Bulb ratings of exterior lights (→ page 317)
⑴ NOTE
If a significant weight is upfitted to the vehicle, it is
recommended to measure the upfitted vehicle height Position of fuse box in BR 907 vehicle
and recalibrate the DISTRONIC PLUS sensor height
1 Position of fuse box
accordingly. Please visit a local Mercedes-Benz deal-
ership.
⑴ NOTE

For easier integration of aftermarket electrics/ elec-
tronics, we recommend the use of PSM (ED5) and
its extension harness (E5M). For more information,

please see section 8.10 Parametrerizable Special

Module (PSM/ MPM) (→ page 296).

Additional fuse for camper vans
7 Design of bodies
Code E1R E1Y Long-term startability

To ensure startability even with long non-operational
Main fuse locations lmax.[A]
times, an extra function has been developed for the
F8 100 100 Sprinter. When the battery reaches a critical value, this
F9 150 80 function becomes active and maintains the startability
F10 80 80 of the vehicle.
F12 40 40
Own points of interest (POIs) in navigation system
Upfitters for RVs have the option of integrating their own
ⓘ The valid fuse assignments and values for each of
points of interest (POIs) in the Mercedes-Benz vehicle
the vehicles are available in the supplement "Fuse
navigation system. This allows the end customer of
assignment", which is part of the accompanying
the RV manufacturer to navigate directly to the nearest
vehicle documents and which is available in XENTRY
Mercedes-Benz service point or contract partner.
(see Chapter 2.3.3 XENTRY Kit (→ page 19) ).
https://xentry.daimler.com/home/ Pre-installation for rear speakers
A pre-installaton for rear speakers (code EP7) is avail-
7.15.5 New features for RVs able to allow RV manufacturers to connect additional
speakers to the radio in their body.
Pre-installation for switch panel (code E3J) For further information on this pre-installation, see
Sprinter is equipped with two switch panels ex-factory: Chapter 7.14.10 Pre-installation for rear speakers
a two-switch panel (to the left of the steering wheel on (code EP7) (→ page 217).
left-hand drive vehicles) and a six-switch panel (to the Retrofitting rear seats
right of the steering wheel on left-hand drive vehicles).
For the retrofitting of seats in the rear, the information
The switch frames have dummy covers.
and specifications in Chapter 7.3 Retrofitting seats
The upfitter can use special switches (switches avail- (→ page 190) must be observed.
able from Eugen Kurz KG), i.e. instead of installation of
the dummy covers and actuation via the PSM (MPM).
Advantage: By using the available switch panels and
switches, upfitters can utilize their own functions in the
Sprinter design.
For further information on operating switches, see
Chapter 8.4.5 Operating switches (pre-installation)
(→ page 241) in this guideline.
Radio operating time

With the special equipment code E1X (MBUX multime
dia system with longer shutoff delay), the radio operat
ing time has been increased to 6 hours (depending on
the battery state of charge).
For a long radio operating time, we recommend fully
charging the starter battery.
For RVs with code X2R (Conversion to RV requirement),
this code E1X is added automatically.
⑴ NOTE
In order to use multimedia systems while stationary
with an external power supply, a power feed to the
starter battery of at least 140 W is required.
7 Design of bodies
7.15.6 Airbags for RVs Additional requirements for window airbags

(code SH9):
Additional airbag systems can be ordered for RVs under
the following special equipment codes: • Code SH9 can only be ordered in combination with
code F28 or for panel vans.
• Driver thorax/pelvis side airbag (code SH1)
• Side window blackout curtains or awnings on side
• Front passenger thorax/pelvis side airbag
windows are not permitted in combination with this
(code SH2)
equipment.
• Window airbags for driver and front passenger
• Installed windshield blackout curtains/awnings/
(code SH9)
shelves and their retaining systems must not impede
Special requirements and information apply to the the deployment areas of the airbags.
use of these special equipment options in RVs, which
• All work on an A-pillar with window airbags is prohib-
can be found in the following chapters and must be
ited.
observed:
• The attachment of holders and brackets to the A-pil-
• Chapter 4.5.1 Modifications to airbags and seat belt
lar trim is to be avoided.
tensioners (→ page 77)
• Chapter 5.2 Welding work (→ page 85) Additional requirements for thorax/pelvis side
• Chapter 5.4 Painting work/preservation work airbags (code SH1/SH2):
(→ page 88) • Code SH1/SH2 can only be ordered in combination
• Chapter 6.1.4 Air suspension (→ page 98) with code F28 or for panel vans.
• Chapter 6.2.1 General information on the body in • Installed window blackout curtains/awnings and
white/body (→ page 101)) their retaining systems on driver/front passenger
side windows must not impede the deployment areas
• Chapter 6.2.2 Attachment to the frame
of the airbags.
(→ page 105)
• The use of armrests on both sides of the seat is not
• Chapter 6.4.1 General information (→ page 138)
permitted in combination with this system.
• Chapter 6.4.2 Safety equipment (→ page 139)
• Aftermarket seat covers are not permitted in combi-
• Chapter 7.4 Modifications to closed cargo vans nation with the thorax/pelvis side airbag system.
(→ page 192)
• Safe routing of the airbag ignition lines must be guar-
anteed by means of dedicated seat swivel consoles
(no twisting/pressure points on ignition lines).
7 Design of bodies
7.16 Bodies on chassis with lowered roof
Code FA1 "Lowered roof" is available for semi-inte-

grated and alcove bodies on vehicles with code F28
"Base with doors". Code FA1 comprises the following
changes from the standard version:
• The height of the roof is reduced by approx.
70 mm/2.76 in.
• The vehicle is cut in the area of the roof/door portal,
reinforced by means of body in white modifications
and then painted in the area of the body in white
modifications.
• The standard-equipment sun visors and grab handles
are mounted in the same position at modified attach-
ment points.
Location of auxiliary roof frame
• The roof lining can be attached at the previous
attachment points, but must be trimmed and 2 Auxiliary roof frame
adjusted to fit the interior at the front and sides by a Distance between top edge of longitudinal frame mem-
the upfitter. ber and top edge of auxiliary roof frame:
• The vehicle is fitted with a temporary roof bow for 3500XD, 4500 a = 1540 mm/60.47 in
transportation.
• Before the body is erected it is necessary for the
upfitter to install the auxiliary roof frame supplied at
the attachment points provided in order to ensure
adequate equivalent rigidity. This provides a lowered
attachment plane for bodies.
• Body limits for camera-based support systems
must be observed, see 8.9.5 Highbeam Assist,
Lane Keeping Assist and traffic sign recognition
(→ page 286) and 8.9.6 Rain sensor and Headlamp
Assist (→ page 286).
7 Design of bodies
7.16.1 Mounting the auxiliary roof frame 7.16.2 Mounting the body on the auxiliary roof
frame
The temporary roof bow (1) must be detached before
mounting the auxiliary roof frame (2). The body can be attached to the auxiliary roof frame by
The auxiliary roof frame (2) must then be mounted at • Bolts
the points provided using six M10 x 20 10.9 round • Rivets
headed bolts (tightening torque 40 Nm +/- 2 Nm;
8.28 ft lb +/- 0.41 ft lb). • Adhesive bonding
• Welding
⑴ NOTE
Holes must not be drilled in the corners of the auxil-
iary roof frame.
The auxiliary roof frame must not be cut.
The introduction of force to the auxiliary roof frame
must occur by way of an area load (line load). Point
loads must not be introduced into the auxiliary roof
frame.
Mounting of auxiliary roof frame The load on the auxiliary roof frame while driving
1 Transport roof bow
must not exceed 100 kg/220.5 lbs. When the vehicle
2 Auxiliary roof frame is stationary, a load of 200 kg/491 lbs is permissible.
3 Cutting area with reinforcements (body in white modifi-
cations)
Attachment areas for auxiliary roof frame on vehicles with

lowered roof
b Attachment area
c No drilling allowed
Please also observe 5.3 Anti-corrosion protection
measures (→ page 86). The department responsible
will be happy to answer any questions 1.7 Contact
(→ page 11).
7 Design of bodies
7.17 Semi-integrated bodies and optional mount-

ing of free-standing bodies
A non-positive connection between cab and body is The descriptions apply for cabs both with and without
required on vehicles with semi-integrated bodies e.g. rear panel.
semi-integrated RVs, integral box bodies etc.
For vehicles with free-standing bodies (e.g. box bodies),
it is also possible to optionally connect it to the cab. For
this, the same specifications apply as for semi-integrated
1
bodies. The body must have adequate inherent rigidity in
the attachment area (avoid local compression).
The connection between the cab and the body must be
continuous at the B-pillars and the roof frame (either
full length or in sections). For a specific implementation
and other measures, an evalution with the responsible
department is necessary. As part of the eXpertUpfitter 2
program, please refer to www.UpfitterPortal.com. N60.80-2416-00
Attachment of body to B-pillar and roof (example of

free-standing body, schematic diagram)
1 Roof
2 B-pillar
7 Design of bodies
Attachment of body (box body etc.) to B-pillar

(z-axis)
The body side wall must always be connected to the
B-pillar. The connection between body and basic vehi-
cle must be non-positive.
It must be assured that forces are transmitted between
the body and the B-pillar. This can be achieved by e.g.:
Variant 1
Attachment of body to B-pillar via a plate with
t = 2 mm/0.08 in angled at approx. 2x45°.
The plate must be bonded across its entire surface
area.
2
3
1
y
x
N60.80-2417-00
Variant 1: Attachment of body to B-pillar via plate (example with and without rear panel)
1 B-pillar
2 Bonding flange
3 Plate
7 Design of bodies
Variant 2
Attachment of body to welding flange of B-pillar with
angle pieces.
4 3
5
2 y
x
N60.80-2418-00
Variant 2: Attachment of body to B-pillar via bracket (example with and without rear panel)
1 B-pillar
2 Bonding flange
3 Front wall of body
4 Bracket
5 Rivet
7 Design of bodies
Attachment of body (box body etc.) to roof frame

(y-axis)
In addition to the connection between body side wall
and basic vehicle, it is necessary to form a non-positive
connection between body and basic vehicle in the area
of the roof frame on vehicles with integral bodies. This
can be achieved by e.g.:
Variant 1
Attachment of body to roof frame via a plate with
t = 2 mm/0.08 in angled at approx. 2x45°.
The plate must be bonded across its entire surface
area.
2
3
1
y
x
N60.80-2419-00
Variant 1: Attachment of body to roof frame via plate (example with and without rear panel)
1 Roof frame
2 Bonding flange
3 Plate
7 Design of bodies
Variant 2
Attachment of body to welding flanges of roof frame
using angle pieces.
4 3
5
2 y
x
N60.80-2420-00
Variant 2: Attachment of body to roof frame welding flange via bracket (example of with and without rear panel)
1 Roof frame
2 Bonding flange
3 Front wall of body
4 Bracket
5 Rivet
On vehicles with cut roof frame, the upfitter must

ensure force transfer to the simulating structure
(→ page 123). Therefore, an evalution with the respon-
sible department is necessary.
7 Design of bodies
7.18 Buses and People Mover
Prior to conversion into a bus, please note: Installation of third-party windows

Conversions to standard vehicles may invalidate the If the upfitter is going to install aftermarket windows,
operating permit. Please refer to country and/or code W94 “No windows in bus version” is available
state-specific legal regulations. For US operating per- from the factory. It is not permissible to install pan-
mits, the approval conditions and requirements of the oramic windows on a cargo van without code W78
Department of Motor Vehicles (DMV) must be met. For by cutting out the stamped window shape without
Canadian operating permits, please refer to provincial ensuring equivalent rigidity.
transportation ministries. Ensure compliance with FMVSS/CMVSS regarding
Further general technical information: escape windows.
• Local and country-specific laws and regulations must For cargo vans with window prep package, aftermarket
be observed. emergency window exit needs to be installed for bus
• Ensure an equivalent replacement structure in the conversions. Please ensure that all applicable regula-
body-in-white for modifications to the roof and roof tions pertaining to FMVSS/CMVSS 217 are followed.
bow structure.
• Ensure that all installed components are not under
static load.
• All solutions must be coordinated with
Mercedes-Benz (development, calculation, rough
roads, durability, NVH, anti-corrosion protection,
sealing, etc.).
Body-in-white
If the body-in-white is modified or cut, e.g. to lower the
vehicle floor in order to gain cargo capacity, to install
emergency exits or similar, the anti-corrosion protec
tion measures specified by Mercedes-Benz AG (as per
the currently valid Sprinter Body and Equipment Guide-
line) must be carried out and all other specifications in
the current Body and Equipment Guideline regarding
modifications to the body-in-white must be observed.
Particular attention must be paid to the following chap-
ters of the BEG:
• Chapter 4.3.1 Modifications to the body in white
(→ page 72)
• Chapter 4.3.2 Limit values for the vehicle frame
(→ page 72)
• Chapter 4.3.3 Roof/roof load (→ page 73)
• Chapter 6.2 Body in white/body (→ page 101)
• Chapter 6.3.3 Exhaust system (→ page 132))
7 Design of bodies
Retrofitting an air conditioning system Interior

See Chapter 6.5.1 Retrofitting an air conditioning sys- Refer to local and country-specific legal regulations.
tem (→ page 152) See also the following chapters on the vehicle interior:
• The additional belt pulley, code N63, is available • Chapter 4.5.1 Modifications to airbags and seat belt
from the factory as special equipment for driving tensioners (→ page 77)
air-conditioning compressors and should be utilized.
• Chapter 4.5.2 Modifications to seats (→ page 77)
• If other air conditioning systems are installed,
the equipment manufacturer’s guidelines must be • Chapter 6.4 Interior (→ page 138)
observed.
Doors and entrances
• On no account should the installation of an air condi-
All modifications to doors or entrances must
tioning system impair vehicle parts or their function.
comply with the specifications described in this Body
• If compact systems are mounted on the cab roof and Equipment Guideline:
(evaporator, condenser and blower), the permissible
• Chapter 8.8 Windows and doors (→ page 269)
roof loads must not be exceeded: Chapter 4.3.3
Roof/roof load (→ page 73). • Chapter 6.2.6 Side wall, windows, doors and flaps
(→ page 111)
• Pipes and electric lines must be routed correctly.
• Chapter 6.4.2 Safety equipment (→ page 139)
• More detailed information on retrofitting air condi-
tioning systems can be obtained from the relevant Local and country-specific legal regulations for door
department 1.7 Contact (→ page 11). locks and hinges as well as for rearview mirrors (espe-
cially in the case of modifications which affect the view
As part of the eXpertUpfitter program, please refer to
of the rearview mirror) must be observed in particular.
Further information on subsequent modifications (e.g.
to the body in white, interior, and doors and entrances)
can be obtained from the Upfitter Portal (→ page 11).
8 Electrics/electronics
8.1 General information
• Electrical and electronic components must fulfill

⚠ WARNING
local and national test requirements as well as
Modifications to electronic components, their soft- ISO 16750 test requirements.
ware, or wiring can impair the functioning of those • Observe the notes on (→ page 235) when installing
electronic components and/or of other networked auxiliary batteries.
components. Safety-relevant systems in particular
may be affected. Because of this, they may no longer • Cables routed around the exhaust systems must be
function properly and/or compromise the operational insulated against high temperatures (→ page 255).
safety of the vehicle. • Cables must be routed in such a way that there are
There is a heightened risk of accident and injury! no kinked points (→ page 95).
Never carry out any modifications to the wiring and • Before any long non-operational periods (> 20 days),
electronic components or their software. Have all the chapter on maintenance and storage of batteries
work on electrical and electronic equipment carried (→ page 53) must be observed.
out at a qualified specialist workshop. • Observe the operator's manual.
Some of the safety systems only function when the ⓘ You can obtain more information from the depart-
engine is running. For this reason, do not switch off the ment responsible 1.7 Contact (→ page 11).
engine when the vehicle is in motion.
⑴ NOTE
⑴ NOTE
The upfitter is responsible for functional safety of the
A positive total charge balance must be ensured body modification work performed by the upfitter as
when additional electrical consumers are installed well as for the observance of the applicable stan-
(see Chapter 7.17 Semi-integrated bodies dard and regulations. Furthermore, the upfitter must
and optional mounting of free-standing bodies guarantee compliance with the international standard
(→ page 226) and Chapter 8.4.6 Retrofitting electri- ISO 26262 concerning functional safety, if applicable.
cal equipment (→ page 242)). Please also refer to 49 CFR 567.5 in the US and to
Do not release or remove the battery terminals when Motor Vehicle Safety Regulation 6(1)-6(7) in Canada
the engine is running. If the vehicle is equipped with for requirements for manufacturers of vehicles manu-
code E30 (1-pin battery main switch), the isolator factured in two or more stages.
must not be actuated while the engine is running. See Chapter 2.4 Product safety and product liability
Use rapid charger on the batteries only after discon- (→ page 20).
necting them from the vehicle's electrical system.
Both the positive and negative terminals must be
disconnected.
8.2 Electromagnetic compatibility (EMC)
Electromagnetic compatibility describes the ability

of an electrical system to act neutrally in the vicinity
of other systems when operating at full function. The
system in question does not interfere with any of the
active systems in the vicinity, nor does it suffer any
interference.
Electrical interference occurs in vehicle on-board elec-
trical systems because of the various consumers.
Mercedes-Benz tests all factory-installed electrical and
electronic components for their electromagnetic com-
patibility in the vehicle. If subsequent modifications are
made, this may cause a reduction in comfort in some
cases (e.g. radio noise).
When retrofitting electrical or electronic systems, they
must be tested for electromagnetic compatibility and
this must be documented.
All electrical equipment fitted must be tested in accor-
and ULC in Canada.
The notes under Chapter 8.4.6 Retrofitting electrical
equipment (→ page 242), Chapter 8.6 Mobile com-
munications systems (→ page 263), and Chapter 4.6
Limit values for electrics/ electronics (→ page 80)
must be observed.
The following standards provide information on this:
• CISPR 12
• CISPR 25
• DIN EN 55012
• DIN EN 55025
• ISO 7637
• ISO 10605
• ISO 11451
• ISO 11452
• MBN 10284
• UN R 10
8.3 Battery
8.3.1 Main battery

⑴ NOTE
The main battery is located on the floor on the left-
hand side to the front of the driver’s seat. The vehicle systems (standard and ex-factory special
equipment) are powered by the main battery.
The on-board electrical management system mon-
itors the voltage of the main battery and stops the
vehicle systems functioning when the state of charge
drops below the 40% limit in order preserve enough
voltage to start the vehicle. The electronic ignition
lock (EIS) and the tachograph are not affected by this
shut-down.
If an auxiliary battery is used (see Chapter 8.3.2 Aux-
iliary battery (→ page 236)), ensure that the function
of connected consumers is not impaired.
If one or more vehicle systems are operated while the
Installation position of the main battery
vehicle is in a stationary position (e.g. radio oper-
1 Main battery ations in a RV), then ensure that the main battery
maintains a positive charge balance by starting the
engine or through an external power supply.
In the case any additional electrical consumers other
than the standard vehicle power requirements are
needed, please use the upgraded battery (code ED4).
An auxiliary battery must be used for high electrical
demand. If current draw is 25A or greater, an auxiliary
battery (code E2M or E2I) must be used. An AGM bat-
tery must always be used.
ⓘ In order to facilitate tapping power from the

auxiliary battery (code E2I or E2M), a tapping point
(fuse box) is available in the driver seat frame.
This means that it is not necessary to install
additional wires from the vehicle interior (upfitter
consumers) to the auxiliary battery in the engine
compartment or under the passenger's seat, see
Chapter 8.4.8 Power tapping (→ page 243)
⑴ NOTE
Electrical cables must not connect directly to the
ground terminal of the battery.
8.3.2 Retrofitting an auxiliary battery
Auxiliary battery, general
⑴ NOTE
Aftermarket battery with capacities > 100 Ah must
not be connected directly to the vehicle electrical
system because this may damage the base vehicle.
Please select a suitable generator to ensure a posi-
tive overall charge balance.
When operating loads on the auxiliary battery, ensure
that the permissible total current of 80A across the
battery cut off relay is not exceeded. The battery
charging current with the engine running must also
E2M: Auxiliary battery in engine compartment (e.g. LHD
vehicle)
Only the same type of battery (AGM) must be used for
main and auxiliary batteries. If the vehicle is to be started using an external power
It is recommended to always use the ex-factory special supply, then either the jump-start connection point or
equipment options offered by Mercedes-Benz AG if the main battery must be used.
these equipment are required for an auxiliary battery.
Two auxiliary batteries are available:
⑴ NOTE
• Code E2I: Auxiliary battery for retrofitted consumers,
in front passenger seat base, battery size H8 (92 Ah The auxiliary battery (E2I, E2M) must not be used for
AGM) jump starting as this could result in damage to the
vehicle.
• Code E2M: Auxiliary battery for retrofitted consum-
ers, in engine compartment, battery size H6 (70 Ah
Aftermarket auxiliary batteries must be connected to
AGM)
the vehicle on-board electrical system using a suitable
cutoff relay and fuse. For more information, refer to 1.7
Contact (→ page 11).
When installing an auxiliary battery, ensure that the
same type of battery (AGM battery) is used as the
starter battery.
If the auxiliary battery is located in the passenger
compartment, sufficiently dimensioned ventilation must
be realized through a central vent hose leading into the
atmosphere. If necessary, the second channel in the
battery should be sealed with a stop plug.
The auxiliary battery may only be used to power auxil-
N82.00-3421-00
iary consumers such as the stationary heater, loading
E2I: Auxiliary battery in front passenger seat base (e.g. LHD
aids or electrical equipment in RVs (refrigerator, etc.).
vehicle)
Other auxiliary batteries
⑴ NOTE
If the vehicle is already equipped with an auxiliary
battery, no further auxiliary batteries may be con-
nected in parallel without a charging current limiter.
This can be realized through supplementary elec-
tronics. A maximum charging current of 80 A for all
auxiliary batteries must be ensured. If this is not the
case, the basic vehicle may be damaged.
A positive total charge balance is to be assured
through selection of a suitable alternator.
Retrofitting multiple auxiliary batteries requires an
evalution with the responsible department. As a part
of the eXpertUpfitter program please refer to www.
UpfitterPortal.com.
The current limitation system, which limits to 80 A, The charging current limiter (DC/DC converter)
allows for multiple batteries to be added in parallel if between the electrical system (vehicle battery) and
the batteries are the same type, have the same capac- additional battery allows for different battery technolo-
ity and same age in cross connection. gies and additional batteries to be used.
N82.00-2212-00
Current limitation system
8.3.3 Battery maintenance and storage

Batteries must be regularly checked for voltage drop
(self-discharge) - even when removed. With low-mainte-
nance batteries, only the fluid level does not need to be
checked.
Information on maintaining and storing batteries can be
found under 3.11.2 Battery maintenance and storage
(→ page 53).
8.4 Interfaces
8.4.1 CAN bus and networking The following table applies to cables with an insulating
limit temperature of > 105 °C/221 °F
⚠ WARNING
Max. permanent Fuse rating Line cross-section
As all consumers are networked and internally
current
monitored by the system, no modifications should
[A] [A] [mm2] [in2]
be made to the CAN bus (e.g. breaking, extending or
0 - 4.9 51 0.5 0.001
tapping). Any change to the cable harness in terms
5 - 9.9 101 1 0.002
of length, cross-section or resistance can result in
10 - 18 201 2.5 0.004
safety-relevant component failures or comfort impair-
ments. 19 - 28 301 4 0.006
29 - 35 402 6 0.009
36 - 48 502 10 0.015
Internal and external vehicle diagnosis can be car-
49 - 69 702 16 0.025
ried out by means of the OBD diagnostic socket (SAE
70 - 98 100 25 0.039
1962). Every control unit is capable of self-diagnosis
and is equipped with an internal fault memory. 99 - 123 125 35 0.054
124 - 148 150 50 0.078
Communication with the control units can be estab-
lished using a diagnostic device and the software devel- 1 Type C; DIN 72581 male spade connector
oped for this unit. At Mercedes-Benz, this diagnostic 2 Type E; DIN 72581 male spade connector
tool is called the “XENTRY” diagnostic system and has
the associated hardware and software, XENTRY Kit. 8.4.3 Cable extension
If cables are lengthened (e.g. in connection with a
ⓘ You can obtain further information on this topic wheelbase extension), cables of the same or a greater
from your Mercedes-Benz Service Center. cross-section must be used. We recommend the use
of lines complying with LV112. The protective effect of
⑴ NOTE retaining elements must not be impaired.
Do not make any permanent connection to the OBD Connections between electric lines and electrical
diagnostic socket as this can impair vehicle functions. components (e.g. plugs) are to be secured against
rocking to and fro, through the use of suitable mount-
ing material.
8.4.2 Electric lines/fuses All connections must be made professionally and

water-tight in accordance with IP 69k (protected for
If the routing has to be altered, avoid routing across high-pressure cleaning).
sharp edges and through narrow cavities or near mov-
ing components. Lines to the ABS sensors of the rear axle must be
adapted for the specific vehicle and may be length-
Only unleaded PVC-jacketed cables with an insulation ened by maximum 2.7 m (8.86 ft). The lines to each
operating temperature limit > 105 °C/221 °F may sensor must be twisted with a loop length of 30±5 mm
be used. Connections must be made in a professional (1.18±0.2 in).
manner and must be watertight.
The line must be dimensioned in accordance with the
current level drawn and protected with fuses.
Please do not block any access points to fuse box.
Lengthening of wiring harnesses - Comfort and Further information on lengthening wiring harnesses
passive safety systems, on-board electrical system, can be found in the WIS documents:
bus system • AR00.19-P-0100A (Wiring harness, general methods)
The Mercedes-Benz work instructions on the repair of • AH00.19-P-1000-08A (Parts solutions and what
cables also apply for the lengthening of cables. The may/may not be repaired/extended)
instructions can be found in WIS (→ page 18). Work
on the vehicle must always be carried out using the If the prescribed methods are followed and approved
latest workshop aids (e.g. EPC net, WIS net, XENTRY, materials and tools are used, it is possible to lengthen
special tools) from the manufacturer for the vehicle lines without any loss in quality.
in question. The safety notes and safety precautions The following repair methods are approved:
must be observed and precautions against electrostatic • Soldering
discharge (ESD) must be taken. Please get in touch
with the contact person responsible for your mar- • Raychem (use of solder connectors)
ket. ESD protection is only effective when the safety • Raychem in combination with pigtail
regulations/safety precautions are complied with. All • Crimping
operation steps, including test procedures, must be
carried out in accordance with the WIS instructions. Refer to the WIS document AR00.19-D-0100A to select
Information about ESD are available in the WIS docu- the suitable work method.
ment AH54.00-P-0001-01A.
Soldering
The following must not be modified or extended:
Select the line connectors or solder sleeves. Solder the
• Airbag control unit connector coupling stripped lines in accordance with the WIS instructions:
• ESP® control unit connector coupling • AR00.19-P-0100-05A
• Engine control unit connector coupling • AR00.19-P-0100-09A
• High-voltage lines
Crimping
• Antenna lines
Crimp the stripped lines in accordance with the WIS
• Fiber-optic cables
instructions:
• Lines of bus systems, see Chapter 8.4.1 CAN bus
• AR00.19-P-0100-03A
and networking (→ page 239)
• AH00.19-P-1000-09A
• Lines with a cross-section > 4 mm² (0.0062 in2)
Refer to the WIS document AH00.19-P-1000-08A, e.g. ⓘ For further information consult the Workshop Infor-
an ESP® plug must not be "modified". mation System (WIS) and also see Chapter 2.3.2
Workshop Information System (WIS) (→ page 18)
WIS can be accessed at the following address:
www.startekinfo.com/home
The methods focus on soldering (specifically Raychem) ⓘ For information regarding the procurement
and crimping. of the operating switches, reach out to local
Soldering (specifically Raychem): Mercedes-Benz Service Center.
In the Raychem method, special solder connectors are The reserved load switch part numbers are:
used. The solder connectors contain the solder and are Three different versions of load switches are available
insulated and sealed. A special hot-air blower is used to from factory for installation in the aforementioned
heat them. Do not use a cigarette lighter! switch panel for upfit functions:
The connections must be checked for a resistance of • A907 905 3902 9107 (Single pole changeover (CO)
less than 0.5 ohms using an appropriate multimeter contact, latching, function lighting)
according to the circuit diagram.
8.4.4 Additional electric circuits

If additional electric circuits are installed, they must be
protected against the main power circuit by fuses of
adequate rating.
The lines used must be rated for the load and they A907 905 3902 9107
must be protected against the effects of breakaway,
• A907 905 4002 9107 (Sing pole normally open (NO))
impact and heat.
contact, momentary, function lighting)
8.4.5 Operating switches (pre-installation)
Switch panel pre-installation

As a pre-installation for operating switches installed
by the upfitter, two switch panels are available in the
area of the steering wheel. These contain two slots A907 905 3902 9107
on the left of the steering wheel and six slots on the • A 907 905 4102 9107 (Double pole changeover
right of the steering wheel. Depending on the equip- contact (CO), latching, NO function lighting)
ment installed, these may be added automatically and
partially populated with switches. If they are not added
automatically due to the vehicle equipment, the pre-in-
stallation can be ordered separately under the code E3J
(Switch panel pre-installation).
A907 905 4102 9107

Part numbers for mating parts to the switch:
• Connector (housing): A013 545 4026
• Contact for wires 0.35 qmm: A008 982 2426
1 2
Switch panels N54.15-2312-00
Parts can be ordered directly from the supplier through
the following contact:
1 Van switch panel to left of steering wheel (LHD vehicle) Eugen Kurz KG
2 Van switch panel to right of steering wheel (LHD vehicle)
Ulrich Pflüger
Rebengasse 12
These switches are load switches which supply the D-89073 Ulm
interface for the upfitter. The switches bear no symbols Tel. +49 731 66535 / Fax +49 731 601283
and can be individually inscribed with laser lettering at a Mail: [email protected]
size of 8x8 mm.
8.4.6 Retrofitting electrical equipment 8.4.7 Retrofitting an alternator

Please observe the following if electrical accessories If additional electrical consumers are retrofitted, the
are retrofitted: increased power requirement can be met by fitting
• A positive charge balance must be ensured by the higher-rated alternators.
upfitter. The following alternators are available as special equip-
• For higher electrical power requirements, the alterna ment (option codes) from the factory:
tors reviewed by Mercedes-Benz must be used, see
the following Chapter 8.4.7 Retrofitting an alterna- Alternator availability
tor(→ page 242). Diesel Gas
Code 4 cyl 6 cyl 4 cyl
• Do not connect additional alternators to the existing (OM651) (OM642) (M274)
on-board electrical system; the electrical systems
M40 (200 A) Standard - -
should be galvanically isolated.
M46 (220 A) - Standard -
• Do not connect additional consumers to fuses M60 (250 A) Option* - Standard
already assigned.
* M60 is standard in some cases depending on coding
• Do not connect additional lines (e.g. with insulation
Alternator voltage 14.3 V
piercing devices) to existing lines.
• Provide sufficient protection for consumers using If additional assemblies are fitted, the factory-fitted
additional fuses. power take-offs must be used (→ page 154).
• Do not block access to any fuse box
• All installed electrical consumers must be tested
as per UN-R 10 in its currently valid version, see
Chapter 8.2 Electromagnetic compatibility (EMC)
(→ page 234).
• Additional electrical consumers must be connected
by means of the terminal strip for auxiliary con-
sumers (code EK1) available from the factory as
described under 8.4.8 Power tapping (→ page 243).
⚠ WARNING
Tampering with or unauthorized installations in the
vehicle electrical/electronic systems can impair the
functioning of these systems. This can lead to failure
or malfunctioning of components or of parts relevant
to safety, and may result in accidents or damage to
the vehicle.
ⓘ Furthermore, tampering with the vehicle electrical/

electronic systems can invalidate the implied war-
ranty or the general operating permit.
For retrofitting alternators, we recommend N62 ver- 8.4.8 Power tapping

sions available from the factory as special equipment
Depending on the vehicle's as-built configuration, there
(front engine power take-off with carrier for additional
are different possibilities for auxiliary consumers to tap
alternator).
current. Power can be tapped via the terminal strip for
For retrofitting N62 or N63, Mercedes-Benz recom- electrical connection (special equipment EK1) or at the
mends that a Mercedes-Benz qualified technician per- auxiliary battery tapping point.
forms the retrofit. Please visit the local Mercedes-Benz
dealership for servicing. For eXpertUpfitters, the ⓘ For more information on tapping power for special
installation guide for retrofitting N62 or N63 is available equipment, refer to 1.7 Contact (→ page 11).
on WIS. For engine OM642, please refer to document
'AN23.10-D-0001TSB' on WIS. For engine OM651,
⑴ NOTE
please refer to document 'AN23.10-D-0001TS' on WIS.
The following points must be observed if you intend to When installing additional electrical consumers, espe-
have other alternators retrofitted: cially on vehicles with special equipment installed ex
factory which uses the auxiliary battery (fuse box in
• On no account should the installation of an alterna- driver seat frame), the upfitter must ensure a positive
tor impair vehicle parts or their function. overall charging balance.
• The battery must have sufficient capacity and
the alternator must generate sufficient power
Additional information on special equipment can be
(→ page 242).
obtained from your Mercedes-Benz Service Center or
• The alternator circuit must be provided with addi- under 3.12 Special equipment (→ page 55).
tional fuse protection (→ page 239).
• The cable cross-section must be dimensioned accord-
ing to the current level drawn (→ page 239). The
higher power draw may necessitate the replacement
of the starter/alternator wiring harness. For this we
recommend Mercedes-Benz G enuineParts.
• The additional belt pulley, code N63, is available from
the factory as special equipment for driving air-con-
ditioning compressors.
• Electric lines must be routed correctly
(→ page 239).
• There must be no impairment of the accessibility or
easy maintenance of installed equipment.
• There must be no impairment of the required engine
air supply and cooling (→ page 135).
• The guidelines of the equipment manufacturer for
compatibility with the basic vehicle must be observed.
• The operating instructions and the maintenance
manual for the additional assemblies must be sup-
plied on handing over the vehicle.
The characteristics of the LIN alternators are fixed in
the engine control unit – for this reason the
Mercedes-Benz alternator cannot be replaced by an
aftermarket alternator.
No D+ (engine running positive signal) output available
at alternator with LIN Bus technology, only at upfitter
socket EK1 under driver seat.
Power tapping via terminal strip for electrical

connection
The terminal strip (special equipment code EK1) is
installed inside the driver seat frame (at the center, on
the left-hand side in direction of travel) and has three
connectors:
1 2 3
N54.15-2309-00
Terminal strip EK1 (X145/1)
Terminal Power Voltage/

fuse rating
1 Terminal D+ Power with engine 12 V/10 A
N54.15-2308-00
running
Position of terminal strip EK1 in driver seat base (LHD 2 Terminal 30T Battery direct power 12 V/25 A
vehicle) 3 Terminal 15 Ignition power 12 V/15 A
1 Terminal strip EK1
Electrical joint bolts in the fuse box must be tightened
to the following torques:
Bolt size Tightening torque [Nm]

M4 3
M6 6
The terminal strip EK1 is supplied directly from the

main battery and is the supply point in the main
on-board electrical system at which the upfitter may
connect his or her consumers. Other consumers can
be connected via the PSM (MPM) and the auxiliary bat-
tery. If terminal 30T is used, a positive overall charge
balance must be ensured in all vehicle conditions. Do
not connect any consumers on terminal 30T of the EK1
which require a quiescent current > 1mA when vehicle
is idle.
In start/stop mode, brief voltage dips (at restart) up
to 7.0 V at the EK1 are possible. The voltage dips are
typically in the region of 9.0 V. Proper circuit protection
should take this into account.
When the vehicle is locked and CAN is awake, in rare
cases up to three brief voltage interruptions can occur
at intervals of approximately 40 minutes.
Power tap at auxiliary battery tapping point

In order to facilitate tapping power from the auxiliary
battery (code E2I or E2M), a tapping point (fuse box) is
available in the driver seat frame. The tapping point is
the busbar in the fuse box with the direct line from the
auxiliary battery (positive pole).
The cover must be removed to connect and install the
fuse.
N54.15-2310-00
Position of auxiliary battery fuse box in driver seat base (LHD

vehicle)
2 Fuse box
Fuse box
A6 A5 A4 A3 A2 A1
129 ± 0,7
6 5 4 3 1
N54.15-2311-00
Assignment of fuse box (top view)
Connec- Min./max. Fuse Function Maximum Cable lug Coding Bolt

tion permissible type line cross-sec-
no. fuse rating tion
A1 -/100A SF30 Any upfit usage 25 mm2/ Complies with work 2 M6

0.039 in2 spec., see drawing
A2 -/250A SF51 Any upfit usage 35 mm2/ Complies with work 8 M8
A3 - - Auxiliary battery 35 mm2/ Complies with work 2 M8
A4 125A/150A SF30 Battery cutoff relay 35 mm2/ N046234006005 - M6
0.054 in2
A5 -/8OA SF30 Sockets, auxiliary 2 x 16 mm2/ Complies with work 8 M6
heating 2 x 0.025 in2 spec., see drawing
A6 -/8OA SF30 Sockets, auxiliary 2 x 16 mm2/ Complies with work 7 M6
heating 2 x 0.025 in2 spec., see drawing
Cable lugs complying with the work specification (see Work specification for cable lugs
table) are preferred. Torque relief on these is through
M6 A0030002599 ZGS001
the housing. If other cable lugs are used, separate
M8 A0040024499 ZGS002
torque reliefs (A 907 545 52 00) must be used at the
M6 bolt.
The electrical connecting bolts in the fuse box must be Please note:
tightened to the following torques: • No additional consumers may be connected to facto-
ry-installed fuses.
Bolt size Tightening torque
M6 8 Nm/1.66 ft lb ±10% • If all the connections at the fuse box are fully occu-
M8 16 Nm/3.31 ft lb ±10% pied, the positive pole of the auxiliary battery is to be
used for connecting further consumers.
• A suitable fuse box with fuse is required for these
⑴ NOTE
additional consumers.
If a vehicle is already equipped at the factory with a • A positive total charge balance must be ensured in
consumer which uses the fuse box in the seat box, all vehicle conditions.
this is only available under certain conditions. The
sum of the individual currents must not exceed the • Connection numbers A1 and A2 are available
maximum current-carrying capacity of the fuse box of with auxiliary battery to any upfitters to connect any
300 A. There is otherwise a risk of overload. electrical consumers.
Fuse
The auxiliary consumer can be connected to the auxil-
iary battery with a suitable fuse as per ISO 8820 SF30
(contact cavities 1, 5 and 6) or SF51 (contact cavity 2).
Preconditions for connection to the auxiliary battery
include:
• Auxiliary battery fuse box ex factory in seat base
• Use of the following retaining plates (busbar side),
part number M6 A 907 545 60 00 or M8 A 907 545
61 00 for torque relief
• Suitable fuses as per ISO 8820 (SF30 or SF51)
8.4.9 Interface overview

The electrical interfaces available as special equipment
on the vehicle are depicted in the illustration below:
2 6
Schematic diagram: Electrical interfaces on the vehicle
Code Description
1 EK1 Terminal strip for the electrical connection on the driver's seat base
2 L72 Electrics for body interior lighting, 3-pin connecting point in the left seat base
(applies only for Cab Chassis)
3 LC4 Push button switch in overhead control panel (OCP)
4 L76 Extended tail lamp wiring harness (2 m/78.7 in)
5 L77 Additional electrical equipment for turn signal lamps
6 E5M Expansion of PSM (MPM) standard contact
Code table for Sprinter BM 907 (further special equip-

ment)
Code Description
LV4 PRE-INSTALLATION FOR FRONT FOG LAMPS WITH CORNERING LIGHT FUNCTION
LV6 PRE-INSTALLATION OF ELECTR. EQUIPMENT FOR 3RD BRAKE LAMP
E2F PRE-INSTALLATION FOR WINDSHIELD HEATER
FR7 PRE-INSTALLATION OF ELECTRICS FOR REVERSING AID
FV1 PRE-INSTALLATION FOR REVERSING CAMERA WITH INSIDE REARVIEW MIRROR DISPLAY
E3J PRE-INSTALLATION FOR SWITCH PANEL
ED8 PRE-INSTALLATION OF ELECTRICS, PARAMETERIZABLE SPECIAL MODULE
E2A TAPPING OF BODY MANUFACTURER SPECIAL SIGNALS IN COCKPIT.
EP7 PRE-INSTALLATION OF ELECTRICS FOR REAR SPEAKERS
E4A ANTENNA INTERFACE FOR RADIO, NAVIGATION AND MOBILE RADIO
JH6 PRE-INSTALLATION OF COM MODULE FOR DIG. SERVICES (LTE)
ER0 RADIO PRE-INSTALLATION
J1V PRE-INSTALLATION FOR BLIND SPOT ASSIST
L90 OMISSION OF TAIL LAMPS
L91 PRE-INSTALLATION FOR LED TAIL LAMPS
⑴ NOTE
The regulatory requirements for installing lighting
systems must be observed, see Chapter 8.5 Illumina-
tion (→ page 254)).
A description of the codes and specifications for
exterior lights can be found in Chapter 10.2 Bulb
ratings of exterior lights (→ page 317)).
8.4.10 Speed signal 8.4.11 Travel distance signal

The analog vehicle speed signal in the instrument clus- A digital travel distance signal is permanently present
ter has been discontinued. If required, a digital signal at PSM output 15 (plug 2, pin 3). When the ignition
can be provided by the PSM (MPM) via a special data is off, no wheel speed pulses are output. The pulses
entry. are accurate at speeds of 3 km/h (1.86 mph) and
The digital speed signal (positive to ground) acts as above. When the PSM control unit is in OFF mode, the
a distance and speed signal for external electronics, wheel speed (RDZ) signal output driver is deactivated.
e.g. speed-dependent volume control. The signal is 48 pulses/revolution are output (96 signal flanks/
protected against short-circuit to ground and battery revolution) in the vehicle speed range from 0 km/h
voltage and is not monitored. to 362 km/h or 225 mph. This results in an output
frequency from min. 0 Hz to max. 2414 Hz.
The signal is output at 4 pulses per meter/1.22 pulses
per foot. The pulse width is 4 ms.
8.4.12 Ground bolts
At 112.5 km/h or 69.9 mph, the pulse duration is the
For retrofitted electrical bodies or implements, the
same as the pulse pause. This 1:1 ratio is maintained
ground bolts approved by Mercedes-Benz must be used
for higher speeds. This means that, at higher speeds,
to achieve an optimum ground connection to the basic
the pulse length and the pause length become shorter
vehicle.
at the same time.
There are two ground bolts (M6) in the area of the
The speed signal is made available on the upfitter CAN
driver seat in the left seat base; a further ground bolt
in a format complying with SAE-J1939.
(M6) is located under the vehicle on the crossmember
Value range: 0 - 250,996 km/h or 156.0 mph in front of the rear axle.
Resolution: 1/256 km/h or 0.0024 mph
Note: This signal is not suitable for calibrated taxime-
ters or similar
.
T High
T LOW T LOW
N30.00-2014-00
Ratio of pulse duration/pulse pause
Speed signal (Imax = 20 mA):

THighUa ≥ 8 V
TLow Ua ≤ 1 V
The following specifications must be observed:

• No other electrical consumers may be connected to
factory ground bolts other than those listed below.
⚠ WARNING
The use of any other ground bolts may lead to mal-
functions of safety systems. This in turn can lead to
the failure of components or safety-relevant compo-
nents and to fault messages in the instrument cluster.
• A maximum of 4 cable lugs may be bolted to a

ground bolt.
Frame ground connection (3.5 t to the front of the rear axle)
• The nuts must be tightened to a torque of 6 Nm or
1.242 ft lb. 1 Ground bolt
• The ground bolts for the safety systems must not be
used for attachments.
For other requirements, please refer to 1.7 Contact
(→ page 11).
N54.18-2184-00
Cab ground connection, body in white (e.g. LHD vehicle)
1 Ground bolt
8.4.13 Additional ground weld studs

This chapter provides information for optional ground
studs in addition to the ones installed as a standard.
The code VV4 includes, depending on the weight vari-
ant of the vehicle, three to four additional ground studs
(M6/M8) located in the area of the front seat bases
and under the vehicle on the cross members. This
allows upfitters to attach auxiliary electrical equipment
to the base vehicle.
For specific model variants, 3D CAD data for
additional ground weld studs (code VV4) is available
for eXpertUpfitters on the Upfitter Portal
(www.UpfitterPortal.com).
⑴ NOTE
The use of any other ground studs may lead to mal-
functions of safety systems. This in turn can lead to
the failure of safety-relevant components and fault
messages in the instrument cluster.
8.4.14 Deep discharge protection (hibernation

mode)
The deep discharge protection system is intended to
prevent impermissible deep discharging of the battery
with the vehicle at a standstill (no-load phase). This
function should ensure the startability of the vehicle
after an extended period of time or in the event of
elevated quiescent currents.
In addition, excessive quiescent currents caused by
faulty components are minimized by hardware resets of
the components.
The functions of the system are distributed between
the vehicle locking system (component Electronic
Ignition Lock (EIS)) and the on-board electrical system
management system (component Body Controller
(BC)). The hardware component responsible is the
battery disconnect switch (BTS).
Terminal 30 (BM 906) is transformed into a switchable
terminal 30T (BM 907).
Another function in the deep discharge protection
system is the "hibernation mode" or "quiescent state"
function. This opens the battery disconnect switch
prematurely, allowing the vehicle to be parked up for
long periods.
The mode can be selected in the instrument cluster
(Hibernation Mode). If a head unit is installed, it is
activated there.
The hibernation mode or the quiescent state allows
almost all of the control units to be switched off. Then
almost the only signal present at terminal 30T is the
EIS or the control unit that is necessary to receive
the signal of the radio remote control. PSM and the
anti-theft alarm system also continue to be supplied
depending on their operating status.
8.5 Illumination
Local and national regulations must be observed. All For the following model designations, the headlamp
applicable FMVSS/ CMVSS guidelines and regulations adjustment for the type approval must always be car-
must also be complied with. ried out by the upfitter at his or her own responsibility
and expense when all the upfit work has been com-
⑴ NOTE pleted:
The specifications and notes in Chapter 10.2 Bulb • Cab-chassis

ratings of exterior lights (→ page 317) must be • Cowl and doors version chassis (code F28)
observed for all exterior lights.
8.5.1 Adjusting the headlamps

Once the upfit has been completed, the upfitter, at his
or her own responsibility and expense, must adjust
the headlamps or check their factory settings and
correct them if they deviate from the specified values.
The adjustment instructions with the valid adjustment
values for the finished vehicle in combination with
the version of headlamp used can be performed by a
local Mercedes-Benz Service Partner. The WIS system
(→ page 18) also allows the upfitter to establish the
currently applicable adjustment specifications for his
or her own headlamp adjustment. Ensure that local and
national registration requirements apply.
The headlamp basic setting must be observed (see
vehicle identification plate).
8.5.2 Mounting additional lamps Additional lights
The national registration regulations apply. For additional lights please connect to PSM or E2A-in-
terface. Please note that these methods do not track
If moving vehicle parts cover lighting equipment by bulb-out-detection.
more than 50% during operation, the vehicle must be
safeguarded accordingly. Code Comment Purpose
Reflectors at the rear of the vehicle must not be L90 Tail lamp deleted For customer using non-
obscured by moving parts. If this is the case, the reflec- OEM incandescent lamp
tors must be duplicated. L91 Pre-installation for For customer using
LED tail lamp non-OEM LED lamp
An appropriate note must be attached at a point where L22 Tail lamp, partial For customer using
it can easily be seen by the driver of the vehicle. LED Mercedes-Benz LED lamp
L76 Extended cable for For customer who needs to
8.5.3 Tail lamps tail lamp extend tail lamp cable
L77 Additional electrical For customer who needs
The following chapter explains how to connect the equipment for turn additional turn signal lamps
aftermarket tail lamps to avoid any failures on the signal lamp on the body
instrument cluster. The chapter also contains informa-
tion on available option codes needed for tail lamps on Tail lamp pin connector for cab chassis
cab chassis.
Pin Color Function
Main tail lamp 1 BN Ground
2 GYGN License lamp
Please make sure to connect the tail lamp using an 3 WHBU Backup lamp
adaptor that has the same pinning assignment as
4 BKWH Turn signal
shown in the table. If the tail lamp pinning assignment
5 BKRD Stop lamp
does not match as guided or the connection is not
6 VTWH Fog lamp (only if PSM)
secured, then an error will appear on the instrument
7 GYBK Tail lamp
cluster.
Left tail lamp
Please do not connect the main tail lamps via PSM or
E2A. The use of PSM or E2A for main tail lamps cannot Pin Color Function
detect any tail lamp failure. 1 BN Ground
Two available options of tail lamps: 2 GYGN License lamp
3 WHBU Backup lamp
• LED tail lamps: Please order option code L91
4 BKGN Turn signal
(Pre-wiring for LED tail lamps)
5 WHGN Stop lamp
• Bulb tail lamps: Please order option code L90 6
(Pre-wiring for incandescent tail lamps) 7 GYRD Tail Lamp
Right tail lamp
⑴ NOTE
• The upfitter must ensure that the operating loads
consume a constant current of at least 20 mA in
each of the brake lights, tail lights, and turn signals
if the upfitter is using codes L90 or L91. The par-
allel connection of, for example, side marker lights
on the tail lights is not permitted.
8.5.4 Marker lamps 8.5.5 Exterior lamps
Clearance lamps/vehicle position lamps Front:

Clearance lamps increase passive safety and are Halogen headlamps
required by law on vehicles with a width of over The exterior lighting functions in the headlamp are
2.032 m/80 in (FMVSS/CMVSS 108). actuated discretely by the Body Controller (BCMFA2).
For cab chassis, there are two options provided by This means that each exterior lighting function in the
Mercedes-Benz that conform to FMVSS/CMVSS 108: headlamp has a separate line.
1. Code L49 (Identification lamps) includes five identi- The exception to this rule are the parking and stand-
fication lamps mounted on the windshield of the vehicle ing lights functions. These functions are actuated via
roof. the same lines, i.e. they are implemented by the same
lamps.
2. Code LV7 (clearance lights pre-wiring) includes wir-
ing harness tied to the roof and allows easy installation Fault monitoring is implemented via the signal acquisi-
of after-market lights on the roof. tion and actuation module (SAM) and is always active
when the relevant function is active and the corre-
sponding light source is actuated. This implemented
function is to be taken into account particularly when
designing and using the upfitter's own electronic bal-
lasts, otherwise faults will be logged in the control unit.
The table below provides an overview of the individual
lighting functions.
Explanations of the following function descriptions:

• Ignition in terminal (tml.) 15 position: Ignition "on",
engine start possible or engine running
• Ignition in terminal (tml.) 15r position: Radio position,
ignition "off", engine not running, radio operation
possible or on-board electrical system voltage "on"
• Ignition in terminal (tml.) 15c position: Ignition "off",
engine not running, driver's door open, on-board
electrical system voltage "on"
Overview of exterior lighting functions in headlamps

Hardware output Front
BC VS30
Function Low beams Perimeter lights Daytime running High beams Turn signals
lights
Side Left Right Left Right Left Right Left Right Left Right
Plug MR1 MR2 MR2 MR1 RBA1 RBA2 MR2 MR1 MR1 MR2
Pin 20 02 01 21 17 56 04 18 01 05
Light pattern, open

model
Conventional ECE
Left parking light X
Right parking light X
Standing lights X X
Low beams X X
High beam/headlamp X X
flasher
Daytime running lights X X
Turn signals (left/right)/ X X
hazard warning light
system
Notes on headlamps
⑴ NOTE
Low beams
In the Sprinter, the standing lights are not activated
Requirements for activation: when the daytime running lights or low beams are
• Ignition in terminal 15 position active. Only the above requirements apply.
• Engine running.
• Rotary light switch in AUTO position Parking lights
• Light sensor detects NIGHT. Requirements for activation:
• OR rotary light switch in MAN position (manual driv- • Ignition at terminal 15c or below, i.e. ignition off and
ing lights) driver's door open
Standing lights/perimeter lights Daytime running lights

Requirements for activation: Requirements for activation:
• Rotary light switch in STL position (standing lights); • Ignition in terminal 15 position
the standing lights are activated regardless of the
• Engine running.
state of the vehicle.
• Rotary light switch in AUTO position
• OR rotary light switch in AUTO position, ignition in
terminal 15r position and light sensor detects NIGHT. • Light sensor detects DAY.
If the light sensor detects DAY, no lighting function is
activated.
• OR rotary light switch in MAN position and ignition in
terminal 15r position
High beam/headlamp flasher The exterior lighting functions in the tail lamp are actu-
Requirements for activation of headlamp flasher: ated discretely by the signal acquisition and actuation
module (SAM). This means that each exterior lighting
• Ignition in terminal 15 position function in the tail lamp has a separate line.
Requirements for activation of high beams: The exception to this rule are the parking and stand-
• Low beams active ing lights functions. These functions are actuated via
the same lines, i.e. they are implemented by the same
Turn signal indicators lamps.
Requirements for activation: On cab-chassis the lines for the license plate lighting
• Ignition in terminal 15r or terminal 15 position are not included (See Chapter 10.2 Bulb ratings of
exterior lights (→ page 317).
Rear end: Fault monitoring is implemented via the signal acqui-
Tail lamps with bulbs and pre-installation for LED sition and actuation module (SAM) control unit and is
tail lamps always active when the relevant function is active and
the corresponding light source is actuated. This imple-
mented function is to be taken into account particularly
when designing and using the upfitter's own electronic
ballasts, otherwise faults will be logged in the control
unit.
Overview of exterior lighting functions in tail lamps

Hardware output Rear end
BC VS30
Function Brake light Tail light
Turn signals Reversing License plate Rear fog light Side marker
light lamp lamp
Side Left Right Left Right Left Right Left Right Left Right Left Right
Plug RBA1 RBA2 RBA1 RBA2 RBA1 RBA2 RBA1 RBA2 RBA1 RBA2 RBA1 RBA1 RBA2
Pin 09 50 13 60 12 61 11 62 16 57 14 15 59
Light pattern
Left parking light X
Right parking light X
Standing lights X X X1) X1) X2) X2)
Low beams X X X1) X1) X2) X2)
Turn signals (left/ X X
right)/hazard warning
light system
Brake light X X
Reversing light X X
Rear fog light X
1) Only panel vans
2) Only cab-chassis
Notes on tail lamps Rear fog light

Requirements for activation:
Brake light
• Ignition in tml. 15 position
Requirements for activation:
• Rear fog light activated via pushbutton switch
• Rotary light switch in MAN position
• Brake pedal operated
• OR rotary light switch in STL position and front fog
Tail light lamps are active.
Requirements for activation: • OR rotary light switch in AUTO position and engine is
running (the low beams are activated automatically).
• OR rotary light switch in AUTO position and standing
• Engine running.
lights and front fog lamps are active.
• Rotary light switch in AUTO position
• Light sensor detects NIGHT. Side marker lamps
• OR rotary light switch in MAN position ( Requirements for activation:

manual driving lights) • Low beams are active.
• OR standing lights are active. See Chapter 10.2 Bulb ratings of exterior lights
• OR parking lights are active (left or right). (→ page 317).
Turn signal lights (indicators)

Requirements for activation: Additional exterior lighting functions:
• Ignition in tml. 15r or tml. 15 position
Front fog lamps
Reversing light Requirements for activation:
Requirements for activation: • Ignition in tml. 15 position
• Ignition in tml. 15 position • Rotary light switch in STL or MAN position
• Reverse gear is engaged. • OR rotary light switch in AUTO position
(AUTO: If the light sensor detects DAY, the standing
License plate lamps
lights are activated automatically too. If the light sen-
Requirements for activation: sor detects NIGHT, the low beams are already active
• Low beams are active. and no further automatic activations occur.)
⑴ NOTE
In the Sprinter, the cornering light function is imple-
mented in the control unit as standard. This also
applies for the pre-installation for front fog lamps with
cornering light function (LV4). For these the upfitter
may only use his or her own, certified front fog lamps.
Side marker lamps 8.5.6 Interior lamps

Requirements for activation: The information about the lamps and switches installed
• The side marker lamps are activated as described and the switching commands for the interior lights are
under "Tail lights". The same conditions and notes transmitted by the Body Controller via LIN to the over-
apply. head control panel.
The overhead control panel also transmits the informa-
Clearance lamp tion about whether and which push button switches are
Requirements for activation: actuated over LIN to the Body Controller.
• The side marker lamps are activated as described The following SA codes for interior lighting are available
under "Tail lights". The same conditions and notes ex factory.
apply.
SA code Name/description
L65 Additional LED dome lamps in the load
compartment of cargo vans provide more
light in the load compartment. One or two
additional lamps are installed, depending on
the wheelbase. The lamp above the hinged
rear door has one push button switch.
L71 Motion detector, available for cargo van.
The interior light is activated when a valid
movement is detected.
L72 Interface for electrics of body interior light-
ing for cab-chassis.
LD0 Overhead control panel with 2 reading
spotlamps.
LC4 Comfort overhead control panel (LED),
including cockpit incident illumination.
LC2 Two LED light strips/work lamps in the load
compartment of the cargo van.
LB9 Exit lamps are integrated in the door on the
driver or front passenger side. These shine
down onto the floor when the doors are
opened. The sliding door has another step
illumination lamp (only in BM 907).
L1D Overhead control panel with bus interior
lighting control
Function description:
⑴ NOTE
• The aftermarket lamps can only be activated by
All interior lamps can be replaced by other upfit- pressing a button manually and do not react to auto-
ter-specific lamps. In order to ensure that the stan- matic light functions (door opening, unlocking, etc.).
dard bulb failure monitor functions correctly, only
• After the manual activation of the aftermarket lamps,
light sources of the same type and same output
they remain active for approx. 20 minutes, provided
rating as standard bulbs may be installed.
that the on-board electrical system does not detect
any undervoltage (battery protection). The time runs
independently of the locking status of the vehicle in
Lamp monitoring
particular.
The overhead control panel or the Body Controller
• After the aftermarket lamps have been deactivated
monitors all outputs for open load (wire break) and
due to undervoltage by the on-board electrical sys-
short circuit.
tem, an engine start is required before the aftermar-
If a lamp is not connected or is overloaded, a fault ket lamps can be reactivated manually.
entry is stored in the fault memory of the Body Control-
• The aftermarket lamps are actuated via a relay and
ler. The owner or driver of the vehicle must be informed
are protected by a 10 A fuse.
about this. The fault entry must be addressed during a
service if the fault memory is read.
The interior lights can also be actuated via the PSM
(MPM). See Chapter 8.10 Parameterizable Special
Module (PSM/ MPM) (→ page 296)
Electrical interface for body interior lighting

(code L72)
In the case of cab-chassis models, the upfitter is
offered an electrical interface in the driver's seat base
for further body modification in the rear of the vehicle
via the special equipment with code L72.
Aftermarket lamps (upfitter lamps) can be connected to
this interface in accordance with the following specifi-
cations.
Optionally, it is possible to connect a pushbutton switch
in the vehicle upfit, which can be used to activate and
deactivate these aftermarket lamps. Functionally, this
pushbutton switch corresponds to the rear light button
in the overhead control panel. If the aftermarket lamps
in the body/ equipment are active, the symbol for the
rear light button in the overhead control panel is illumi-
nated red and thus serves as a function feedback.
Schematic diagram: Circuit diagram of interface of code L72
1 Overhead control panel (with 10-pin connection)

2 Rear interior lamp connection
3 Relay actuation connection special equipment code L72
4 Rear pushbutton switch connection (input)
5 Interior lamp in rear passenger compartment for FHL
model designation
6 Relay
7 Rear pushbutton switch for FHL model designation
8 ABH lamps interface special equipment code L72
9 ABH lamps (scope of body/equipment of upfitter)
10 ABH lamps pushbutton switch
Parameter Symbol Min Type Max Unit Remarks

Series resistor to push- RSer Ω At RSer < 390 Ω, reliable diagnosis of
button switch a short circuit to ground is no longer
possible
Input voltage UILL_RS_Norm 3.1 3.3 3.5 V Pushbutton switch not actuated
(normal mode)
Input voltage UILL_RS_Sleep 4.1 4.3 5 V Pushbutton switch actuated
(sleep mode)
Input capacitance Cin 10 nF
Pushbutton switch IT 10 mA RSer= 0 Ω, pushbutton switch actuated
current
Pushbutton switch IH 150 μA RSer= 0 Ω, pushbutton switch stuck
current with pushbutton
switch stuck
Short-circuit current IK 10 mA Short circuit to ground
Permissible shunt resis- RS 5 kΩ Permissible shunt resistance to ground
tance and tml. 30
8.6 Mobile communications systems
If mobile communication systems (→ page 80) 8.6.1 Equipment

(e.g. telephone, CB radio) are retrofitted, the following
The maximum transmission outputs (PEAK) at the base
requirements must be fulfilled in order to avoid mal-
point of the antenna must not exceed the following
functions developing on the vehicle at a later stage:
values. National and local laws regarding the maximum
All electrical equipment fitted must be tested in accor- allowed transmission output must be observed.
• The mobile communications systems and brackets
and ULC in Canada.
must not be positioned in the deployment areas of
the airbags (→ page 143).
⑴ NOTE
• The equipment must be permanently installed.
The fiber-optic cable must not be kinked. The mini- Mobile devices may only be operated inside the cab
mum bending radius is 25 mm/0.98 in. if they are connected to an exterior antenna which
has been installed in such a manner that it is reflec-
tion-free.
• The transmitter unit must be installed as far away
from the vehicle's electronic system as possible.
• The unit must be protected against moisture and
heavy physical shocks; the permissible operating
temperature must be observed.
8.6.2 Antenna connection and cable routing

(radio communication)
• Comply with manufacturer's notes and installation
instructions.
• An antenna can be installed anywhere on the roof.
The maximum transmission output according to the
installation specifications must not be exceeded.
The connection should be made directly to terminal
30T via an additional fuse. Disconnect the unit from
the electrical system before starting assistance.
The lines must be kept as short as possible. The
lines must be twisted and screened (coaxial cable).
Chafe marks must be avoided.
Ensure that the system has a good ground connec-
tion to the body (antenna and equipment).
The antenna and connecting cables among the
transmitter, receiver and operating panel must be
routed separately from the vehicle wiring harness in
the vicinity of the body ground.
Route the antenna line in such a way that it is not
kinked or pinched.
Comply with the local and national regulations on
the transport of hazardous goods.
8.7 Electronic ignition lock (EZS)
8.7.1 General information 8.7.2 Central locking system/post-delivery

integration of doors of upfitter
• The processes involved in the access authorization
for the central locking system (CL) are verified and
General
controlled by the signal acquisition and actuation
module (SAM) and the door control unit (DCU). Upfitters have the option of adapting the central lock-
ing system to the aftermarket equipment. The following
• Access is authorized at the press of a button on the
functions can be implemented via variant coding in the
remote control key.
electronic ignition lock (EIS) with XENTRY:
• Drive authorization is obtained by pressing the start/
• Automatic locking when last open door is closed
stop push button switch by means of Keyless-Start.
(post function)
The remote control key must be located in the area
between the A- and B-pillars. • Post-delivery integration of upfitter doors into the
central locking system
• Where control units are networked, the electronic
ignition lock sends global information such as the An automatic locking function for speeds above 15
model series and the country variant to the control km/h or 9.3 mph is implemented in the vehicle as
units (global variant coding) on the network. standard. Further details on this function can be found
in the operator's manual.
⑴ NOTE
Automatic locking when last open door is closed
Drive authorization via Keyless-Start only operates (post function)
when the body is not modified in the areas of the
It is possible to use the O-code O22 to implement auto-
A- and B-pillars, and the roof frame in between. (See
matic locking when the last open door is closed. The
Chapter 4.3.1 Modifications to the body in white
function provides that when the ignition is in the radio
(→ page 72).
position (terminal 15r) and the last door is closed, the
The vehicle keys must be stored in such a way that vehicle is globally locked, but in the ignition "on" (termi-
the engine cannot be started unintentionally. In the nal 15) position, no locking of the doors is triggered.
case of RVs, special attention must be paid to the
This function requires the use of door locks with a
storage of the keys on account of the design features
feedback function, as the open/ closed state of each
of these vehicles. This means that it is particularly
door is polled and monitored. If aftermarket doors are
important not to store the keys in the area between
integrated via the PSM, it is not recommended to use
the A- and B-pillar including the roof area between
the O22 function.
the A and B-pillar.
This code can be parametrized via XENTRY, e.g. at a
Mercedes-Benz Service Center. The O-code must first
be entered in the vehicle data card, and then a new
SCN coding of the EIS must be carried out.
Post-delivery integration of upfitter doors Integration of additional doors via PSM (MPM)
Depending on the vehicle equipment, it is possible for The PSM (MPM) can be used to read out signal IDs
upfitters to integrate additional doors in the body into (e.g. "close door", "open door") from the vehicle CAN
the central locking system of the chassis. They are in order to actuate additional central locking system
operated via the ignition key of the basic vehicle. elements or relays in the body via a PSM (MPM) output.
ⓘ Information on parametrization can be found on the

PSM/ MPM (ED5) Information page on the Upfitter
Portal.
Advantage:
• Upfitters can use their own door locks and compo-
nents.
Example of upfitter doors
Disadvantage:
1 Hinged rear door • The additional doors actuated via the PSM (MPM)
2 Side door are not monitored for their "open" or "closed" state.
There are two options for integrating additional doors The vehicle is thus not able to recognize whether all
into the central locking system of the chassis: additional doors are closed and locked after a lock-
• Integration of additional doors via PSM (MPM) ing procedure and no indications are given on the
instrument cluster.
• Integration of additional doors via SAM
Furthermore, the vehicle locks itself automatically
40 seconds after unlocking if only the aftermarket
door is opened. The reason for this is that the open-
ing of the rotary tumbler is not detected.
Condition:
• The special equipment PSM (MPM) (code ED5) and a
custom PSM (MPM) program are required.
Integration of additional doors via SAM The O-codes for body doors are:
Ordering the special equipment code EA5 "Pre-wiring • OA5 - Parameterization for left side door present
central locking (upfitter doors rear)" allows you to inte- • OA6 - Parameterization for right side door present
grate additional doors in the central locking system of
the basic vehicle. • O04 - Parameterization for hinged rear door present
This means that a wiring harness connection point is Now all the doors can be opened and closed with the
installed in the vehicle near the seat on the left for con- vehicle key. The locks used must have an appropriate
necting up to three aftermarket doors behind the B-pil- feedback function so that the central locking system in
lar. Activation of the door signals must be configured the SAM can poll the door status and the instrument
individually via XENTRY using O-codes. These codes cluster can display this door status correctly.
can be parameterized via XENTRY at a Mercedes-Benz Schematic diagram of an example for a body with three
Service Center. The desired O-code must first be writ- aftermarket doors in combination with the special
ten in the vehicle data card, and then an SCN coding equipment "Pre-wiring central locking (upfitter doors
of the signal acquisition and actuation module must be rear)" code EA5:
carried out.
Ex-factory equipment Doors/flaps completed by upfitter
Schematic diagram: Top view of open model with box or RV body
1 Electrical connecting point with code EA5

2 Body Controller
3 Door
4 Tailgate
5 Flap
Advantage: Conditions:
• Parameterization and installation of a PSM is not • Vehicle configuration with special equipment
required. "Pre-wiring central locking (upfitter doors rear)",
• The additional doors actuated via the signal acquisi- code EA5
tion and actuation module (SAM) are monitored for • Locks with a feedback function must be used.
their "open" or "closed" state. The vehicle is thus able The use of genuine Mercedes-Benz locks is recom-
to recognize whether all additional doors are closed mended.
and locked after a locking procedure and an indica- • Max. three additional doors (right door, left door, rear
tion is given in the instrument cluster. doors) are possible
Disadvantage:
ⓘ More detailed information on the integration of
The door status indicators in the instrument cluster additional doors can be found on the Upfitter Portal
are as represented in the Sprinter panel van and have as a bulletin under Technical Documents, Sprinter
not been adapted to different body situations (e.g. box MY2019+ Electric preparation for additional door
body, RV etc.). (Code EA5).
In combination with the three-button key, code FY7: Ambulance pre-installation

The settings required for ambulances, e.g. passive
circuits for rear-end door and sliding door actuator
motors, can be applied with XENTRY as follows:
• Right-hand sliding door "not present"
• Left-hand sliding door "not present"
• Rear-end door "not present"
Three-button key, code FY7 • Common unlocking of control circuits 1 and 2
With correct use of the interfaces and parameteriza- • Front passenger door "not present"
tion, the three-button key (code FY7) makes it possible
to unlock the body door which is being used as a tail-
gate separately, although the body doors can only be
locked globally, i.e. all doors and the tailgate.
8.8 Windows and doors
8.8.1 Window lifters/window hinges The delta corresponds to the maximum permissible
additional weight on the sliding door to the load com-
Anti-pinch protection and automatic window raising
partment.
can only be guaranteed with the original power window
equipment. Certain weights must be added to the basic equipment
depending on the special equipment installed.
The motor is thermally protected, i.e. the availability of
the power window function may be restricted after long If some items of equipment are removed, they must be
operating periods. taken into account in the weight calculation.
The window lifters and the window hinges can be con- Additional data and information can be found in
trolled using the switches in the door control panel. The Chapter 6.2.6 Side wall, windows, doors and flaps
switches in the driver's door are electronically con- (→ page 111)).
trolled and are connected to the LIN bus. The switches Furthermore, the specifications on "Reinforcement of
in the front passenger door are voltage coded. All the sliding door load compartment with rear seats" for
switches may only be replaced with equivalent genuine the countries in question must be observed, see Chap-
parts. ter 6.4.3 Seats (→ page 147)
Actuation can also occur via the parameterizable spe-
cial module (PSM/MPM). ⚠ WARNING
Modifications to
8.8.2 Sliding door
• door kinematics
The electrical components of the sliding door on the • guidance systems (rails, sliding carriages, etc.)
Sprinter BM 907 (only for the electric load compart-
ment sliding door and particular special equipment) are • locking systems (closing assists, anti-entrapment
connected to the on-board electrical system via a fixed strips, locks, arresters, etc.)
electrical connection in the form of a cable track (drag • end stop systems (buffers etc.)
chain). This is located under the step for the sliding • extensive modification of the body-in-white struc-
door. ture
The cable track must be taken into consideration in the may result in the door opening unintentionally.
event of any modifications around the entrance. If the
upfitter wants to use the cable track, an evalution with There is a risk of accident!
the responsible department is necessary. As part of the No modifications may be made to any of these
eXpertUpfitter program, please refer to www.Upfitter- systems. Furthermore, care must be taken to ensure
Portal.com. an extensive connection and center of gravity (CoG)
The system for the electric sliding door has been distribution at the doors.
designed for a maximum door weight of 65 kg/143 lbs,
and this value must not be exceeded due to modifica-
tions. ⓘ The upfitter is responsible for the conversions and
modifications on the vehicle.
⚠ WARNING
⑴ NOTE
door kinematics or the locks, rails, carriages, closing Correct operation of the integrated anti-pinch protec-
aids and anti-entrapment strips. tion function (anti-entrapment strip and path/time
monitoring) must be ensured in the event of any mod-
ifications in this area, e.g. the window installation.
The ex-factory weight of the load compartment slid-
ing door for each vehicle model and wheelbase, and
additional weights for some items of special equipment,
is listed in Chapter 6.2.6 Side wall, windows, doors and
flaps (→ page 111).
8.8.4 Outside mirrors

The output of the mirror heater (12 V/20 W) is moni-
tored by the door control unit. The mirror heater (if a
genuine part) is deactivated if a fault entry is stored.
The mirror heater must be designed to be equivalent to
the genuine part.
The door control unit must be modified by coding if
different mirrors (without heating) are used.
The mirrors are adjusted via the operating switch in the
driver's door and the adjustments are transmitted via
the LIN bus to the door control unit. The door control
unit in turn actuates the actuator motors.
The mirror adjustment drives must be designed to be
equivalent to the genuine drives.
The design of the outside mirror (with or without Blind
Sliding door with cable track
Spot Assist (→ page 277)) must be observed.
1 Cable track (drag chain)
8.8.5 Windshield heating/rear window heating
8.8.3 Windshield wipers The original heaters can be replaced with heaters with
Mercedes-Benz recommends the use of genuine the same power rating:
Mercedes-Benz wiper motors. • Windshield heater:
If necessary, a second wiper motor can be connected P = max. 790 W at 13 V
via a relief relay (Ri >80 ohms). • Rear window heater:
The wiper motor must be connected to the signal P = 2 x 151 W ± 15 W at 13.5 V
acquisition and actuation module (SAM) by means of a If higher heating outputs are required, the relays, lines
readback line. If there is no readback line, a fault mes- and fuses must be modified accordingly.
sage will be stored in the fault memory of the SAM. If the vehicle has the battery management function, it
may be necessary to adapt this function.
8.9 Driving assistance systems
ⓘ Furthermore, tampering with the vehicle safety or

⚠ WARNING
driver assistance systems and safety-relevant com-
Driving safety and driver assistance systems are ponents can invalidate the warranty or the general
merely aids. operating permit.
If you fail to adapt your driving style or if you are
inattentive, the driving safety systems and driver ⓘ For information regarding the equipment on
assistance systems can neither reduce the risk of an vehicles with driving assistance systems and the
accident nor override the laws of physics. The driver combinations thereof, please refer to 1.7 Contact
is responsible for driving safely and in keeping with (→ page 11).
traffic regulations. The driver's driving style must
always be adapted to suit the current road, traffic and
weather conditions.
The driving safety systems described only work as

effectively as possible when there is adequate contact
between the tires and the roadway. Refer in particular
to the information on tires, recommended minimum
tread depths etc. under 3.8 Tires (→ page 45),
Checking the tires (→ page 54),
4.2 Limit values for the suspension (→ page 68) with
4.2.3 Approved tire sizes (→ page 70),
6.1.5 Wheels/tires (→ page 98),
6.2.7 Fenders and wheel wells (→ page 114).
In wintry driving conditions, always use winter tires
(M+S tires) and, if necessary, snow chains. Only in this
way will the driving safety systems described in this
section work as effectively as possible.
⚠ WARNING
Tampering with or unauthorized installations in
vehicle systems, safety-relevant components and
driver assistance systems can impair the functioning
of these systems. This can lead to failure or malfunc-
tioning of components or of parts relevant to safety,
and may result in accidents or damage to the vehicle.
8.9.1 Electronic Stability Program (ESP®) For vehicles where exceptions apply, the ESP® can
be deactivated under certain conditions. More infor-
ESP® is a dynamic vehicle control system which regu-
mation can be requested from the Upfitter Portal
lates both the longitudinal and lateral dynamics of the
(→ page 18)
vehicle.
If there are any deviations from the specifications on
Greater driving stability is provided by ESP® with an
the ESP®, UIS must be requested online via the Upfit-
extended sensor system that constantly compares the
ter Portal (→ page 18).
current actual vehicle direction with the desired direc-
tion of movement. For more information on the mandatory ESP®, please
reach out on the Upfitter Portal (→ page 18).
ESP® can improve vehicle stability in all driving situ-
ations, e.g. when accelerating, braking and coasting, www.UpfitterPortal.coms
when driving in a straight line and cornering.
Together with the signals of other sensors, a processor
monitors that the direction specified by the driver is
maintained.
If the vehicle deviates from the correct path (over-steer-
ing or under-steering), the system can produce a stabi-
lizing counteraction by applying the brakes on individual
wheels.
A new ESP® variant is available for Sprinter. This variant
can be ordered with the vehicle version for high load
(code B01) separately for specific applications.
Detailed information can be found in Chapter 4.2.1
Suspension of Sprinter – BR 907 (→ page 68)
This code is only recommended for upfitted vehicles
with high center of gravity according to the specifica-
tions in Chapter 9.1 Center of gravity (→ page 309)
ESP® is required on passenger cars, multipurpose pas-
senger vehicles, trucks and buses with a gross vehicle
weight rating of 4536 kg/10000 lbs or less (according
to FMVSS/CMVSS 126).
8.9.2 Crosswind Assist

⚠ WARNING
Crosswind Assist (code JA8) detects the influence of
On no account may any of the following modifications crosswind (lane keeping) through the installed ESP®
be made to vehicles equipped with ESP®: components and can counteract it by applying the
• Modifications to the permissible gross mass brakes on individual wheels with the help of the ESP®.
• Wheelbase modifications Crosswind Assist (code JA8) is added automatically as
• Modifications to the sensors (steering angle sen- standard in combination with ESP® 9.3 for the Sprinter
sor, yaw rate sensor, wheel speed sensor) BR 907.
• Changes to the vibration characteristics at the All modifications to the vehicle crosswind area should
installation location of the yaw rate sensor by mod- not exceed the maximum permissible dimensions of
ifications to the body the Crosswind Assist function.
• Changes to the position of ESP® components ⚠ WARNING

• Modifications to the suspension Modifications that increase the vehicle crosswind
• Modifications to wheels and tires area include (but not limited to), changes to the
• Modifications to the engine overhang or retrofitting of roof mounts. Increasing the
maximum permissible dimensions of the crosswind
• Modifications to the steering area can impair the intended function of the system.
• Modifications to the brake system
• Changes to the installation position of the hydrau- ⑴ NOTE
lic assembly, its bracket and its mounting on the
basic vehicle The Crosswind Assist can be deactivated under the
following conditions:
• Fastening of any vibration-generating devices in
the vicinity of the ESP® control unit • When the code JA0 "Omission of Crosswind Assist"
is ordered
Modifications to vehicles with ESP® may cause this
system to stop functioning correctly and may lead • For post-delivery deactivation of Crosswind Assist
to system shutdowns and incorrect control interven- code JA8, this code JA8 must be deleted from the
tions. The driver could lose control of the vehicle and data card and the JA0 must be added. After the
cause an accident. data card has been updated, the ESP® must be
recoded by Mercedes-Benz certified technicians.
Following vehicle modifications which can result in
changes to the longitudinal and lateral inclination If the modifications exceed the maximum permissible
(e.g. the installation of heavy parts), the sensor clus- dimensions of the crosswind area, the O-code OB3
ter must be recalibrated in order to ensure that the (deviation from the Crosswind Assist test body) must
ESP is functioning correctly. be added to the vehicle data card in addition to delet
ing the code JA8 and adding the code JA0. After this
step, the ESP must be recoded by Mercedes-Benz
⑴ NOTE
certified technicians.
Changes to the center of gravity height of more than
51.18 in/ 1300 mm (for more information, see Chap
ter 4.1.2 Maximum permissible position of the center ⓘ For further questions please reach out to
of gravity (→ page 58)) require an inspection of the Mercedes-Benz on www.UpfitterPortal.com.
vehicle body by the responsible technical department
of Mercedes-Benz AG (see Chapter 2.1 Advice for
Upfitters (→ page 14)).
In addition, the explanation in Chapter 8.9.2 Cross-
wind Assist (→ page 273) must be observed.
It is recommended to have the recalibration of the sensor

cluster carried out at a Mercedes-Benz Service Center.
The following general considerations must be

⑴ NOTE
followed:
The Electronic Stability Program (ESP® 9.3) is a • Option code JA8 is valid for a vehicle width (without
prerequisite for the Crosswind Assist function. The side mirrors) of up to 2500 mm/98 in, but needs to
addition of code JA8 ex-factory or as a retrofitting be deactivated with option code JA0 if this value is
option code is valid for all vehicle variants. With exceeded. Please note that the maximum permissi-
vehicle modifications that require the deactivation ble box width is 2300 mm/96 in (see chapter 4.1.3
of the ESP® 9.3 the Crosswind Assist function must Vehicle dimensions (→ page 59).
be deactivated as well (see chapter 8.9.1 Electronic
• The body/vehicle width limit values (→ page 58)
Stability Program (ESP®) (→ page 272)
in terms of the installation of headlamps and outside
mirrors on the vehicle are the responsibility of the
ⓘ The local and federal registration regulations must upfitter and must be guaranteed by them.
be observed and complied with when working on • The upfit body must be within the parameters out-
the body of the vehicle. lined in the maximum permissible dimension chapter
Crosswind Assist (code JA8) is not permissible and is 4.1.3 Vehicle dimensions (→ page 59).
blocked for these configurations:
ⓘ For further information regarding permissible
Code Description vehicle dimensions please refer to chapter 4.1.3
O27 Brake control system retrofitted for ABS Vehicle dimensions (→ page 59).
with engine
ⓘ For further questions please reach out to

Mercedes-Benz on www.UpfitterPortal.com.
8.9.3 Active Brake Assist/Active Distance Assist

(DISTRONIC PLUS)
The integrated distance warning function (Active Dis
tance Assist) can alert (warn) the driver with a visual
signal when he approaches too close to the vehicle in 2
front. 1
3
Active Brake Assist (ABA) can help to prevent rear-
end collisions by warning the driver when there is an
imminent danger of collision and then, if the driver fails
to react, by braking the vehicle autonomously or, if N54.70-2063-00
necessary, by boosting the driver's braking command Position of Active Brake Assist sensor (front view)
according to the situation. 1 Position of sensor
Active Brake Assist can also apply the brakes autono 2 Sensor holder
mously (up to maximum 37.28 mph or 60 km/h) in the 3 Signal funnel
event of imminent collisions with crossing pedestrians To ensure that the functioning of the system is not
and cyclists. affected, on no account should the following changes
be made:
The sensor for Active Brake Assist, code BA3, and for
Active Distance Assist (DISTRONIC PLUS), code ET4, is • Changing the position of the sensor
integrated behind the step in the front bumper. • Replacing the original holder with a different one
• Removing the original front bumper or the original cover
⑴ NOTE
• Replacing the original front bumper or the original
After changes to the vehicle width or overhang length, cover with a different one
the corresponding O-codes must be entered in the
• Installing detachable parts which protrude into the
vehicle documentation via XENTRY, an SCN coding of
signal funnel
the control unit must be carried out and, in the case
of changes to the vehicle position due to a change in • Installing metallic detachable parts which could
vehicle weight, the height of the radar sensor above shade or affect the area around the sensor
the roadway must be documented. • Metal or metal-plated pipes (see note) or rounded
The following note on changing the inclination of metal or metalized surfaces located in front of or
the vehicle in the longitudinal direction must also be beside the radar sensor. Exception: When these are
observed. covered with an insulating or radar wave-absorbing
plastic/paint in the direction of the radar sensor.
• Parallel metal surfaces (see note) on both sides of
the radar. Exception: When these are covered with
an insulating or radar wave-absorbing plastic/paint
in the direction of the radar sensor.
• No metal or metalized surfaces perpendicular to
2 each other (see note) beside, above and below the
radar, where the opening of the 90° angle is "visi
ble" to the radar sensor. Exception: When these are
covered with an insulating or radar wave-absorbing
plastic/paint in the direction of the radar sensor.
• Additional paintwork on the cover in front of the
radar sensor. (See warning!)
1 • Application of adhesive films (wrapping) in the vicin

N54.70-2062-00
ity of the radar sensors, see Chapter 3.13 Adhesive
Position of Active Brake Assist sensor decals on the exterior (→ page 56).
1 Position of sensor • Application of filler on the cover in front of the radar
2 Signal funnel
sensor. (See warning!)
⚠ WARNING ⑴ NOTE
Depending on the type and thickness, paints or films Active Brake Assist is a certified system. Modifica-
can cause attenuation of radar waves. This could lead tions of any kind made to the individual components,
to malfunction or system failure. This could cause the the system or the basic vehicle (including the wheel-
driver to lose control of the vehicle. base, track width etc.) which are not explicitly cov-
There is a risk of accident! ered by the Body and Equipment Guideline constitute
an alteration of the certified state.
In repair cases, the existing coat of paint must be

removed in such a way that the plastic cover is not ⑴ NOTE
damaged and the material thickness of the cover is
The Active Distance Assist (DISTRONIC PLUS)
not significantly reduced. The new paint coat structure
requires the installation of a functioning driver seat
must not exceed the following limits:
occupancy recognition system which has been
• A maximum of 2 color coats with a thickness of approved by Mercedes-Benz AG. This can be done by
15 μm/ 5.9e-4 in plus 2 clearcoats may be applied. ordering either the standard equipment "Driver's seat
• With metallic silver, only one coat with a thickness occupancy recognition" (code SK2).
of 15 μm/ 5.9e-4 in plus one coat in white 15 μm/ Further information in Chapter 4.5.2 Modifications
5.9e-4 in thick are permissible. to seats (→ page 77), Chapter 6.4.1 General
• The material thickness must be homogeneous in information (→ page 138) and Chapter 7.14.6 Driv-
order to prevent distortion of the radar waves. er’s and front passenger’s doors connection point
(→ page 213).
• Specified thickness for unpainted covers: 2.42 mm
+/-0.1 mm (0.095 in +/- 0.004 in), without paint.
• Specified thickness for painted covers: 2.42 mm Active Brake Assist (code BA3) can be temporarily
+0.1 mm/-0.2 mm (0.095 in +0.004 in/ -0.008 in), deactivated via the instrument cluster. The system is
without paint. always reactivated after an ignition off/on cycle.
• Further information on painting can be found in Active Distance Assist (DISTRONIC PLUS, code ET4)
Chapter 5.4 Painting work/preservation work can be temporarily activated and deactivated via a
(→ page 88). pushbutton switch on the steering wheel (refer to the
description in the operator's manual for instructions on
• For suspension modifications (e.g. number of axles),
activating/deactivating Active Distance Assist).
see Chapter 6.1 Suspension (→ page 92).
⑴ NOTE
⑴ NOTE
If a body installed by the upfitter changes the incli-
The area in front of the sensor also includes parts
nation of the vehicle in the longitudinal direction by
which are located beside, above or below the sensor,
more than 1.5°, a service calibration of the front
but which protrude further forward than the front
radar system must be performed. If this is not done,
edge of the sensor itself.
the intermittent or permanent failure of Active Brake
Assist and Active Distance Assist can be expected in
If the instructions on prohibited modifications are subsequent operations.
ignored, the system must be deactivated. The deactiva-
tion of the system can only be carried out at a qualified
⑴ NOTE
specialist workshop and requires the following actions:
• Deletion of code BA3/ET4 from the vehicle data card If a significant weight is upfitted to the vehicle, it is
recommended to measure the upfitted vehicle height
• Subsequent recoding of the control units: EIS, instru-
and recalibrate the DISTRONIC PLUS sensor height
ment cluster, head unit and radar sensor
accordingly. Please visit a local Mercedes-Benz deal-
• In vehicles with code ET4, the ESP® must also be ership.
recoded.
The following must be observed when determining the 8.9.4 Blind Spot Assist/Rear Cross Traffic Alert
change in angle: (RCTA)/Exit Warning
• For the angle measurement, either the vehicle must
be standing on a leveled surface or Ex-factory option code JA7
• the angle measurement should always be taken at The Blind Spot Assist/ Rear Cross Traffic Alert (RCTA)/
the same measuring station. Exit Warning functions are available as a special equip-
ment, code JA7, from the factory.
• The spirit level must have an accuracy of at least
0.1°. Blind Spot Assist, also known as Blind Spot Monitoring
(BSM), can warn the driver of vehicles in the respective
• The spirit level must output or display the angles adjacent lane when changing lanes.
digitally.
The Rear Cross Traffic Alert (RCTA) function can warn
• The angle measurement before and after the conver- the driver of traffic crossing behind the vehicle while
sion of the vehicle must always be taken at the same reversing, e.g. when unparking.
point on the chassis. Therefore a location should be
selected which will still be accessible for the angle The Exit Warning function can provide warnings of traf
measurement after the conversion. Measuring at dif- fic approaching from behind when the driver or front
ferent points on the chassis or at points on the body passenger door is opened.
(indirect angle measurement) is not permissible. In order for the Exit Warning to operate correctly, it
must be ensured that the door sensor signals (open or
⑴ NOTE closed state) are available on the CAN bus.
After any damage to the front of the vehicle, have the The radar sensors for Blind Spot Assist, RCTA and
setting and function of the radar sensor checked and Exit Warning (code JA7) are installed behind the rear
recalibrated at a qualified specialist workshop. This bumper on cargo, crew, and passenger vans.
also applies to mild collisions at low speeds, where The signal is transmitted to the driver by means of a
no damage to the front end of the vehicle is visible. luminous symbol in the outside mirrors and an acoustic
The parameterization of the front radar must be warning. The system status is displayed in the instru-
adjusted after the following changes: ment cluster, RCTA and, in the head unit, if the parking
package special equipment (code JB6/ JB7) is installed.
• Springs (refer to Chapter 4.2.8 Modifications
to springs, spring suspension/shock absorbers 1
(→ page 71))
• Tire size (refer to Chapter 4.1.3 Vehicle dimensions
(→ page 59)) 2 N54.70-2064-00
• Track width (only in combination with an UIS, Positions of sensors of Blind Spot Assist (top view)
Chapter 2.1.1 Regulatory Overview
(→ page 14))
• Vehicle width (without outside mirrors/detachable
parts) 1
N54.70-2065-00
Positions of sensors of Blind Spot Assist (ISO layout)
1 Position of sensors
2 Radar range
• No metal or metalized surfaces perpendicular to

each other beside, above and below the radar sen-
sor, where the opening of the 90° angle is "visible" to
the radar sensor. Exception: when these are covered
with an insulating or radar wave-absorbing plastic/
1 2
paint in the direction of the radar sensor.
• No additional paintwork and no film on the cover
(corner bumper) in front of the radar sensor (see
N91.60-2202-00
warning!).
Sensor positions of Blind Spot Assist (schematic based
• Application of filler to the cover or bumper corner in
on example of passenger van)
front of the radar sensor (see warning!).
1 Display of BSM function
2 Position of sensors (location symmetrical to vehicle's • Lengthening and shortening of the overhang are only
longitudinal axis) permitted after consultation with the department
responsible (see Chapter 2.1 Advice for Upfit-
To ensure that the functioning of the system is not ters (→ page 14)) and after the code has been
affected, on no account should the following changes changed accordingly.
be made: If the instructions on prohibited modifications are
• Changing the warning lamps in the outside mirror (if ignored, the system may have to be deactivated. The
no custom warning lamps are used, e.g. with omis- deactivation of the system can only be carried out at a
sion of the doors, code FW8/FW9) qualified specialist workshop and requires the following
actions:
• Relocating the radar sensors
• Deletion of code JA7 from the vehicle data card
• Replacing the original holder with a different one
• Subsequent recoding of the control units: EIS, instru-
• Modifications to the rear bumper in the area of the
ment cluster, head unit, door control units and blind
radar sensor on cargo, crew, and passenger vans
spot sensors
• Application of adhesive films (wrapping) in the vicin-
• Replacement of the mirrors with a variant without
ity of the radar sensors, see Chapter 3.13 Adhesive
warning indicator
decals on the exterior (→ page 56).
Blind Spot Assist can be deactivated via the Assis-
• Attachment of detachable parts that can shade the
tance menu in the instrument cluster. If a head unit is
area of or around the radar sensor
installed, it is deactivated via the Assistance menu in
• Removing or modifying genuine Mercedes-Benz the multimedia system.
detachable parts in the area of the radar sensors
• Installing detachable parts which protrude into the ⚠ WARNING
signal funnel of the radar sensors. Depending on the type and thickness, paints or films
• Metal or metal-plated pipes or rounded metal or can cause attenuation of radar waves. This could lead
metalized surfaces protruding beyond the sensor at to malfunction or system failure. This could cause the
the side. Exception: when these are covered with an driver to lose control of the vehicle.
insulating or radar wave-absorbing plastic/paint in There is a risk of accident!
the direction of the radar sensor.
• Parallel metal surfaces on both sides of the radar.
Exception: when these are covered with an insulating
or radar wave-absorbing plastic/paint in the direc-
tion of the radar sensor.
In repair cases, the existing coat of paint must be Assist/Exit Warning (code J1V) comprises the following
removed in such a way that the plastic cover is not components:
damaged and the material thickness of the cover is • Wiring harness interface in the seat base (further
not significantly reduced. The new paint coat structure information in Chapter 7.14.3 Wiring harness con-
must not exceed the following limits: necting points (→ page 211)
• A maximum of 2 color coats with a thickness of • Two identical radar sensors with plastic holder and
15 μm/ 5.9e-4 in plus 2 clearcoats may be applied. cover for the left and right side of the vehicle, see
• With metallic silver, only one coat with a thickness the following image.
of 15 μm/ 5.9e-4 in plus one coat in white 15 μm/
5.9e-4 in thick are permissible.
• The material thickness must be homogeneous in
order to prevent distortion of the radar waves.
• Specified thickness for unpainted covers: 2.72 mm
+/-0.1 mm (0.107 in +/- 0.004 in), without paint
• Specified thickness for painted covers: 2.72 mm
+0.1 mm/-0.2 mm (0.107 in +0.004 in/-0.008 in),
without paint
• Further information on painting can be found in
Chapter 5.4 Painting work/preservation work
(→ page 88).
Scope of delivery for Blind Spot Assist/Exit Warning on
cab-chassis models, code JV1 (wiring harness of pre-installa-
tion is not shown)
⑴ NOTE
After any damage to the rear end of the vehicle, have 1 Plastic cover
2 Radar sensor
the function of the radar sensor checked at a qual-
3 Plastic holder
ified specialist workshop. This also applies to mild
4 Screws
collisions at low speeds, where no damage to the rear
area of the vehicle is visible.
The CAD data of the components for the pre-instal
The parameterization of both rear radars must be lation code J1V are available for the eXpertUpfitters on
adjusted after the following changes: the Upfitter Portal.
• Rear overhang, see Chapter 6.2.4 Overhang exten- Both radar sensors are to be installed and commis-
sion (→ page 107) sioned in accordance with the following specifications
• Wheelbase using the original holders and covers provided, as well
as an upfitter mounting bracket.
parts)
⑴ NOTE
/
This work must be carried out by the upfitter before
"Pre-installation for Blind0.87
Spot in
Assist/Exit Warning
the vehicle is delivered to the end customer because
for Cab-Chassis" (code J1V)
when the pre-installation for Blind Spot Assist/Exit
The pre-installation for Blind Spot Assist/Exit Warning Warning (code J1V) is ordered, the vehicle is precon-
(code J1V) will be available as ex-factory option code figured at the factory for operation with Blind Spot
for cab-chassis. Assist.
In contrast to the ex-factory option with code JA7, the The above components may only be retrofitted when
Rear Cross Traffic Alert (RCTA) function is not available the vehicle is fitted with the pre-installation, code J1V.
with this pre-installation.
This pre-installation is not available for cargo, crew, and
passenger vans.
The factory scope of the pre-installation for Blind Spot
Special requirements apply for all upfit types in which Specifications for the positioning of the radar
specific outside mirrors installed by the upfitter are sensor system:
used (including fully integrated RVs). In these vehicles, • The radar sensor must always be mounted in the
appropriate warning lamps must be integrated in the area of the vehicle overhang.
mirrors or at a suitable alternative location.
• The maximum distance between the reference point
Information on the basic layout for the positioning of the radar sensor and the wheel center of the front
of the radar sensor system in the vehicle: axle must be no more than 6250 mm/ 246 in in the
x-direction.
Radar sensors reference point:
• The maximum distance between the reference point
• In order for the system to function correctly, the
of the radar sensor and the rearmost reference point
position of the radar sensor in the overall vehicle
for the limit dimension in the x-direction must not
must be known.
exceed 1650 mm/ 65 in, see illustration.
The reference point for dimensioning is on the front
surface of the radar sensor and is defined as follows:
• Centrally at a distance of 22 mm/ 0.87 in from the
lower edge of the radar sensor housing.
It must be ensured that the plug points downward as

specified; refer to the diagram and installation notes.

PD[PP

Positioning of the radar sensor system, limit dimensions in

the rear area
1 Vehicle body (box upfit)

2 Bumper
3 Radar sensor
4 Radar sensor reference point
5 Limit dimension reference point
• The height between the reference point of the radar

Positioning of the radar sensor system sensor and the roadway in the z-direction must be
≥ 350 mm/ 13.78 in and ≤ 1000 mm/ 39.37 in.
1 Reference point This height specification applies for the permissible
gross mass and the curb weight, for all suspension
and wheel/tire combinations, and for all-wheel drive
vehicles.
• No add-on parts protruding from the outer skin Specifications for mounting the radar sensor
(door handles, turn signal lamps etc.) may be The radar sensor may only be installed in combina-
installed between the sensor and the rear end of the tion with the plastic holder and the cover from the
vehicle in a vertical angle of +/- 20° from the sensor ex works scope of delivery. Installation with other
reference point. holders and covers is not permitted.
• When positioning detachable parts in the rear area For the installation of the scope of delivery on the
vehicle, the upfitter must provide a mirror-symmet-
(particularly round metallic objects, such as lad- rical fastening bracket for each side of the vehicle
ders), it must be ensured that the area defined in in accordance with the following specifications and
the principle drawing is kept as clear as possible. illustrations.
Aftermarket parts mounted on the vehicle, such The mounting bracket must accommodate the
as bicycle racks, can also interfere with the radar radar sensor holder so that the plug of the radar
sensor system (cf. graphics of sensor radar ranges). sensor points downwards.
This note must transposed to the upfitter's operating The mounting bracket shall ensure the mounting of
instructions for the Mercedes special equipment "J1V the radar sensor on both sides of the vehicle with
= Pre-installation for blind spot sensor system". a horizontal angle to the rear of 10.5° ±1°, see
schematic diagram.
Vertical inclination must be avoided, i.e. the
installation must be at right angles (90° ±1°) to the
roadway.
After mounting, the cover must protrude at least 2
mm over the outer surface of the side wall at the
rear edge, see schematic diagram.
For mounting the plastic holder, rectangular clip
holes and round holes for screw connections must
be made in the mounting bracket according to the
hole pattern shown below. Please use the CAD data
of the plastic holder A9078840100 for your design
adaptation of the mounting bracket.
Positioning of the radar sensor system, possible installation To ensure that the scope of delivery of the radar
positions at the rear sensor is securely fastened, the plastic holder
must also be screwed in place in addition to the
1 Vehicle body (box upfit) clips. The screws are available under item number
2 Bumper A0059907612.
3 Planar rear panel A recess must be provided at the bottom edge
4 Planar side wall for the passage of the electrical cable and for the
5 Radar sensor drainage of condensation water.
6 Area in which detachable parts are permitted A recess must be provided in the side panel at
7 Area in which detachable parts are not permitted the position in accordance with the specifica-
tions for the limit dimensions on the vehicle (see
In the event of deviations from these specifications, it above), into which the mounting bracket with the
is recommended that the upfitter reach out on Upfitter preassembled components of the radar sensor is
Portal (→ page 18) during the planning phase. installed. An opening of approx. 150 x 150 mm is
usually sufficient for this purpose.
The mounting bracket must be connected to the Overview of O-codes for documentation of rear
side panel in such a way that the radar sensor is radar with code J1V for open model designations
firmly connected for all operating conditions, with- (FHS, FHL)
out contact with surrounding components (avoid-
ance of rattling noises). Additional sealing and
anti-corrosion protection between the body and the a) Height above roadway
mounting bracket is recommended. O-code Designation
The radar sensors are to be mounted symmetrically O8K Rear blind spot radar, Z above ground
on the left and right. This means that the installa- 350 ±50 mm
tion locations of the radar sensors on the left and O8L Rear blind spot radar, Z above ground
right sides of the vehicle must be symmetrical in 450 ±50 mm
terms of their positioning relative to the design level O8M Rear blind spot radar, Z above ground
of the vehicle on both sides.
550 ±50 mm
Under no circumstances may the radar sensors be O8N Rear blind spot radar, Z above ground
installed in doors, flaps or other movable parts, but
650 ±50 mm
must always be connected to the vehicle body in a
fixed, immovable position. O8O Rear blind spot radar, Z above ground
750 ±50 mm
The wiring between the plug on the radar sensor
and the plug of the wiring harness pre-installation O8P Rear blind spot radar, Z above ground
must be designed and installed by the upfitters on 850 ±50 mm
their own responsibility, see the following informa- O8Q Rear blind spot radar, Z above ground
tion. 950 ±50 mm
After successful assembly and electrical connec- O8R Rear blind spot radar, Z above ground
tion, the O-code for wheelbase, track width, body 1050 ±50 mm
width, vehicle rear overhang must be added to the O8S Rear blind spot radar, Z above ground
vehicle documentation via XENTRY if there are any 1150 ±50 mm
deviations from the standard configuration. See the
corresponding chapters in these body/equipment
mounting directives. b) Distance from rear axle (RA)
In addition, the corresponding O-codes for the O-code Designation
installation position (height above roadway and O7K Rear blind spot radar, X to RA 100 ±100 mm
distance to rear axle) of the radar sensor must be O7L Rear blind spot radar, X to RA 300 ±100 mm
entered in the vehicle documentation via XENTRY,
see the following overview. O7M Rear blind spot radar, X to RA 500 ±100 mm
O7N Rear blind spot radar, X to RA 700 ±100 mm
O7O Rear blind spot radar, X to RA 900 ±100 mm
O7P Rear blind spot radar, additional X to RA
+1000 mm
O7Q Rear blind spot radar, additional X to RA
+2000 mm
X Z
Y Y
Schematic illustration of assembly on vehicle: Horizontal section (left, Z plane),

Vertical section (right, X plane)
1 Plastic cover
2 Radar sensor
3 Plastic holder
4 Screw connection
5 Clips
6 Radar sensor plug
7 Mounting bracket (exemplary)
8 Side panel structure
Hole pattern for mounting bracket (for details see CAD data)
Notes on the electrical connection Please contact your Mercedes-Benz Service contact
The connecting point of the vehicle-side wiring harness person to procure the connector plugs under the above
for the Blind Spot Assist pre-installation code J1V in the item numbers or, if necessary, under a successor part
driver's seat base area has the plug with item number number.
A2105404381. The mating connector has the item The upfitter is solely responsible for routing the wiring
number A2105404981 and the following PIN assign- harness from the radar sensor to the pre-installation
ment: connection point. The specifications and information
in Chapter 8.4 Interfaces (→ page 239) must be
Pin assignment for 4-pin plug observed.
⑴ NOTE
When installing and testing the radar sensors, it
should be noted that the workplace and the workers
must have ESD protection (safety measures against
electrostatic discharge). This also applies for the
shipping container and the warehouse areas where
4-pin plug A2105404981
the sensors are packed or unpacked.
Pin Function If this is not observed, damage to the radar sensors
1 Ignition (terminal 15) from electrostatic discharges should be expected.
2 Peripherals CAN High Generally, only slight damage occurs at first, but with
3 Peripherals CAN Low continued operation this initial damage gradually
4 Ground (terminal 31) spreads until the sensor starts failing from time to
time and eventually fails permanently. This means
The plug of the electrical connection on the radar that Mercedes-Benz AG will not assume any war-
sensor has the item number A2100072999. The mating ranty or goodwill costs in the event of failing radar
connector has the item number A2105404581 and the sensors in combination with code J1V in the event of
following PIN assignment (different left/right): non-compliance with the ESD protection specifica-
tions and hardware failure attributable to this, unless
Pin assignment for 8-pin plug the component damage demonstrably occurred
before or during delivery to the upfitter.
8-pin plug A2105404581
Pin Function, right Function, left

1 Ground (terminal 31) Ground (terminal 31)
2 CAN High CAN High
3 CAN Low CAN Low
4 - -
5 - -
6 - -
7 Ground -
8 Ignition (terminal 15) Ignition (terminal 15)
To guarantee proper operation of the system, the

⑴ NOTE
following modifications are prohibited in addition to
the prohibited modifications listed in the Chapter 6.6.2 After any damage to the rear end of the vehicle, have
Attachment(→ page 157): the adjustment and function of the radar sensor
• Replacement of the supplied genuine Mercedes-Benz checked at a qualified specialist workshop. This also
components with other parts. applies to mild collisions at low speeds, where no
damage to the rear area of the vehicle is visible.
If the instructions on prohibited modifications are
ignored, the system must not be ordered. The parameterization of both rear radars must be
adapted in case of the following changes (examples,
Blind Spot Assist can be deactivated via the Assis-
list is not complete):
tance menu in the instrument cluster. If a head unit is
installed, it is deactivated via the Assistance menu in • Rear overhang, see Chapter 6.2.4 Overhang exten-
the multimedia system. sion (→ page 107)
• Wheelbase
⚠ WARNING
Depending on the type and thickness, paints or films parts)
can cause attenuation of radar waves. This could lead
to malfunction or system failure. This could cause the
driver to lose control of the vehicle. ⑴ NOTE
There is a risk of accident! It is recommended to include this information in

regards to code J1V in the upfitter's supplemental
In repair cases, the existing coat of paint must be instructions.
removed in such a way that the plastic cover is not
damaged and the material thickness of the cover is
not significantly reduced. The new paint coat structure ⓘ For more information on the code J1V, please
must not exceed the following limits: refer to Upfitter Portal technical bulletin: Sprinter
• A maximum of 2 color coats with a thickness of MY2023+ Pre-installation of Blind Spot Sensor f
15 µm plus 2 clearcoats may be applied. or Cab-chassis (J1V)
• With metallic silver, only one coat with a thickness

of 15 µm plus one coat in white 15 µm thick are
permissible.
• The material thickness must be homogeneous in
order to prevent distortion of the radar waves.
• Specified thickness of base material for unpainted
covers: 2.42 mm ±0.1 mm
• Specified thickness of base material for painted
cover (measured without paint):
2.42 mm +0.1 mm/-0.2 mm
• More detailed information on the paint is available
in Chapter 5.4 Painting work/preservation work
(→ page 88).
8.9.5 Highbeam Assist, Lane Keeping Assist and ⓘ Further information on the calibration of Highbeam
traffic sign recognition Assist, Lane Keeping Assist and Traffic Sign Assist
can be found in the Workshop Information System
⑴ NOTE (WIS) (→ page 18).
On vehicles with bodies that protrude beyond the

8.9.6 Rain sensor and Headlamp Assist
limit shown below (e.g. RVs with alcove bodies), the
function of the camera may be impaired. The rain sensor (code JF1) and Headlamp Assist (code
LA2) may only be installed with the windshields avail
Therefore, it is not recommended to install Highbeam
able as standard or special equipment. There is other
Assist (code LA1), Lane Keeping Assist (code JW5),
wise a risk of malfunction. The overhead control panel
Active Lane Keeping Assist (code JB4), and Traffic
(OCP) must also be fitted (contains the interface).
Sign Assist (code JA9), on vehicles with alcoves
longer than 1150 mm/45 in, measured from zero
(zero: top right/left outer corner of windsield) or with ⑴ NOTE
alcoves below zero. On vehicles with bodies that protrude beyond the
limit shown below (e.g. RVs with alcove bodies), the
function of the rain sensor, code JF1, and Headlamp
⑴ NOTE
Assist, code LA2, may be impaired.
On no account should any modifications be made to
the position of the camera or the surrounding area
(e.g. changing the standard windshield). Otherwise
the camera may not be able to function properly.
In case of modifications to the vehicle that lead to a

change in the angle, e.g. increase in weight or replace-
ment of suspension strut, the camera must be read-
justed. Have the readjustment carried out at a qualified
specialist workshop possessing the required expertise
and tools in order to perform the necessary work.
Mercedes-Benz recommends that you use a Mer-
cedes-Benz Service Center for this purpose.
Highbeam Assist, code LA1, can be deactivated via
the rotary light switch. When the rotary light switch is
at "Auto" and the lever is at "high beams", Intelligent
Headlight Control is active.
Lane Keeping Assist,code JW5, and Active Lane Keep-
ing Assist, code JB4, are activated/deactivated via a
menu item in the instrument cluster or or head unit. Limit for bodies on vehicles with rain and light sensor
Traffic Sign Assist, code JA9, is usable under identical
1 Rain and light sensor
conditions. It can only be used in combination with the
2 Body limit
navigation system of the NTG6 and the high instrument
cluster. The functions of Traffic Sign Assist can be ⑴ NOTE
switched on and off in the menu of the head unit.
On no account should any modifications be made
Highbeam Assist (code LA1), Lane Keeping Assist
to the position of the rain and light sensor or the
(code JW5), Active Lane Keeping Assist (code JB4), and
surrounding area (e.g. changing the standard wind-
Traffic Sign Assist (code JA9), may only be installed
shield). Otherwise the rain and light sensor may no
with the windshields available as standard or special
equipment. There is otherwise a risk of malfunction.
Information on installation on base vehicles

(code F28)
750 mm 400 mm
Proper functioning can be impaired by overhanging
29.53 in 15.75 in
parts:
• Deviations from the standard occur depending on the
overhang. It should be noted that there may be other
effects on the system depending on the weather situa-
tion/ shade or seasons (height of the sun).
1
• With overhangs of 200 mm/ 7.87 in or more, the
function of the light sensor is impaired in terms of its 2
ability to measure the correct light intensity.
With longer overhangs, the automatic activation of
the windshield wipers in rain (the rain function) can
also be impaired.
N82.35-2103-00
113,8 mm
Overhand deviation
4.48 in
1 Position of sensor
2 Position of sensor for alcove vehicles
With a roof overhang up to max. 400 mm/ 15.8 in

y (measured from the outer edge of the windshield, see
picture), the rain sensor (code JF1) and Headlamp
x
Assist (code LA2) can still function correctly.
If an overhang longer than 400 mm/ 15.8 in over the
N82.35-2102-00
windshield is planned, the Headlamp Assist for roof
Lead angle overhangs (code LA3) must be ordered ex factory. With
this, the sensor of the Headlamp Assist (code LA2)
x Position sensor
is relocated at the factory to a lower position on the
y Lead angle (ideally 90°)
windshield so that there are no functional limitations
due to the body.
It must be ensured that the overhang does not exceed
the specified limit value 1150 mm/ 45.3 in (measured
from the outer edge of the windshield, see picture).
On vehicles with roof overhangs of more than 400
mm/ 15.8 in, the rain sensor (code JF1) is blocked
and cannot be ordered in combination with the special
Headlamp Assist for roof overhangs (code LA3).
⑴ NOTE
There must be no infrared-absorbing films on the
windshield in the area of the sensor.
8.9.7 Tire pressure loss detection system

Furthermore, the vehicle may no longer meet certifica-
⚠ WARNING
tion requirements.
Modifications in the hatched/gray area (see figure)
can impair the function of the tire pressure loss
detection system due to the effects of electromag
netic reflections. This might result in the driver being
unaware of any tire pressure loss in certain driving
situations.
Do not carry out any modifications in the hatched/
gray-shaded area (see illustration) of the vehicle sub
structure, including the vehicle axles and the com
ponents of the tire pressure loss detection system
(code RY2).
727 mm
28.62 in
ECU
N40.15-2032-00
Restricted areas for tire pressure monitoring system (applies for both versions of the system used in the Sprinter)
Modifications to the components of tire pressure loss 8.9.8 Parking Package with 360° camera (JB6)/
detection system (code RY2) or influencing them by Parking Package with reversing camera
modifying or adding electromagnetic fields or reposition- (JB7)
ing the system components is not permitted.
• If approved detachable parts are retrofitted, it is
If, despite this, body work is planned for the vehicle necessary to have the respective Parking Package
underbody, an evalution with the responsible depart- JB6/JB7 coded with the appropriate parameter set
ment is necessary. As part of the eXpertUpfitter pro- by your Mercedes-Benz partner.
gram please refer to www.UpfitterPortal.com.
• Aftermarket painting of the bumper is not permitted
All the criteria of UN-R 64 must be satisfied. After a with the ultrasonic sensors fitted. The coat of paint
maximum of 10 minutes of driving (over 25 km/h), the impairs the emission and reception of the ultrasonic
tire pressures of all 4 wheels must be evident in the signals.
instrument cluster. If this is the case, then the control
unit has received signals from all four sensors. It is rec- ⑴ NOTE
ommended that the vehicles be tested with maximum
equipment. All electrical consumers (radio, headlamps, Sensors which are already painted must not be
refrigerator etc.) should be switched on. repainted or touched up.
Mercedes-Benz does not issue certificates for body Unpainted sensors and sensors painted in a
equipment in connection with this vehicle system. range of colors are available from Mercedes-Benz.
After upfit has been carried out in this area, it may be

necessary for the tire pressure loss detection system to The maximum thickness the paint coat on the cover
be retested in accordance with UN Regulation No. 64 may have without impairing sensor operation is
or No. 141 by a state-recognized inspection organisa- 120 μm/ 4.72e-3 in. This also includes repeated paint
tion at the expense of the upfitter. This serves to prove applications and the coat from cathodic electrodeposi-
that the vehicle registration eligibility as per this regu- tion (KTL coat). The KTL coat thickness is between
lation still exists as the tire pressure monitoring system 12 μm/ 4.7e-4 in and 25 μm/ 9.8e-4 in.
has not been affected. It is therefore necessary to make spot checks of the
The pressure sensors with battery and transmitter are paint coat thickness to ensure faultless operation of
integrated into the tire valves. The optional spare wheel the sensors.
must be identically equipped (→ page 100). It is essential that the cover and the cylindrical edge of
If the rims used are not standard wheels on the the sensor diaphragm to be coated evenly with paint
planned Sprinters BM 907, they must be assembled and covering at least 2 mm/0.08 in.
with the valve and tested for correct seating and
sealing. The costs of any tests are to be borne by the
upfitter.
The system includes a control unit (ECU), located
below the underbody between the axles. The unit can
receive tire pressure information from sensors that are
screwed into the rims and connected with the valves.
These transmit the measured pressure as 433 MHz
radio-frequency telegram to the control unit.
Shields and pulsing consumers on the underbody
can impair radio reception, with the result that some
tire pressures may not be displayed. A maximum of
4 sensors are assigned to the system and monitored
simultaneously.
8.9.9 Reversing camera

1
Overview of the available codes
2 mm
0.08 in
Code Description1)
FR3 Analog reversing camera with inside rearview
mirror display
FR8 Digital reversing camera with head unit display
FV1 Pre-installation for analog reversing camera
with inside rearview mirror display
FR7 Pre-installation for digital reversing camera
N98.00-2211-00 with head unit display
Area of cylindrical edge of the sensor membrane to be E3M MBUX multimedia system with 7-inch touch-
painted screen
E4M MBUX multimedia system with 10.25-inch
1 Area to be painted
2 Maximum coat thickness 120 µm/4.72e-3 in touchscreen
O1N Activation of digital reversing camera without
⑴ NOTE guide lines
The coat of paint may not be removed mechanically, 1) This description is intended as an explanation and is not
as this could damage the cathodic dip coating or the the same as the code designation.
sensor diaphragm.
A) Reversing camera from Mercedes-Benz
production plant
⑴ NOTE Two reversing camera systems are available from the
If the surface has been cathodic dip primed, the paint- factory:
must not be removed by chemical means. This could • Analog reversing camera with inside rearview mirror
damage the cathodic dip coating and a new coating display (code FR3)
cannot be applied afterwards. Nor is it permitted to • Digital reversing camera with display via the head
touch up damaged areas chemically or mechanically. unit (code FR8)
⑴ NOTE ⑴ NOTE
Detachable parts fitted in the detection range of No modifications of any kind may be made to the
the sensors may impair operation of the Park Assist factory-installed camera systems.
system (e.g. trailer hitch, overhangs of bodies, wheel
carriers, steps, brush guards).
⑴ NOTE ⑴ NOTE
The guide lines of the digital reversing camera (code If you are using analog cameras other than those
FR8) in the head unit display are designed exclusively approved by Mercedes-Benz, these must comply with
for the base model vehicle. the analog standard NTSC 60 Hz.
Therefore, if approved detachable parts are retrofitted
to the rear area of the panel van models, it is neces-
sary to have the relevant parameter set coded in the ⓘ This pre-installation provides interfaces for con-
reversing camera by a local Mercedes-Benz/ Freight- necting the reversing camera in the driver seat
line Service Partner. frame in open models and in the area of the 3rd
If the vehicle is lengthened at the rear with the brake lamp on closed models (on the roof at the
upfitter's own detachable parts so that it deviates top of the rear), see the further information at the
from this configuration, the guide lines of the end of this chapter.
reversing camera must be deactivated.
⑴ NOTE
To hide the guide lines, SCN coding must be carried
out using O-code O1N "Activate reversing camera The reversing camera system is classified as ASIL
without guide lines" via XENTRY (see Chapter 2.3.3 Level A according to ISO 26262. For all the compo-
XENTRY Kit (→ page 19)). nents involved, it must be ensured that no delayed or
frozen images can occur (see the section on com-
missioning at the end of this chapter). For eXpert-
B) Retrofitting of a reversing camera Upfitters, an appropriate verification of this must
There are two options for retrofitting a reversing cam- be provided to Mercedes-Benz AG (see Chapter 1.7
era: Contact (→ page 11)).
Variant 1: Analog reversing camera

• Pre-installation of reversing camera with inside rear-
view mirror display (code FV1)
This special equipment is available for panel vans and
cab-chassis.
It is recommended to use the analog camera approved
by Mercedes-Benz AG. This is available as a single part
from the Mercedes-Benz Service Partner under the
following item number:
• A 000 905 61 13
From mid-2022, the analog camera will be replaced
by a new type of camera. This is available under the
following item number:
• A 000 905 68 15
The relevant wiring harness is available under the fol-
lowing item number:
• A 907 540 90 82
ⓘ Please consult your Mercedes-Benz Service Partner

for advice regarding successor item numbers if the
above item numbers are unavailable.
ⓘ For more information, please reach out to the Upfit-

ter Portal (→ page 18). www.UpfitterPortal.com
Variant 2: Digital reversing camera If the digital reversing camera is procured from
• Pre-installation for electric ultrasonic reversing aid Mercedes-Benz AG as a single part, the upfitter must
(code FR7) for retrofitting of a digital reversing cam- build his or her own holder or housing.
era with head unit display For this, the specifications below for the housing or
This special equipment is only available for cab-chassis. holder and their positioning and installation position
must be observed and complied with.
For panel vans, the special equipment code FR8 must
be used, see section A). Requirements for the aftermarket housing or aftermar-
ket holder:
⑴ NOTE IP protection class IPX4K must be observed.
The plugs of the cables must be located in the dry
Only the digital reversing camera approved by Mer- area of the vehicle.
cedes-Benz AG may be used for the digital reversing
Precautions must be taken to ensure that no fluid
camera system. accumulates in the housing.
Any other digital camera is not permitted because it The cable routing into the vehicle interior must be
is not approved for combining with the other system sealed.
components (e.g. the head unit display). A minimum bending radius of 8.4 mm/ 0.33 in
Code FR7 is only possible in combination with the must be observed for the routing of the connection
line attached to the camera (see figure “Camera
special equipment MBUX multimedia system with
with wiring harness and IP protection classes”).
7-inch touchscreen (code E3M) or with 10.15-inch
touchscreen (code E4M).
R
This pre-installation provides the interface for connect-

ing the reversing camera in the driver seat frame of
cab-chassis, see the further information at the end of
this chapter.
Information on retrofitting the digital reversing
camera with the pre-installation code FR7
The digital reversing camera can be procured as fol-
lows:
• Variant a: As a single part
N82.00-2228-00
Variant a: Single part Camera with wiring harness and IP protection classes
The digital reversing camera is available as a single part
(the package includes the hardware and software) from R Application range of minimum bending radius
your Mercedes-Benz Service Partner under the follow-
ing item number:
• A 000 900 50 24
The relevant wiring harness is available under the fol
lowing item number:
• A 907 540 91 82
ⓘ Please consult a local Mercedes-Benz Service Part-

ner for advice regarding successor item numbers if
the above item numbers are unavailable.
ⓘ For more information, please reach out to the Upfit-

ter Portal(→ page 18). www.UpfitterPortal.com
Requirements concerning positioning and ⓘ The reference point for the camera height and
installation position: the offset to the center is always the center of the
• The camera must be positioned so that the rear- camera lens.
most contour of the rear end of the vehicle is clearly
visible in the head unit display (see figure “Camera
positioning with upfitter housing”).
• The positioning and installation position of the cam- 3 3
era must meet the specifications, see figures “Cam-
era positioning with upfitter housing” and “Permissi-
ble installation position”.
• The cable outlet of the camera is positioned off-cen-
2
ter. To ensure the image is displayed correctly, the
camera must always be installed with the cable out-
1
let pointing upward (see figure “Camera positioning
with upfitter housing”).
4
N82.00-2230-00
Permissible installation position (schematic diagram)

2 1 Minimum height hmin= 1675 mm/ 65.94 in
2 Maximum height hmax= 2785 mm/ 109.65 in
3 Maximum deviation bmax= ±200 mm/ 7.87 in (relative to
the center of the vehicle)
5 4 Upper edge of vehicle longitudinal frame member
4
N82.00-2229-00
Camera positioning with upfitter housing (schematic diagram)
1 Cable outlet (specification: must always point upward)

2 Viewing angle = 37°
3 Viewing area (asymmetrical)
4 Center line of camera lens
5 Viewing angle limit
Electrical requirements for camera system and The reversing camera system must be tested and must
connecting points function flawlessly under real-life conditions (including
The connecting points for the analog and digital upfitter requirements):
reversing cameras are located in the driver seat frame • When reverse gear is engaged, the picture from the
in open models. The connecting point for the analog reversing camera is displayed completely and with
reversing camera in closed models is located in the out errors in the head unit display.
area of the 3rd brake light (on the roof at the top of the • No guide lines are displayed.
rear).
• The rear end of the vehicle is clearly visible.
The wiring harness and plug to be connected to this
wiring harness must satisfy the following requirements: • Image noise, distortions, mirroring or delays must
not occur.
• The connectors of the camera are only approved for
a dry environment. For a detailed description of the commissioning pro-
cess, please refer to the WIS (Workshop Information
• No further connecting points are permissible System).
• The quality of the video/high-frequency line must For further questions, please reach out on the Upfitter
meet at least the requirements of the 50-ohm LEONI Portal.
Dacar® 462 for mobile applications up to 6 GHz.
• The line quality was designed for a line length of ⑴ NOTE
9600 mm/ 377.95 in from the seat base connecting The reversing camera system is classified as ASIL
point to the camera. If a longer line is required, its Level A according to ISO 26262. For all the compo-
functional capability must be assured by means of nents involved, it must be ensured that no delayed or
tests conducted by the upfitter. frozen images can occur (see the section on commis-
• The reversing camera system must not be disrupted sioning at the end of this chapter). Appropriate verifi-
by EMC influences, e.g. by 230 V systems, actuators cation of this must be provided to Mercedes-Benz AG
etc. via your contact person at Technical Consulting (see
Chapter 2.1 Advice for Upfitters (→ page 14)).
ⓘ Further information can be found on the Upfitter
Portal.
ⓘ For a detailed description of the commissioning
Requirements for commissioning process, please refer to the WIS (Workshop Infor-
The digital reversing camera must be put into operation mation System).
by coding using the XENTRY Kit (see Chapter 2.3.3
XENTRY Kit (→ page 19)). We recommend that you ⓘ If you have any further questions, get in touch with
have this carried out in a Mercedes-Benz workshop. your contact person at Technical Consulting (see
Chapter 2.1 Advice for Upfitters (→ page 14)).
⑴ NOTE
In addition to code FR7, the code O1N "Activation of
reversing camera without guide lines" must be coded
into the vehicle.
8.9.10 Parktronic sensors

Parktronic is an electronic parking aid with ultrasound
and uses six distance sensors in the front bumper and
six distance sensors in the rear bumper to monitor
the vehicle´s surroundings. The Parktronic provides a
visual and acoustic indication of the distance between
the vehicle and an obstacle.
30°
The following pictures show the field of vision and the
signal funnel of one Parktronic sensor.
Example of one sensor
To ensure that the system function is not affected, on

no account should the following changes be made:
• Changing the position of the sensor
• Mounting of detachable parts that can shadow
the area of or around the sensor
• No additional painting and no foils (also refer to
the warning)
• Range of ultrasonic is about 1.2 m/47.2 in
⚠ WARNING
Depending on the version and thickness, paints or
film coatings and installed equipment in front of the
bumpers causes dampening of waves. This could lead
to malfunction or system failure. The driver could lose
control of the vehicle and cause an accident.
The area of or around the sensor must not be
painted, covered with a film or covered by any after-
market equipment.
Field of vision
⑴ NOTE
After any damage to the rear of the vehicle or after
any modification to the
• rear overhang
• axle distance
• height of the rear bumper
• new parameters for the sensor
60° has been made, the setting and function of Parktronic
Example of field of vision of one sensor sensor has to be checked at a qualified specialist
workshop. This setting also needs to be checked if
mild collisions at low speeds has occurred where no
damage to the front end of the vehicle is visible.
8.10 Parameterizable Special Module (PSM/

MPM)
Parameterizable Special Module (PSM), or also known PSM is connected to the vehicle network via the body
as Multi-Purpose Module (MPM) for Sprinter BM 907, is CAN bus and therefore has access to the specific mes-
an electronic control unit that connects to the vehicle’s sages sent by the linked control units (e.g. door status,
CAN bus system and can read and control various vehi- vehicle speed, engine speed, parking brake active).
cle functions. Because Mercedes-Benz restricts modifi- PSM can translate the messages from various bus data
cations of the CAN bus system and direct access to the into switching signals at the outputs provided ("high" or
vehicle networks, PSM has been developed to provide "low") or PWM signals (pulse width modulation). Indi-
an indirect access to the vehicle CAN bus. PSM can be vidual signals is monitored or generated at analog and
purchased under the option code ED5 and part number digital inputs and outputs.
A907 900 53 03. Pre-wiring for PSM (MPM) can be PSM provides a clearly defined, diagnostics-compatible
ordered using the option code ED8 for the customer who and EMC-tested interface between the vehicle and the
wishes to install PSM in the future. Without the option body.
code ED8, PSM cannot be retrofitted onto the vehicle.
PSM provides an interface, not a system. The PSM
⑴ NOTE functionality available via the interface is protected as
per ISO 26262, generally by a QM process. The pro-
The wirings on the vehicle must not be tampered with tection of functions in which the PSM is involved and
for this could lead to fault messages from the other compliance with applicable standards (e.g. ISO 26262
control units on the CAN bus. on functional safety) and specifications are always the
Please utilize fuses for any electronic consumers responsibility of the upfitter.
connected to PSM.
⑴ NOTE
The PSM control unit is located in the driver seat box.
PSM can be installed or removed by first removing When uploading a new PSM coding, all previous
the driver’s seat and then the driver seat base cover. parameterizations are erased. We recommend backing
Once the seat has been removed, the bracket for PSM up stored PSM program beforehand.
control unit can be found directly beneath the parking
system control unit.
ⓘ For additional information, please refer to the
PSM Upfitter Portal technical bulletin: Sprinter MY2019+
Parameterizable Special Module (ED5). Inquiries
on PSM programs as well as requests for custom-
ized PSM programs for eXpertUpfitters can be
requested on www.UpfitterPortal.com.
Fr ⓘ PSM is parameterized using XENTRY. Further infor-

ont mation on XENTRY (→ page 19).
PSM is connected to two fuses in the fuse box on the ⓘ Information on standard PSM programs can be
driver’s seat frame. Fuses for PSM, F14 and F15 are obtained from your local Mercedes-Benz Service
shown in the picture below. Center.
Location of fuses for PSM (MPM)
8.10.1 PSM (MPM) Functions

⑴ NOTE
Some of the functions provided by PSM (MPM) using the Lock/ unlock function by PSM is internal lock/
interior CAN bus (CAN B) are reading and controlling: unlock feature cannot override the external lock/
• Inputs unlock function by the key FOB.
- Digital
- Analog
⑴ NOTE
• Outputs
For vehicles with a factory-installed communication
- Pulse-Width-Modulation (PWM) signals
module:
• Illumination and signaling horn
Based on the group-wide resolution from the control
- Low beams
committee on fully automated driving, ethics and
- High beams the law, Mercedes-Benz AG only makes vehicle data
- Headlight flasher available via internal back ends. Internal backends are
- Horn Mercedes me connect or the Extended Vehicle Back-
• Central locking end. External vehicle data transmission via the PSM is
- Lock/ unlock vehicle no longer available as standard.
- Lock/ unlock cab Exceptions continue to exist for multi-brand appli
- Lock/ unlock cargo cations, fleet applications and car-sharing. This is also
so for use cases in which the PSM serves as the basis
• Windshield wipers
for an additional vehicle body and no vehicle data are
- Speed control of windshield wipers sent to a third-party back end.The Mercedes-Benz AG
• Electric sliding door will continue to support for individual PSM request for
• Displays in instrument cluster usage inside the vehicle environment. For more infor-
mation, please reach out to: www.UpfitterPortal.com.
• Further data from interior CAN
- Audio muting For individual support, please use the inquiry function
- Acoustic warning tone (internal buzzer) on www.UpfitterPortal.com.
• Electric step
The above list is not a complete list of all the functions
offered by PSM (MPM). More information on the PSM
(MPM) functions are available on the Upfitter Portal.
The mini-PLC (mini programmable logic controller) used
in PSM programming is a module with freely program-
mable and freely interconnectable function blocks for
creating any signal links that may be required:
• 96 AND/ NAND/ OR/ EXOR/ NOR/ EXNOR
• 24 RS and D flip-flops
• 12 retriggerable/ non-retriggerable timer stages
• 12 hysteresis links with adjustable thresholds
• 24 threshold switches with 3 stages
• 12 counters
8.10.2 PSM (MPM) Pin Assignment A plug and play solution is provided with the option
code E5M (extension of PSM standard contact). Upfit-
PSM consists of two plugs upfitters can connect to. Plug
ters can directly connect their own wiring harness to the
1 is composed of fifteen 2.8 mm MCP pins, and plug 2 is
PSM extension plugs, E5M (non-retrofitable Y-harness).
composed of thirty-two 0.64 mm MQS pins. Below image
provides detailed information on each pins on PSM (MPM).
Pin Assignment of the PSM (MPM)
8.10.3 Additional information on PSM (MPM)

PSM (MPM) programs are parameterized using XENTRY
(→ page 19)
Programming of PSM (MPM) software can only be
performed by trained and authorized Mercedes-Benz
personnel. Uploading of PSM (MPM) software can be
performed by any individual trained and authorized by
Mercedes-Benz personnel.
ⓘ Additional information on standard parameterization

possibilities can be obtained from Mercedes-Benz
Service Center. Standard PSM programs for Sprint-
ers are available at local dealerships. Inquiries on
PSM programs as well as requests for customized
PSM programs for eXpertUpfitters can be requested
on www.UpfitterPortal.com.
E5M input and output extension plugs pin assignment

(SAM)
The power circuit on the Sprinter BM 907 comprises

the signal acquisition and actuation module (SAM) in
connection with a fuse and relay block (SRB). These
limit switches supply the systems and control units
with power, depending on the function sequence. The
requirements are relayed to the SAM either over CAN
or via directly scanned switches and sensors. The fuses
on the fuse and relay blocks also provide protection for
individual components.
The fuse and relay box acts as a monitor for electrome-
chanical switching units.
You will find information about other functions in the
chapter "Technical details" (→ page 316).
8.12 Electrical circuit diagrams 8.13 Telematics
Electrical circuit diagrams can be made available to The table below lists the abbreviations used in the field
eXpertUpfitters as part of the eXpertUpfitter Program. of telematics.
Abbrevia- Meaning/description
tion
Electrical circuit diagrams can also be called up in the HU Head Unit
Workshop Information System (WIS) (→ page 18). Connect5 Multimedia system with 7" display
https://www.startekinfo.com/home NTG6 Multimedia system incl. navigation with 7" or
https://xentry.daimler.com 10.25" display
DVI Digital Visualization Interface
CAN Controller Area Network
CAR PC Control unit or PC installed in the vehicle
TMDS Transition-Minimized Differential Signaling
RGB signal Red, Green and Blue signal
PSM Parameterizable Special Module
DAB Digital Audio Broadcasting
LTE Long Term Evolution
AM/FM Amplitude Modulation/Frequency Modula-
tion
SDARS Satellite Digital Audio Radio Services
HDMI High-Definition Multimedia Interface
RHC Right hand circulation polarization
MBUX Mercedes-Benz User Experience (multime-
dia system based on Connect5 or NTG6)
AUB Antenna switchover box
GPS Global Positioning System
GNSS Global Navigation Satellite System
For further questions regarding telematics, please refer

to 1.7 Contact (→ page 11).
8.13.1 Overview of the Infotainment system The functions of the various head units are described in
the operator's manual.
The new NTG6 telematics generation has been inte-
grated in the Sprinter and thus offers the entertainment
convenience familiar from the passenger car model ⓘ The notes and specifications for operating the
series. Numerous entertainment and user experience multi-media and vehicle systems in Chapter 7.15.5
applications are available with the Mercedes-Benz User New features for RVs (→ page 222) and Chap-
Experience MBUX special equipment. ter 8.3.1 Main battery (→ page 235) must be
observed.
In addition to the radio pre-installation special equip-
ment (Code ER0) and radio pre-installation with DAB
(Code E7A), the following infotainment systems are also
available:
Code Infotainment system Telephony Smartphone Navigation Reversing 360° Voice control
(Bluetooth®) integration camera camera ("Hey Mercedes")
E1O MB audio system Yes No No No No No
E3M MBUX multimedia sys- Yes Yes1) No Yes Yes No
tem with 7" touchscreen
(Connect5)
E3M MBUX multimedia sys- Yes Yes2) Yes Yes Yes Yes
+ tem including navigation
E1E with 7" touchscreen
(NTG6)
E4M MBUX multimedia sys- Yes Yes2) Yes Yes Yes Yes
tem including navigation
with 10.25" touchscreen
(NTG6)
1) Smartphone integration via Apple CarPlay® (ACP)

and Android Auto® (AA) wireless, country-dependent
availability only in combination with the "Communication
module for digital services" in the vehicle (Code JH3),
see Chapter 8.14 Connectivity solutions (→ page 308)
2) Smartphone integration via Apple CarPlay® (ACP) and
Android Auto® (AA) via cable (USB-C)
Further details on the Infotainment systems, the other

special equipment and the equipment packages can be
obtained from the corresponding sales information and
from your Mercedes-Benz sales partner.
The functions of the various telematics equipment are
described in the operator's manual for your vehicle.
ⓘ The information and specifications on operat-

ing multimedia and vehicle systems in Chap-
ter 7.15.f New features for RVs (→ page 222) and
Chapter 8.3.1 Main battery (→ page 235) must be
observed.
8.13.2 Antennas
Antenna variants with equipment

Equipment/ Antenna type Picture Explanation
function
Radio pre-instal- ANTENNA FOR RADIO 1 AM/FM1
lation/entry-level Object no. A9079051702 FAKRA code A
radio/Connect5 2 FM2
FAKRA code E
3 Not available
4 Not available
NTG6/navigation/ ANTENNA FOR RADIO TEL 1 TEL
ED3 GNSS FAKRA code D
Object no. A9079051802 2 FM2
4 1 FAKRA code E
3 GNSS
3 2
FAKRA code C
4 AM/FM1
N82.62-2054-00 FAKRA code A
DAB ANTENNA FOR RADIO TEL 1 Tel
GNSS DAB FAKRA Code D
Object no. A9079051902 2 FM2/DAB2
FAKRA Code E
3 GNSS
FAKRA Code C
4 AM/FM1/DAB1
FAKRA Code B
Overview of antennas for vehicles with and without

cab roof ex factory
For vehicles without cab roof (cab base vehicles code
F28) a pre-installation for antennas is available as
special equipment (code E4A) instead of the antenna
ex works, see Chapter 7.14.8 Connecting point for
antenna switchover box for third-party antennas (code
E4A) (→ page 215).
This special equipment includes an antenna switch box
in the driver's seat base as an interface for an acces-
sory antenna used by the upfitter and the associated
cable set for the power supply.
The following illustrations of the connection diagrams
must be observed.
The installation instructions and specifications of the
manufacturer of the accessory antenna must also be
observed.
Connection diagram: Vehicles with pre-installation for
The antenna switch box is used exclusively for mod- antenna (code E4A)
ulating signals from an accessory antenna for further
signal processing in the Mercedes-Benz head unit. It is 1 Power supply 12 V (tml. 30 from wiring harness)
not permissible to connect the factory-fitted antenna, 2 Antenna switch box (AUB)
which is available from Mercedes-Benz Service, to the 3 Antenna ABH interface (code E4A)
antenna switch box. 4 Power supply 12 V through AUB
5 Accessory antenna
6 GSM interface in radio slot
7 Two LTE antennas in the cockpit (second antenna always
with code F28)
Connection diagram: Vehicles with ex factory antenna
1 Power supply (external feed) through HU (Head Unit)
Requirements on antenna switchover box for Satellite radio for USA/Canada

upfitter antenna For SDARS (Satellite Digital Audio Radio Services),
The antenna switchover box must be supplied with the the antenna A2139055105 and the antenna dome
following signals: A2388270100 must be used. Please contact your Mer-
• FM (87 MHz – 108 MHz) cedes-Benz Service Partner to obtain these components.
The design specifications can be found in the current
• AM (531 kHz – 1720 kHz and 5.9 MHz – 26.1 MHz)
SiriusXM guideline, which can be requested from this
• DAB band III (174–240 MHz) antenna manufacturer.
• Impedance 50 ohms
There are two positions associated with the location of
the above parts depending on the vehicle type.
Global Navigation Satellite System (GNSS)
The connection of the navigation system must be sup-
plied with the following signal:
Antenna
Antenna type Patch
Frequency 1575 MHz – 1606 MHz
Gain in antenna 2 dBic, mean value Theta 0 - 20° N82.62-2061-00
Polarization RHC
Position of antenna for the cab chassis
Amplifier
Reinforcement 28 dB core
Noise factor ≤1 dB (without filter)
Impedance 50 ohm
Power supply
Operating voltage 4.5 V – 5.5 V
Power consumption 20 mA± 3 mA
Phantom power Yes Position of antenna for the cargo van
⑴ NOTE
To ensure that no interference with the satellite
signals occurs due to upfitting, the antenna must be
positioned at the highest point on the vehicle.
⑴ NOTE
For vehicles that do not have code E1S (Sirius XM
satellite radio), satellite antenna can be installed by
following the WIS document SM82.62-D-0009SG.
Modification Guidelines:
If the vehicle is equipped with a roof cut-out (option
code FA1 or F28), please adhere to the following
points:
• Do not modify the wiring connections around the roof
cut-out. Please use the following figures for refer-
ence.
• A portable antenna is provided as an additional part
which is located in the glovebox.
If the vehicle is equipped with an antenna but the
position needs to be modified, please adhere to the
following points:
• The cable connection to the antenna is a FAKRA
connector with a female connection. Extension
cables are available from third party sources
and can be used to reposition the wiring harness.
• Ensure that the new antenna position complies with
Sirius XM requirements. (http://pixelsatradio.com/
content/pdfs/antenna_aiming.pdf)
N82.62-2063-00
Cable harness layout for cab chassis
N82.62-2064-00
Cable harness layout for cargo van
8.13.3 Speakers Additional speaker pairs are available for the cargo and
crew van model designations as a special equipment
Connect5 and NTG6 have 5 channels for connecting
(Code EL9) in the rear passenger compartment.
speakers to the system.
As standard with Connect5 and NTG6, two pairs of This enables fade-in/fade-out of the rear left (RL) and
speakers (woofer/ mid-range speaker and tweeter) are rear right (RR) audio sources in Connect5 and NTG6.
fitted in the front left (FL) and front right (FR) in the
The total impedance per channel must not be less than
doors. For a better sound experience, the NTG6 has an
2 ohms.
additional mid-range speaker (Cen).
Ch2 A3 FR - Aeff 4.5 A 1,5 mm² 0.0023 in²

Ch2 A2 FR + Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch1 A12 FL + Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch1 A11 FL - Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch3 A24 RL - Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch3 A25 RL + Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch4 A15 RR + Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch4 A16 RR - Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch5 B1 Cen + Aeff 4.5 A 1,5 mm² 0.0023 in²
Ch5 B10 Cen - Aeff 4.5 A 1,5 mm² 0.0023 in²
N82.62-2065-00.
Connections for speakers
1) Only with NTG6
8.14 Connectivity solutions

Mercedes me connect
⚠ WARNING
Using the Mercedes me connect App while driving will
distract you from traffic conditions. This could cause
8.14.1 Mercedes me connect for personal use you to lose control of the vehicle, which could result in
Mercedes-Benz Vans offers Mercedes me connect for an increased risk of endangering yourself and others,
individual customers2. Mercedes me connect provides including the risk of accidents, personal injuries and
an individual experience through the vehicle-integrated death. In order to help prevent distracted driving, the
Communication Module (LTE)3 and the Mercedes me use of the Mercedes me connect App is not permitted
connect App. Your Mercedes me connect equipped Van while operating a motor vehicle. Please follow all appli-
will enhance your experience during purchase, service, cable federal, state and local laws and restrictions and
and throughout your ownership. Mercedes me connect is observe the legal requirements of the country in which
focused on your comfort and individual experience. you are currently located.
Mercedes me connect consists of a multitude of ser- For further information on Mercedes me connect visit
vices1,3. Because your safety is our priority, we encour- https://www.mbvans.com/en/connectivity.
age you to take advantage of Software Updates for your For information on service availability and eligibility of
Van and to stay connected with our Customer Assistance your Van1,2,3, visit https://www.mbusa.com/en/legal-
Center in case of an emergency or breakdown. Keep notices/connected-vehicle or contact your dealer.
track of your Van’s location status when parked by using
the Mercedes me connect App. Easily lock/unlock doors
remotely through the App. If your Van is equipped with
1 Models shown may include options/packages not stan-
an MBUX Multimedia System, Mercedes me connect dard on a Sprinter (as of MY19 and newer) or a Metris
provides you with online services such as Live Traffic (as of September 2019 production, MY 20). Specifica-
Information4 and Online Map Updates4 to keep your tions are subject to change. Services require vehicle cel-
Van’s navigation system up to date. lular connectivity and availability of vehicle GPS signal.
2 Mercedes me connect is available for the United States of
America for Sprinter (as of MY19 and newer) and Metris
8.14.2 Mercedes me connect for business use equipped with a Communication Module (LTE) (as of Sep-
As a commercial customer you also have the opportunity tember 2019 production, MY20). Contact an authorized
Mercedes-Benz Vans dealership for more information.
to use Mercedes me connect for your business. The Mer-
3 The availability of services in addition to the integrated
cedes me connect services for commercial customers
Communication Module for Digital Services (LTE) depends
ensure that you and your company remain connected to on the network coverage of the mobile network provider.
your Van(s) at all times and from anywhere1,2,3. With the The Communication Module for Digital Services (LTE) is
Mercedes me connect App, you will have the most up to not available in the US Virgin Islands or Puerto Rico. The
date and important information about your vehicle right Communication Module for Digital Services (LTE) is equip-
at the palm of your hands2. Take advantage of software ped in the Sprinter (as of MY 19 and newer) and optionally
equipped in the Metris (as of September 2019 production,
updates, maintenance information and more with Mer-
MY20 and newer). The availability of certain features may
cedes me connect for business use. be impacted at the current time.
As a company administrator, you can reach out to your 4 The information from this service is shown on the touch-
preferred dealer and register for a new Mercedes me screen of the MBUX Multimedia System. Live Traffic Infor-
mation can only be used in conjunction with the MBUX
connect company profile. The dealer can assist with add-
Multimedia System with 17.8 cm (7-inch) touchscreen and
ing your company vehicles to your new company profile. navigation or the MBUX Multimedia System with 26 cm
Upon completion of your newly created company profile (10.25-inch) touchscreen options. While the navigation sys-
the company admin listed on the account will be able to tem provides directional assistance, the driver must remain
manage company vehicles, users and services, and more focused on safe driving behavior, including paying attention
in the Mercedes me connect Portal. Additional users, to traffic and street signs. The driver should utilize the sys-
tem's audio cues while driving and should only consult the
such as drivers, will be able to use many of the Mercedes
map or visual displays once the vehicle has been stopped
me connect services that are already available for per- in a safe place. Maps do not cover all areas or all routes
sonal use in the Mercedes me connect App and the Van1. within an area. Please follow all applicable federal, state
and local laws and restrictions.
9 Calculations
9.1 Center of gravity
The overall height of the center of gravity (vehicle with 9.1.1 Determination of the center of gravity in
equipment/complete body but without load) should be the x-direction
kept as low as possible.
The position of the center of gravity in the longitudinal Center of gravity coordinates in x-direction
direction of the vehicle (x-direction) is specified relative (front/rear axle load distribution)
to the center of the front axle.
Recommended Procedure:
The center of gravity height (z-direction) is specified
In the first series of measurements, the vehicle
with reference to the roadway. should be weighed with the complete equipment or
Mercedes-Benz recommends that you have the position body but without payload.
of the center of gravity checked by a approved and In the second series of measurements, the vehicle
experienced testing institution. should be weighed with the complete equipment
or body and with a payload appropriate for its
If the center of gravity is determined by the upfitter, the intended purpose, taking into account the permissi-
procedures described under 9.1.1 Determination of the ble gross mass and the permissible axle loads.
center of gravity in the x-direction (→ page 309) and For the measurements, the tire pressure at all
9.1.2 Determination of the center of gravity in the z-di- wheels should be set to 6 bar.
rection (→ page 311) must be followed and qualified Completely fill all fluid reservoirs for operating
person must perform the services to achieve realistic fluids (fuel tank, AdBlue® tank, washer fluid reser-
and useful results. voirs and, if installed, hydraulic fluid reservoir).
The vehicle must be measured in a load condition Shut off the engine on the scales, shift the trans-
appropriate for its intended purpose. (See the following mission to neutral position and release the brakes.
pages for examples.) The vehicle must be parked horizontally on level
ground for weighing.
Likewise, the web-based “Vehicle Center of Gravity and
Axle Weight Calculator” provided by NTEA might be First weigh the individual axle loads (front and rear
axle loads) and then the gross vehicle mass.
helpful. Mercedes-Benz does not take responsibility of
the accuracy of the calculated values by the NTEA web- Using these measurements, the position of the
center of gravity in the longitudinal direction of the
based calculator.
vehicle can be calculated using equations (3) and
www.ntea.com/weightcalculator (4).
Use (2) to check the results from (3) and (4).
⑴ NOTE
Practical determination of the center of gravity
position in the x and z-directions may only be carried
out by appropriately qualified staff using suitable and
calibrated vehicle scales.
In order to reduce measuring errors, each measure-
ment value should be determined at least three times
and the average should be calculated from these
three values.
⑴ NOTE
The calculated center of gravity position in the z-di
rection (CoG height) must not exceed the limit values
specified under Chapter 4.1.2 Maximum permissible
position of the center of gravity (→ page 58)
9 Calculations
Illustration of coordinates and dimensions
Axle load calculation Weights:

(1) GG Gross mass of vehicle
GG = GHA + GVA GVA Front axle load of empty vehicle
(specification or weighing of the chassis in question)
l = lV + lH (2) GHA Rear axle load of empty vehicle
(specification or weighing of the chassis in question)
Dimensions
Calculation of the center of gravity in the lV Distance of overall center of mass of empty vehicle
x-direction from front axle
(3) lH Distance of overall center of mass of empty vehicle
GHA × l from rear axle
lV =
GG l Wheelbase
SG Overall vehicle center of gravity
GV A × l (4)
lH = ⓘ The wheelbase "I" is defined by the vehicle model
GG designation (see order) or must be determined by
means of a length measurement according to coun-
try and/or state specific regulations.
9 Calculations
9.1.2 Determination of the center of gravity in

⑴ NOTE
the z-direction
In order to avoid erroneous measurements, please
Center of gravity coordinates in z-direction (height note:
of center of gravity hS for the overall vehicle) When weighing with the vehicle level, the vehicle
For determination of the overall center of gravity height must be exactly horizontal. Any height differences
of the vehicle above the roadway hS by the upfitter, between the axles caused by the scales must be
compensated for accordingly.
Mercedes-Benz recommends the following procedure
after completion of the vehicle: Both axles must be blocked to prevent suspen-
sion jounce and rebound when raising to the
After conversion, the vehicle should be weighed on required lift height.
a plate-type scale or suitable wheel load scale in two When raising, the left and right sides must be
different drive positions in succession. Here, the axle raised in parallel.
loads measured when the vehicle stands horizontal No part of the vehicle may bottom out when rais-
and level (GVA or GHA, see 9.1.1 Determination of the ing to the required lift height.
center of gravity in the x-direction (→ page 309)) All vehicle wheels must be able to roll: Gearshift
and the axle loads for an axle raised by h' (QHA or system in neutral position, all brakes including
QVA) must be determined. The lift height h' should be parking brake released, chocks placed at a suffi-
as large as possible in accordance with the front and cient distance from the wheels if necessary.
rear overhang angle of the vehicle (also known as the Set all tires to an internal pressure of
angle of approach or departure). The target value is 6 bar.
h' > 1100 mm/43 in (wheelbase 3250 mm/144 in) Between the individual measurements and to
and 1400 mm/55 in (wheelbase 4325 mm/170 in). turn it around (in order to weigh the other axle),
move the vehicle under its own power so that any
In order to reduce measuring errors, at least six individ- stresses in the vehicle are relaxed.
ual measurements must be performed for each vehicle
Make sure that no objects inside the vehicle can
axle when measuring the axle load: three per axle when
move during the measurements.
the vehicle is in a level state and three when an axle is
raised. Based on the three measurements in each con- It must be ensured that all fluids (operating
fluids and other media specified/required for the
dition, an average should be calculated for each axle. intended purpose (e.g. hydraulic oil, fresh water
For this, the equations (5) to (7) are to be used. Import etc.)) and the gear and equipment required for
ant: The measurement results must be close together. operation as well as the necessary counter bal
lasts are all topped up and present.
If individual measurements vary widely from each
other, the deviating individual measurement must be
repeated. The total value between the raised front and
rear axles is then calculated.
In order to improve the accuracy of the final result, the
axle load change should be determined both with a
raised rear axle and with a raised front axle.
9 Calculations
Recommended Procedure Using the calculated values, the height of center of

In the first series of measurements, the vehicle gravity can be calculated using equations (5) to (7).
should be weighed with the complete equipment or When calculating using the equations (3) to (9), all
body with axle blocking but without payload. length measurements must be used in millimeters
In the second series of measurements, the vehicle (mm) and all weights must be used in decanewtons
should be weighed with the complete equipment or (1 daN = 10 N).
body with axle blocking and with a payload appro- G = 1 daN = 10 N is the weight force correspond-
priate for its intended purpose, taking into account ing to the mass m = 1 kg/2.2 lbs.
the permissible gross mass and the permissible
axle loads.
Inflate the tires up to an internal pressure of 6 bar.
Completely fill all fluid reservoirs or operating fluids
(fuel tank, washer fluid reservoirs, hydraulic fluid
reservoir, coolant reservoir, AdBlue® tank etc.) and
load or attach all the gear and equipment required
for operation as well as the necessary counter
ballasts.
Shut off the engine on the scales, shift the trans-
mission to neutral position and release the brakes.
Position the vehicle with the rear axle (HA) at a
horizontal and level position on the scales and
determine the axle load.
Raise the front axle (VA) by the lift height h'.
Increasing the height h' while taking the other
boundary conditions of the vehicle into account
improves the final result. The value h' must be
determined for all individual measurements with
raised axle and should be identical wherever
possible. As an alternative to measuring the raised
height h', the angle a between the wheel hubs can
be determined.
Determine the resulting axle load shift (QHA) at the
rear axle (HA) on the scales.
Lower the vehicle and perform lifting measure-
ments 2 and 3. Between all the individual measure-
ments and to turn it around (in order to weigh the
other axle), move the vehicle under its own engine
power so that any stresses in the vehicle/chassis
are relaxed.
After the third measurement, lower the vehicle,
turn it around, and carry out corresponding mea-
surements on the front axle (initially GVA with the
vehicle level, and then QVA with the rear axle raised
by height h').
9 Calculations
Illustration of coordinates and dimensions
Determining the height of the center of gravity

ⓘ The wheelbase "I" is defined by the vehicle model
hS = ha + rstat (5) designation (see order) or must be determined by
means of a length measurement according to coun-
rstat Loaded tire radius try and/or state specific regulations.
QVA Front axle load with vehicle raised at rear
QHA Rear axle load with vehicle raised at front
hS Height of center of gravity above roadway
ha Height of center of gravity above wheel center
h' Height by which the vehicle was raised
SG Overall vehicle center of gravity
1 Weighing device
Formulas for raised front axle:

l QHA − GHA 2
hS = × × l −h2 + rstat (6)
h GG
Formulas for raised rear axle:

l Q V A − GV A 2
hS = × × l − h2 + rstat (7)
h GG
⑴ NOTE
The calculated center of gravity must not exceed the
limit values specified under 4.1.2 Maximum permissi-
ble position of the center of gravity (→ page 58).
9 Calculations
Examples for loads appropriate for the intended purpose for:

• RVs • Touring coaches
- All reservoirs for operating fluids 100% full, includ- - All reservoirs for operating fluids 100% full,
ing fuel tanks including fuel tanks
- Number of registered seats each loaded with - 1x driver 80 kg/ 176.37 lbs.
80 kg/ 176.37 lbs. - All registered seats and standing room occupied
- Fresh water tank empty if located in the under with 80 kg/ 176.37 lbs.
body, full if locates above the vehicle floor - The luggage compartment must be loaded appro-
(depending on the layout of the vehicle) priately for the intended purpose in terms of
- Waste water tank empty weight and load height.
- All cabinets, stowage boxes and the rear hold with - Stowage areas above the passengers filled
typical RV loads, if appropriate up to the maximum - For roof-mounted air conditioning systems,
possible load capacity of the stowage compart- simulate the weight and installation location
ments
- Including all planned and available special equip-
ment (e.g. awning, roof-mounted air conditioning
system, bicycle rack, SAT system, solar system,
pop-up roof etc.)
- Unavailable special equipment is to be simulated
by appropriate dummy weights at the correspond-
ing installation location.
• Box bodies
- All reservoirs for operating fluids must be
100% full, including fuel tanks
- 1x driver 80 kg/ 176.37 lbs.
- The box body must be loaded appropriately for
the intended purpose in terms of weight and load
height.
- Including the refrigeration unit, if planned for the
body
9 Calculations
9.2 Location of fifth wheel coupling
Calculating the position of the fifth wheel coupling
ⓘ For information on modifications to the light duty

truck, see 7.10 Light duty truck (→ page 201).
N00.00-2724-00
Drawbar ratio of fifth wheel coupling
A Permissible gross mass of semitrailer

0,. 6 × 9,. 81 × Z × A
D= (8) D Drawbar ratio of coupling
Z +A−L FH Maximum permissible rear axle load
FHL Rear axle load of unladen vehicle
FH* Resulting max. rear axle load
To avoid exceeding the maximum axle loads, the posi-
tion of the fifth wheel coupling is calculated as follows: The permissible axle loads must be maintained at the
front and rear axles.
FH ∗ × IR
H= (9) H Distance between front axle and fifth wheel coupling
L lR Wheelbase
L Max. fifth wheel load
FH ∗ = FH − FHL (10) Z Permissible gross mass of towing vehicle
0,. 6 × 9,. 81 × Z × A
L=Z +A− (11)
D
10 Technical details

(SAM)
Not all functions are supported by all control unit variants. Depending on the equipment, only "minimal" variants of the SAM or
door control unit are fitted, for example. In such cases, the control unit concerned must be retrofitted if necessary.
Function Codes affected SAMVAR1 SAMVAR2

Wipe/wash windshield Standard without code X X
Rain sensor JF1 X X
Wipe/wash rear window W78 X
Washer fluid level Standard without code X X
Front halogen exterior lighting Standard without code X X
Front LED exterior lighting LG7 X X
Rear bulb exterior lighting Standard without code X X
Full LED exterior lighting L22 X X
Fog/cornering lights L13 X
Highbeam Assist LA1 X X
Light sensor LA2 X X
Daytime running lights Standard without code X X
Clearance lamps L07 X X
Side marker lamps LB1 X X
Additional turn signal lamps on the roof LB3 X X
Side markers for USA Standard without code X X
Additional lamps for USA L49 X
3rd brake lamp LB5 X X
Central locking for mechanical sliding door on right T16 X X
Central locking for mechanical sliding door on left T19 X
Central locking for mechanical rear-end doors W54 X X
Central locking system for rear doors on crewcab Standard without code
X X
(for FHL)
Additional lock (double lock) FY2 X
Rear interior lights L65, LB9 X X
Driver/front passenger seat heating H16, H15 X
Heating Standard without code X X
Front air conditioning system HH4, HH9 X X
Rear air conditioning HH7, HK4, H08 X
Brake wear indicator Standard without code X X
Outside temperature/brake fluid/coolant level indicator Standard without code X X
Windshield heater F49 X
Rear window heater H22 X
Stationary heater H12 X
Motion detector for interior lights L71 X
Electronic theft warning (ATA) FZ5, FY1 X X
Engine hood switch MJ8 X X
Battery management Standard without code X X
Alternator management Standard without code X X
Support battery for automatic transmission G42, G43 X X
Cutoff relay for ABH auxiliary battery E36 X
Terminal strip for electrical connection (ABH) EK1 X
Rear 12 V socket ES2 X
10.2 Bulb ratings of exterior lights
The tables below describe the different variants of the

exterior lights with the corresponding light source types
and power output data. Differences between panel van
models and cab-chassis models are described in each
case.
These specifications must be observed when install-
ing lighting systems, see Chapter 8.5 Illumination
(→ page 254).
Special equipment scope "Deactivation of lamp

failure indicator" (code JW2) - Notes on the
meaning of the entries in the tables in the following
chapters:
• "Yes" means that, in the event of a malfunction of the
lamp, e.g. due to bulb failure, there is no message
in the instrument cluster and no entry in the fault
memory of the diagnostic interface.
• "No" means that this function is not available and
therefore there is still a message in the instrument
cluster and an entry in the fault memory of the diag-
nostic interface.
Light sources of the conventional exterior lighting are
actuated via pulse width modulation. An effective value
is always set. The frequency varies according to coun-
try, and is 100 Hz for all countries except for the USA
and Canada where it is 120 Hz.
ⓘ Information on plugs/mating connectors on

the basic vehicle is available from the depart-
ment responsible (→ page 14) or in Chap-
ter 2.3.2 Workshop Information System (WIS)
(→ page 18).
10.2.1 Conventional headlamps
Function Type Power [W] Remarks Deactivation

of lamp failure
indicator
Code JW2
High beams H15 2×55 Operated via control unit BCMFA2 Yes
Low beams H7 2×55 Operated via control unit BCMFA2 No
Daytime running lights H15 2×21 Operated via control unit BCMFA2 Yes
Standing lights W5 W 2×5 Operated via control unit BCMFA2 Yes
Turn signals PY21 W 2×21 Operated via control unit BCMFA2 No
10.2.2 Conventional tail lamps
Function Type Power [W] Remarks Deactivation of

lamp failure indi-
cator
Code JW2
Turn signals PY21 W 2×21 Standard in tail lamp, panel van/ No
cab-chassis
Tail light P21 W 2×21 Standard in tail lamp, panel van No
R5 W 4×5 Standard in tail lamp, cab-chassis No
Reversing light P21 W 2×21 Standard in tail lamp, panel van/ Yes
cab-chassis
Rear fog lamp P21 W 1×21 Standard in tail lamp, panel van/ Yes
cab-chassis
Brake light P21 W 2×21 Standard in tail lamp, panel van/ No
cab-chassis
Rear license plate lamp – – Standard in cab-chassis: Code JW2 not
Illuminated via a windows in the bottom available
of the left tail lamp
panel van:
See table of additional lighting functions
10.2.3 Conventional tail lamps on cab-chassis with

code L90
Code L90 causes the tail lamp to be omitted and also the installation of conventional tail lamps (bulbs) on
the coding in the Body Controller to be adapted to suit cab-chassis.

lamp failure indi-
cator
Code JW2
Turn signals PY21 W 2×211) No
Tail light R5 W 2×51) No
Reversing light P21 W 2×211) Yes
Rear fog lamp P21 W 1×211) Yes
Brake light P21 W 2×211) No
Rear license plate lamp – – Code JW2 not
available
1) The current dropping below a minimum value of 60 mA
results in fault entries and fault messages in the instru-
ment cluster if the code JW2 is not used.
10.2.4 LED tail lamps on cab-chassis with

code L91
Code L91 causes the tail lamp to be omitted and also
the coding in the Body Controller to be adapted to suit
the installation of LED tail lamps on cab-chassis models.

lamp failure indi-
cator
Code JW2
Turn signals LED 2×61) No
Tail light LED 2×91) No
Reversing light LED 2×3.51) Yes
Rear fog lamp LED 1×3.51) Yes
Brake light LED 2×61) No
Rear license plate lamp LED - Yes
1) The current dropping below a minimum value of 60 mA
results in fault entries and fault messages in the instru-
ment cluster if the code JW2 is not used.
10.2.5 Additional lighting functions
Function Type Power [W] Remarks Deactivation of lamp

failure indicator
Code JW2
Third brake light LED 1×1.3 Standard for closed model No
Pre-installation for 3rd brake lamp, code LV6,
available for open models1)
Clearance lamps LED 2×1 Open model, special equipment code L07 Yes
Side marker lamp LED 6×1 Closed/open model, code LB1 Yes
Pre-installation for side marker lamps,
code LB2
Rotating beacon H1 2×55 Closed model, code LB7 Code JW2 not avail-
Rotating beacon, yellow, front left/rear right able7
Open model, code LB8
Rotating beacon, yellow, front left
Closed/open model, code LV1
Pre-installation for rotating beacon
Fog light with cornering H11 2×55 Closed/open model, integrated in bumper, Yes
light function LED 2×55 code L13 Yes
Pre-installation for fog light, code LV42)
LED fog light with code L933)
Fog light without cornering H11 2×55 Closed/open model, integrated in bumper, Yes
light function LED 2×553) code L16 Yes
Pre-installation is not available
LED fog light in combination with code L933)
Additional turn signal LED 2×5 Open model, special equipment, additional Code JW2 not avail-
lights turn signal lamps, code L774) able7)
W16W 2×16 Closed/open model designation, standard in No
outside mirror5)
LED 2×3.8 Closed model, special equipment, additional Code JW2 not avail-
turn signal lamps on roof, code LB36) able7
P21 W 2×21 Closed/open model designation, side turn No
signals on fender with code L44 (without turn
signal light in outside mirror)5)
Rear license plate lamp W5W 2×5 Standard in license plate holder, closed Yes
model
1) Note that the fault monitoring for the pre-installation is 6) Additional turn signal lights with the code LB3 can only
always active, so the installation and use of a 3rd brake be ordered on closed models. These are mounted on
light are required. the roof at the rear. They are actuated in parallel with
2) The current dropping below a minimum value of 500 mA the turn signal lights in the tail lamp. Due to the failure
results in fault entries and fault messages in the instru- monitoring of the turn signal lights in the tail lamp, the
ment cluster if the code JW2 is not used. specified power rating of the additional turn signal lamps
3) The current dropping below a minimum value of 100 mA must not be exceeded. There is no failure monitoring of
results in fault entries and fault messages in the instru- these additional turn signal lights.
ment cluster if the code JW2 is not used. 7) Fault monitoring does not occur.
4) Additional turn signal lights with the code L77 can only
be ordered on open models. They are actuated via the
additional turn signal module. There is no failure moni-
toring of these additional turn signal lights.
5) It is possible to actuate a turn signal light either in the
outside mirror or on the fender. The same connection on
the door control unit is used. Therefore, it is not possible
to combine turn signal lights in the outside mirror and on
the fender.
10.3 Trailer hitch hole patterns
On cab-chassis, the reinforcement of the trailer

coupling in the left/ right rear longitudinal member
is installed in the vehicle as a standard. If this is not
desired, then the code QW1 must be deleted when the
vehicle is ordered. For cab-chassis, it is not possible to
retrofit a trailer coupling with omission of the longitudi-
nal member reinforcement (code QW1).
For cargo, crew, and passenger vans, the longitudinal

member reinforcement must be ordered at the same
time (code Q11). If the vehicle does not have this
special equipment, it is not permitted to install a trailer
coupling (see warning).
1 1
N31.10-2322-00 N31.10-2321-00
Longitudinal member on BM 907 Cab Chassis Longitudinal member on BM 907 Crew, Passenger and Cargo
with code Q11 Van model with code Q11
1 Trailer hitch insert, code Q11 1 Trailer hitch insert, code Q11
⚠ WARNING
Risk of accident due to the impermissible attachment
of a trailer hitch!
If a trailer hitch is retrofitted and you attach a trailer
hitch or other components, the longitudinal frame
member will be weakened and can break. In this
case, the trailer can detach from the vehicle.
10.3.1 Installation dimensions, version 1
55 mm
2.17 in
100 mm
3.94 in
N31.10-2340-00
Vehicle model Wheelbase Dimension a Dimension x Overhang dimension

Cargo van/ 3665 mm/144 in (A2) 35 mm/1.4 in 26 mm/1.02 in 1246 mm/49 in
passenger van 4325 mm/170 in (A3) 35 mm/1.4 in 26 mm/1.02 in 1621 mm/64 in
8550 lbs to 11030 lbs 4325 mm/170 in (A3) 35 mm/1.4 in 26 mm/1.02 in 2021 mm/80 in
Overhang dimension = vehicle overhang
34 mm
1.34 in
m
1 3 m in
ø .51 25 mm
0 0.98 in
55 mm
2.17 in
100 mm
3.94 in
N31.10-2341-00
Single cab; basic variants 3.5 t (2.8 t - 4.1 t)/8550 lbs (8550 lbs - 9040 lbs)
Overhang dimension = vehicle overhang including rear lamp
44 mm
1.73 in
90 mm
3.54 in
N31.10-2342-00
Vehicle model Wheelbase Dimension a Dimension x Overhang dimension

Chassis/platform 3665 mm/144 in (A2) 27 mm/1.1 in 34 mm/1.3 in 1418 mm/55.8 in
with cab 11030 lbs 4325 mm/170 in (A3) 27 mm/1.1 in 34 mm/1.3 in 1518 mm/59.8 in
Overhang dimension = vehicle overhang including rear lamp
10.4 Soundproofing
If modifications are carried out on any parts whose

operation produces noise, e.g.:
• Engine
• Exhaust system
• Air intake system
• Tires, etc.
sound level measurements must be taken.
National and local regulations and guidelines must be
observed.
Noise-insulating parts fitted as standard must not be
removed or modified.
The level of interior noise must not be adversely
affected.
⑴ NOTE
To prevent modifications from changing the vehi-
cle's sound levels, it must be ensured that interior
sound levels are minimized when planning bodies
(→ page 148).
Index
A D
Additional assemblies..................................... 81, 152 Damage prevention................................................. 83

Additional lamps.................................................... 255 Design data.............................................................. 18
Airbag............................................................... 77, 146 Design of bodies.................................................... 180
Airbag control unit................................................. 140 Doors.............................................................. 265, 269
Air conditioning system........................................ 152 Drivetrain............................................................... 126
Air intake........................................................ 110, 135 Drivetrain limit values............................................. 74
Air suspension......................................................... 98 Driving assistance systems.................................. 271
Alternator....................................................... 156, 242 Dump trucks.......................................................... 200
Antenna.................................................................. 263
E
Anti-corrosion protection.................................. 49, 86
Area to be painted................................................. 287 Electrical circuit diagrams.................................... 298
Assembly frame..................................................... 180 Electric lines.......................................................... 239
Assembly frame as floor assembly....................... 188 Electrics................................................................. 233
Assembly frame limit values................................... 82 Electrics/electronics limit values........................... 80
Assembly frame section dimensions.................... 182 Electromagnetic compatibility (EMC)................... 234
Attachment above cab.......................................... 157 Electronic ignition lock (EZS)................................ 265
Attachments.......................................................... 157 Electronic Stability Program (ESP)....................... 272
Attachment to the frame............................... 105, 183 Engine air intake.................................................... 135
Auxiliary heating.................................................... 154 Engine cooling....................................................... 135
Axle loads................................................................ 69 Engine cooling system.......................................... 135
Engine peripherals........................................... 74, 126
B
Exhaust system..................................................... 132
Battery................................................................... 235 Exterior lamps........................................................ 256
Blind Spot Assist................................................... 277
F
Body....................................................................... 101
Body in white................................................... 72, 101 Fenders.................................................................. 114
Box bodies............................................................. 197 Fifth wheel coupling...................................... 203, 312
Brake hoses............................................................. 84 Frame end crossmember...................................... 118
Brake system..................................................... 71, 94 Front axle (FA)......................................................... 92
Bulb ratings of exterior lights............................... 314 Front axle load......................................................... 58
Fuel......................................................................... 126
C
Fuel level sensor shield......................................... 126
Cab......................................................................... 110 Fuel system............................................................ 126
Cable extension..................................................... 239 Functional reliability.............................................. 271
Cables and lines...................................................... 84 Fuses...................................................................... 239
Cab roof................................................................. 110
G
CAN bus........................................................... 80, 239
Cargo liftgate......................................................... 169 Gas-shielded plug welding...................................... 48
Cargo Van............................................................... 192 Ground bolts.......................................................... 250
Cargo Van/Passenger Van roof............................ 118
H
CB radio................................................................. 263
Center of gravity calculation................................. 306 Handover.................................................................. 53
Central locking system.......................................... 265 Highbeam Assist and Lane Keeping Assist.......... 283
Collision Prevention Assist................................... 275
I
Conventions................................................................8
Copyright................................................................. 10 Identification data................................................... 39
Crosswind Assist................................................... 273 Illumination............................................................ 254
Installations........................................................... 158
Index
Interface overview................................................. 248 Overhang extension............................................... 107

Interfaces............................................................... 239
P
Interior................................................................... 190
Interior lamps........................................................ 260 Painting work........................................................... 88
Interior noise......................................................... 148 Platform bodies..................................................... 196
Position of the center of gravity............................. 58
J
Power tapping........................................................ 243
Jaw-type coupling.................................................. 173 Preservation work................................................... 88
Product liability....................................................... 20
L
Product safety......................................................... 20
Lifting platform...................................................... 169 Propeller shafts..................................................... 137
Lifting work platform............................................. 206
R
Limit values for additional assemblies................... 81
Limit values for attachments.................................. 81 Radiator grille........................................................ 135
Limit values for electrics/electronics.................... 80 Rain and light sensor............................................. 283
Limit values for engine peripherals/drivetrain...... 74 Recovery vehicles.................................................. 204
Limit values for the basic vehicle........................... 58 Refrigerated vehicles............................................. 198
Limit values for the body........................................ 82 Remote control key............................................... 265
Limit values for the body in white.......................... 72 Repair....................................................................... 51
Limit values for the suspension.............................. 68 Rescue card/QR code rescue sticker.................... 40
Limit values for tire sizes........................................ 70 Retrofitting electrical equipment.......................... 241
Load compartment sliding door........................... 269 Reversing camera.................................................. 287
Loading cranes...................................................... 166 Roof loads................................................................ 73
Load rails............................................................... 158 Roof racks.............................................................. 158
Lowering the roof height....................................... 110 RV - Recreational vehicles..................................... 219
M S
Maintenance............................................................ 51 Safety equipment.................................................. 139

Major assemblies.................................................. 136 Seat belt tensioners................................................ 77
Marker lamps......................................................... 256 Seats.............................................................. 147, 190
Material quality...................................................... 180 Selecting the basic vehicle..................................... 35
Maximum permissible position of the center of Self-supporting bodies.......................................... 189
gravity...................................................................... 58 Semitrailer tractors............................................... 201
Mercedes PRO....................................................... 305 Shelf systems........................................................ 158
Mobile communications systems................... 80, 263 Shock absorbers................................................ 71, 94
Model code.............................................................. 30 Side marker lamps................................................... 80
Model designation................................................... 34 Signal acquisition and actuation module (SAM). 297,
Model overview....................................................... 34 313
Modifications to seats............................................. 77 Sliding door............................................................ 269
Modifications to the basic vehicle.......................... 92 Soundproofing................................................. 50, 323
Modifications to the interior................................. 190 Special equipment................................................... 55
Motorhomes.......................................................... 219 Springing............................................................ 71, 94
Mounting plate...................................................... 203 Stabilizer bars.......................................................... 94
Steerability............................................................... 58
N
Steering geometry................................................... 71
Noise level............................................................. 148 Storing and handing over........................................ 91
Storing the vehicle.................................................. 52
O
Suspension.............................................................. 92
Operational safety................................................... 10 Suspension limit values.......................................... 68
Outside mirrors..................................................... 270
Index
Tack welding............................................................ 49
Tail lamps............................................................... 255
Technical limit values for planning......................... 58
Telephone............................................................... 263
Thorax/pelvis side airbag..................................... 144
Threaded connections............................................. 46
Tie-down eyes........................................................ 158
Tire load capacity.................................................... 37
Tire pressure monitoring....................................... 285
Tires................................................................... 45, 98
Tire sizes.................................................................. 70
Torsionally stiff body types................................... 205
TPMS...................................................................... 285
Trademarks.............................................................. 22
Trailer hitch............................................106, 172, 176
Trailer hitch hole patterns..................................... 319
Transmission output........................................ 80, 263
Two-way radio........................................................ 263
Underrun protection.............................................. 176

Upfitter Portal.......................................................... 18
Vehicle identification data...................................... 39

Vehicle position lamps............................................ 80
Vehicle safety.............................................................9
Vehicle speed signal.............................................. 250
Vehicle stability....................................................... 44
Ventilation.............................................................. 149
Welded connections................................................ 47
Welding work........................................................... 85
Wheel alignment...................................................... 71
Wheels..................................................................... 98
Wheel wells............................................................ 114
Wind deflectors..................................................... 157
Window airbag....................................................... 145
Window heater....................................................... 270
Window lifters/window hinges............................. 269
Windows................................................................. 269
Windshield wipers................................................. 270
Workshop Information System (WIS)..................... 18
XENTRY Kit............................................................... 19
© 2022 Mercedes-Benz USA, LLC. All rights reserved.

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Body and Equipment Guideline

Sprinter – Model Designation 907

Mercedes-Benz USA, LLC

3.6 Vehicle identification data............................39

2 Mercedes-Benz | Body and Equipment Guideline Sprinter - BM907, Edition 2022-5

Mercedes-Benz | Body and Equipment Guideline Sprinter - BM907, Edition 2022-5 3

7.10 Light duty truck..........................................201 8.4.4 Additional electric circuits..........................241

4 Mercedes-Benz | Body and Equipment Guideline Sprinter - BM907, Edition 2022-5

8.10.1 PSM (MPM) Functions................................297

Mercedes-Benz | Body and Equipment Guideline Sprinter - BM907, Edition 2022-5 5

6 Mercedes-Benz | Body and Equipment Guideline Sprinter - BM907, Edition 2022-5

1.1 Purpose of Body and Equipment Guideline

Chapter 2 General (→ page 14)

You can obtain further information from any

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The following conventions are used in this Body and

ⓘ This symbol indicates useful notes or further infor-

→ This symbol indicates where you can find further

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1.3 Vehicle safety

Vehicle modifications by the upfitter

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1.4 Operational safety 1.6 Granting of body technical assistance

Modifications by upfitters should not affect the safety

Some of the safety systems only function when the

1.5 Note on copyright

All the text, illustrations and data contained in these

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Technical advice on the parameterizable special

Advanced support for eXpertUpfitter program

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1.9 Parts Use

In the case that these conversion parts cause damage

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2.1 Advice for Upfitters

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2.2 Upfitter responsibilities

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2.3 Product and vehicle information for upfit-

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2.3.3 XENTRY Kit

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2.4 Product safety and product liability

2.4.1 Product safety 2.4.2 Product liability

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2.4.3 Safety-relevant features The following customer-related influences must be

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2.5.1 Mercedes-Benz brand in interaction with 2.5.4 Trademark rights

2.5.2 Function of a brand

2.5.3 Trademark protection

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2.5.5 Advice on applying Mercedes-Benz 2.5.7 Brand separation/identity

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Trademarks at the vehicle rear

Use of the Mercedes star

Upfitter trademarks in combination

If parts such as airbags, batteries, fuel tanks, high-volt