Get Chassis Modifications Guide for Volkswagen Transporter Van Fifth Generation (2003-2015)

If chassis is transported on their own axles on public roads, it is mandatory to use transport equipment (wheel housings at

the back and ballast weight, PR-No. 2 A1). The wheel housings are suitable for permanent usage.

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

guidelines). Data status August 2007

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Chassis Modifications

a) with driver s cab

The maximum permitted cut-out is limited by the C-pillars, the C-bow and the cab floor. If also the B-bow and parts of

the roof are being removed, it is required to install a reinforcing frame according to drawing ENT-156011.

(illustration 5.3)

The connection between boot attachment and cab must be realised form-locking (i. e. elastically). This means that

the connection must not be force-locking. Instead, the connection has to be realised in such a way that the occurring

torsions between boot and cab are not directly guided into the driver™s cab, but are absorbed within the connection. (This

possibility is shown in ENT-156011).

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

guidelines). Data status August 2007

50

• Additional fastening points for special attachments

The side rails are hollow profiles. If it is required to drill there, this may only be performed in the neutral zone

(centre of side rail, but with sufficient distance to the flange). In addition, spacer bushings must then be welded

in.

• Boreholes which are applied ex-works at the upper and lower belt of the side rails must not be drilled and/or

extended. In addition, these boreholes must not be used for holding any instruments, modules, etc.

• Boreholes for connecting passages for pipes, electric cables, tackle blocks, etc. and for attaching add-on

parts (clamps, etc.). In exceptional cases, we approve of boreholes to be carried out in the bar of the side rails

or in the cross-members. In this case, however, it is strongly recommended to get in touch with us.

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

guidelines). Data status August 2007

51

b) With double cab

Cut-out at the rear wall

The maximum permitted cut-out is limited by the B-pillars, the B-bow and the floor of the driver™s cab.

Roof cut-outs between the bows are to be realised in compliance with the specifications for box-type delivery vans/station

wagons (section 3.2 Roof cut-outs).

It is not permitted to remove the B-bow and/or C-bow.

The trailing link arms behind the rear wall must not be removed without being replaced by an adequate component.

A possibility for a transfer according to ENT-149918 is represented below.

Connections between boot attachments and double cab must be realised form-locking and elastically (according

to boot attachment/driver™s cab)

Modification of chassis with driver s cab

Cut-out at the cab rear wall and roof for a connecting passage between driver™s compartment and the attachment be

realised. Position and size of the cut-out and the layout of the reinforcing frame, which will be required for this situation,

can be taken from ENT-156 011.

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Modification of chassis with double cab

pressure struts for the safety belts according to ENT-149 918. (Required for usage for the standard trailing link arms, if

these must be removed for installing special attachment.)

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

guidelines). Data status August 2007

54

Weld work at the vehicle frame should remain limited to absolutely necessary exceptions.

Before performing weld works at the vehicle, it is required to disconnect the car battery. If cables are damaged which are

routed not openly with the battery being disconnected, short-circuits may lead to severe damages.

When performing electric welding works, the earth terminal of the welding set must be directly connected to the vehicle

part to be welded. Otherwise, the high current and the occurring high voltage peaks may damage the mechanical and

electronic vehicle parts.

Only inert gas should be used for welding.

In exceptional cases, also well drained stick electrodes - 2.5 mm - with lime-basic coating may be used.

If additional brackets, etc. are welded, it is only permitted to weld in the so-called neutral zone. Plug welding is always the

preferred method. Avoid weld joints running diagonally to the frame.

Note: The corrosion-inhibiting coating on the side rails is damaged in the welding area as a result of the thermal stress

developing during welding. For this reason, this coating has to be suitably repaired.

Example of a plug weld

Brackets for attachments according to the series requirements.

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

guidelines). Data status August 2007

55

If a wheel-base extension is to be performed

• work should start with the long wheel base.

• the frame should be disconnected approx. 480 mm behind the driver™s cab.

The max. permitted total weights, axle loads, rear overhangs (depending on the wheel base), etc. are to be observed. For

this purpose, adhere to the sections "Dimensions and Weight".

Frame of the chassis (extended)

-Side view-

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

guidelines). Data status August 2007

56

Subframe

The subframe must consist of steel. It is required for attachments whose lumped loads are guided into the chassis, e. g.

for dump trucks and tractive units.

The subframe is used to distribute the forces, which are induced punctiformly, uniformly over the entire chassis frame. For

this purpose, it should lie above the side rails and be guided to the driver™s cab. In addition, it should be tapered in the

front section.

The various air gaps between chassis and subframes need not to be filled. With a floor frame it is possible to fix

self-supporting attachments directly at the standard brackets.

Subframes and self-supporting attachments are to be fixed at the chassis using all available brackets.

Mounting Frame

The mounting frame is exclusively used for directly receiving auxiliary units, etc. Only screws are permitted for attaching

the mounting frame at the chassis frame. The mounting frame needs not to cover the entire chassis frame - as is the

case with the subframe.

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

General instructions on the modification of standard vehicles It is not permitted to modify spring characteristics,

brake system and steering unit. Exceptions must be approved by Volkswagen AG before the modification is carried out. If

noise-emitting parts (e. g. engine, tyres, exhaust system, etc.) are modified, it is required to perform noise measurements

according to EC directives. The permitted values must not be exceeded. If the car body is to be modified in the area of the

petrol tank, it is required to dismount the tank beforehand.

Shackle attachment for the first two fastening points, left/right, behind the driver™s cab (if required).

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

guidelines). Data status August 2007

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Attachments with high centre of mass

At vehicles with high attachments or with a raised overall centre of mass, the driving conditions are limited.

Stabilizer bars are used to prevent excessive heeling of the vehicles.

The following table shows which centre-of-mass height is permitted for vehicles with standard equipment. These heights

must not be exceeded. In addition, the table shows for which vehicle variants stabilizer bars or reinforced stabilizer

bars are recommended.

The maximum permitted centre-of-mass heights indicated in the table may under no circumstances be exceeded.

Max. permitted

Overall

centre of

centre-of-mass height of

attachment and net load

Centre of

Stabilizers

mass of the mass of the above lane in mm

chassis

Dimensions Dimensions

mm X

757

vehicle

Dimension Z

Standard

equipment

Stabilizers

OAB &

OBB

PR-

No.

Front Rear

Type

mm Y

858

axle

OJ1

OJ2

Box-type/station

S

-

1140

1180

Flatbed/double

cab

OJ2 S

-

688

850

Chassis

-

654

757

850

1160

1185

Box-type/station OJ3 S

Flatbed/double

OJ3 S

-

688

850

1120

cab

Chassis

OJ3 S

-

654

757

850

980

Box-type/station OJ2 A

B

1480

1510

1460

1405

1430

1390

Flatbed/double

OJ2 A

B

688

654

757

688

654

980

cab

Chassis

OJ2 A

OJ3 A

Flatbed/double

cab

Pritsche/Doka

OJ3

A

Chassis

OJ4

s - 23 mm stabilizer bar, front, available as standard

A - 27 mm stabilizer bar, front, available as extra equipment (OAB)

B - 26 mm stabilizer bar, rear, available as extra equipment (OBB)

Note: The PR-No. OJ2 and OJ3 include also the syncro variants.

Centre-of-mass height specifications according to directive 71/320 EEC Since 01/01/1991, all utility vehicles must

comply with the requirements of the "EC Directive on Brake Systems, 71/320/EEC". The adoption of this EC directive

into German traffic registration regulations (StVZO) results in a situation in which these technical directives must also be

fulfilled at single acceptances (trial runs).

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For all permitted weights, the centre-of-mass height, Y, must not be exceeded.

All centre-of-mass heights indicated in the adjacent table always refer to the vehicle being loaded up to its respective

permitted total weight.

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

guidelines). Data status August 2007

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Chassis Modifications for Your Volkswagen Transporter Van Fifth Generation (2003-2015)

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