Body assembly guidelines Volkswagen ... - Aufbaurichtlinien

Body assembly guidelines Volkswagen Nutzfahrzeuge
The LT
The following pages contain technical guidelines for custom body manufacturers/ coachwork specialists for
construction and assembly of custom body-related parts and conversions.
The body assembly guidelines should be strictly adhered to if modifications are made with the intention of
doing so.
Included in the Volkswagen body assembly guidelines are also the body dimension plans for our
commercial vehicles Crafter, Transporter T4 and T5, Caddy and LT. These can be installed in 3 formats (TIF,
DXF, IGES) for CAD programs and as PDF files.
Advice: If further technical queries about the series production vehicle arise over and beyond these
guidelines, please contact your local conversion expert at your importer.
Volkswagen Nutzfahrzeuge
Brieffach 2965/5
Postfach 21 05 80
D - 30405 Hannover
Fax. +49 (0)511 / 7 98 - 85 00
Online contact: http://www.vwn-aufbaurichtlinien.de/de/kontaktformular
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
http://www.vwn-aufbaurichtlinien.de
Data status October 2009

General information
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.
Note:
Changing the steering and braking forces for vehicle conversions for disabled persons is not possible.
Airbag
If the attachment manufacturers modify the structure of the vehicle, e. g.
• modifications of the front section of the vehicle
• mounting of belt retractors if the B-pillars are left out
• modifications of the floor structure in the area of the airbag trip device
• modifications of the seats, resulting in altered kinematics of the passengers
• modifications of the airbag-system cabling
• modifications of the system design
the safe functioning of airbag and belt retractor can no longer be guaranteed. These component parts may only be used
after having been approved by Volkswagen AG.
Emission behaviour (exhaust gas/noise)
If parts are to be modified that are producing exhaust gas and noise (e. g. engine/injection pump/control unit, exhaust
system/catalytic converter, air suction installation, tyres, etc.), it is required to perform exhaust gas and noise
measurements. It is also necessary to adhere to the current versions of the specific national directives and regulations.
For this reason, parts which are installed as standard to reduce emissions should not be removed or changed. Otherwise
the license may expire.
Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body
guidelines). Data status August 2007

The company Paulisch GmbH & Co. KG
Eisenbahnstraße 17
Postfach [P.O. box] 1405
97804 Lohr am Main, Germany
Phone +49-9352-855260
Fax +49-9352-855102
is our supplier of serial seats for the passenger compartment. This firm is also offering two seat variants which can be
positioned against the driving direction without changing the standard seat mounting points in the 1st row of seats. This
applies to the narrow triple seat and the double seat. Since we do not supply these seat variants, it is only possible to
order them directly from this manufacturer. These seats are already provided with (automatic) lap belts. The pre-cut fabric
covering material reference allows for the omission of the three-point belts!
Prices: State 21 November, 1997:
• Narrow triple seat based on standard seat, with upper part turned by 180° and with the seat mating-part sets,
including the installation materials for the vehicle floor, excluding head restraints. DEM 1292/piece (without
turnover tax)
• Double seat, as above, DEM 968/piece (without turnover tax)
The prices are ex-works from Lohr am Main, Germany, excluding packaging.
The head restraints can be ordered as replacement parts from Volkswagen using Part No. 2D0 881 901... The nav_side
missing here depends on the selected seat cover.
Note:
Since the floor attachment for the above mentioned seat variants are taken over from the standard seat variants without
modifications, it is possible to replace the above mentioned seat variants by the corresponding standard seat variants, if
the backrest locking at the side panel, which is required for this, was appropriately retrofitted according to the series
specifications.
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

At the multi-purpose/box-type delivery van, attachment and base group form a self-supporting unit. Supporting parts of this
self-supporting unit must not be removed without being replaced by another component. Baffles have no supporting
function. Modifications, even the complete removal, are permitted. If car-body parts are to be modified or to be installed, it
is only permitted to weld if bonding is not possible.
• Cut-outs in the side wall
If profiles are cut in order to install cut-outs (windows, doors, bonnets, ventilation, air exhaust, etc.), the cut-outs
must be reinforced by an enclosing frame and must be welded to the cut profiles.
• Roof heightening (plastic roof)
refer to item 3.6, Roof design
At closed bodies with partition walls ventilation slots are located in the partition wall and the D-pillars. At car modifications
it is only allowed to cover these ventilation slots, if new slots are produced in the cab instead. For example in the cab
doors.
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

If the wheel base is to be modified or if the overhang is to be extended, the material quality and dimensions of the
lengthening piece must correspond to the chassis frame (St 12.03). Functioning, smoothness and free movement of
instruments and operating equipment as well as the stability of supporting parts must not be impaired by the performed
modifications.
Cut-outs in the backwall of the driver s cab must be provided with an enclosing frame. The remaining diagonal struts and
cross-beams are to be reinforced by junction plates and are to be welded to the inserted frame.
The distance between cab and attachment must be at least 50 mm.
Frame modifications
• The permitted axle loads must not be exceeded. It is also required not to fall below the permitted minimum front
axle load.
• Attach the underrun protection as explained for standard vehicles.
• Extend the subframe up to the frame end.
• Check the function of the towing device.
• Reinforcements must be available for desired towing device.
The side rails are hollow profiles (cap profiles). If it is required to drill, the appropriate operations may only be performed in
the specified areas.
It is not permitted to drill:
• At the upper and lower belt of the chassis frame. Exceptions are boreholes at the rear frame end. However,
these boreholes must not lie in the area that are reserved for the supporting functions of the rear axle. In addition,
they must not be applied to parts that are attached to the frame.
• In the range of profile modifications of the frame side-rails (frame drop and frame indent).
• At force-application points (e.g. directly at the spring brackets).
In special cases, it is permitted to drill boreholes in the crosspiece of the frame side rails.
• Distance a: at least 20% of the frame height
• Hole separation b: at least 50 mm
• max. bore diameter: 15 mm
Grind and ream after drilling. Before usage, distance bushes must be welded in.

According to item 2.3, the permitted maximum rear overhangs (depending on wheel base and permitted total
weight) are to be kept.
For this purpose, consider the following instructions:
• If the frame is to be extended by more than 350 mm, an additional cross member is to be installed.
• It is required to check the permitted trailing load (according to the vehicle registration document). Reduce,
if necessary.
• Overhang extension according to the illustration.
As an ex-works preparation, the SBBR line can be installed with a spare section of 700 mm. Ordering options can
be taken from the sales documents.
LT46
LT28
/
LT35

Perform wheel-base extensions of the longest standard base. If the wheel base is to be modified, the next larger standard
wheel-base is to be used and shortened. Reinforce the intersecting point with sheet-metal shoes.
Wheel-base modifications based on displacing the rear axle are not permitted.
Separation points are not permitted in the area of:
• Force-application points
• Axle guiding and axle spring-suspension
• Profile modifications
After the wheel base modification, the chassis has to be reinforced by a continuous subframe.
Moments of resistance required for the subframe:
Up to the max. standard wheel-base: 30 cm3 •
.
• Above the max. standard wheel-base: 15% increase.
The wheel-base modification results in an altered turning circle and changed weight values.
Wheel base modifications lying within the range of the minimum/maximum standard wheel-base, require no special
permission.
Drive shafts
• If wheel-base modifications are to be performed, the drive-shaft arrangement and length must correspond to that
of a comparable standard vehicle.
• The diameter and wall-thickness of the drive-shaft must correspond to that of the standard vehicle.
• If required, use several drive shafts with intermediate bearings.
• The inflection angles (ß1 = ß2) must not exceed 6° . Deviations impair operating life and noise
level.
•
Counterbalance drive shafts before mounting them.

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

General information
When performing welding operations with electrical welding sets, adhere to the following instructions:
• Welding works at the chassis frame may only be performed by trained and sufficiently qualified staff.
• Remove and cover the positive and negative terminals of the batteries.
• Connect earth terminal of the welding set directly to the part to be welded. Caution! The earth terminal of the
welding set must not be connected to any other module (engine, transmission, axles, etc.).
• Do neither touch the housings of electronic modules (e. g. control units) nor electrical lines with the welding
electrode or with the earth terminal of the welding set.
• At cabs which are independently supported, connect the earth terminal of the welding set to the cab.
• Before beginning the welding work, it is required to protect the springs against weld splatters. Do not touch
springs with the welding electrodes or the electrode holder.
Caution!
It is not permitted to weld:
• At modules, such as engine, transmission, axles, etc.
• At the chassis frame (except for wheel base and frame modifications)
Welding at the vehicle frame
At the upper and lower belt of the chassis frame, it is not permitted to weld (except for wheel-base modifications and frame
extension).
Connect the earth terminal of the welding set directly to the vehicle part to be welded.
• Only use well drained electrodes with lime-basic coating. Electrode diameter 2.5 mm.
• Current intensity per mm of the electrode diameter is max. 40 A.
• The electrodes may only be welded together with direct current via the positive pole. In general, the welding has
to be performed from bottom to top.
• Inert gas shielded arc welding is permitted.
• Weld filler rod size between 1 and 1.2 mm.
• The weld material must at least have the same yield point and tensile strength like the material to be welded.
• To avoid a notch effect caused by weld penetrations, slur weld joints and reinforce them using angular profiles.
Avoid weld joints in bend radii. The distance between weld joints and outer edges should be at least 15 mm.
•
Only plug weld in the neutral zone is permitted.

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

Air Suction
Adhere to the following instructions if the engine air-suction is to be modified:
• To ensure the functionality, standard parts, such as filters, tubes, suspensions (oscillating insulation), etc., must
to be mounted according to the same specifications as the standard model.
• The clean-air side and the connection maintenance indicator must not be modified.
• It is not permitted to the change the installation conditions in the area of the inlet port.
• The flow velocities in the intake range, in front and inside the air intake, must not be increased. Do not confine
the unrestricted cross section.
• The water separation of the engine air-suction may be impaired even by small modifications in the area of the
suction opening (e. g. the radiator grill). Therefore, modifications in this always require a permission of the
responsible department.
Exhaust-gas circulation/exhaust system
• Use only original Volkswagen components for modifying the exhaust system.
• Length and mounting position of the flexible metallic hose between exhaust manifold and exhaust pipe must not
be changed.
• The unrestricted cross section of the exhaust pipe behind the sound absorber must not be reduced.
• Pipe bend max. 90°
• Avoid additional pipe bends.
• Bend radii 2.5 d.
• Minimum distance to plastic lines, electrical cables and spare wheels:
200 mm for exhaust systems without shielding,
80 mm for sheet shieldings,
40 mm for sheet shieldings with additional insulation.
•
Additional shieldings are required:
• In the area of operating devices
• in the area of modules, attachments and installations , if they are not made of heat-resistant material.

Cooling:
The cooling system (radiator, radiator grill, air ducts, coolant circuit, etc.) must not be changed.
A sufficient throughput of cooling air must be ensured.
• Keep the air intake of the radiator free
• Do not place any warning signs, plaques or other decorative parts in the area in front of the radiator.
Provide additional cooling devices for modules, devices, etc., if the following conditions apply:
Disk brakes
• Operation at outdoor temperatures above 35°C.
• If the vehicle is standing and high continuous power is drawn off
• The cooling must not be impaired by spoilers below the bumper, additional wheel trim panels or brake disk
coverings, etc.
Preparation 2nd heat exchanger
• At backfitting of a heat exchanger, it is important the bleed the cooling water system completely:
heater output:8,7 kW
air-mass flow: 360 kg / h
volume flow: 1500 l / h
the additonal heat exchanger from the T4-selection can be recommended.
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

General information
• Do not loosen or remove the terminal clamps of the batteries with the engine running.
• Only tow-start vehicle with connected batteries.
• Charge batteries only then with a quick-charger, with the batteries being disconnected from the vehicle circuit.
Positive and negative terminals must be removed. Adhere to the operating instructions!
• Installation of additional electrical consumers.
• Coat cables which are to be routed near exhaust systems with fire-proof material.
• Route cables in such a way that abrasion marks can be avoided.
Electromagnetic compatibility (EMC)
In motor vehicle power-supply circuits, the individual consuming devices cause electrical disturbance variables.
Volkswagen AG checks whether electronic components (which are installed by the manufacturer) are electromagnetically
compatible inside the vehicle.
If electrical or electronic systems are to be upgraded or retrofitted, it is also required to check their electromagnetic
compatibility.
The following standards supply relevant information:
• DIN 40839
• DIN 57879, Part 3
• VDE 0879, Part 3
• VWTL 965
• VWTL 82066
• VWTL 82166
• VWTL 82366
In addition, it is required to consider the EMC Directive 72/245 EC, version 95/54 EC.
More information can be requested from the responsible department.
Supplementary current-collecting consuming devices
Adhere to the following instructions if additional electrical consuming devices are to be installed later on:
• On special request, provide available batteries and generator with higher output.
• Connect no further consuming devices to fuses which are already assigned.
• Connect no additional lines (e. g. with insulation piercing connecting devices) to available lines.
• Protect consumers with additional fuses sufficiently against short circuits.
Subsequent installation of an additional battery
An additional battery may only be installed in connection with a D+ relay. This battery may only be assigned to additional
consuming devices, such as auxiliary heater, loading tailboard or electrical devices to be used in mobile homes
(refrigerator, etc.). If the additional battery is to be placed in the passenger compartment, the ventilation has to be realised
using a central degassing tube leading outside.

Electrical lines
Adhere to the following instructions if electrical lines are to be extended:
• Use only FLKR lines with the same cross section and colour as the standard lines.
• The lines must be coated with an insulating hose (GGVS vehicles with a corrugated hose).
• Attach only original Volkswagen plug connectors to the line ends.
• The connection of electrical lines may only be realised via tapping boxes.
• Cables of the anti-lock brake system may only be extended with original Volkswagen cable-sets.
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

In the event of tampering with the structure of the vehicle by the body manufacturer for example.
• Modifying the front end
• Attaching belt tensioners with no B-pillar,
• Modifications to the floor structure in the area of the airbag trigger control unit,
• Modifications to the seats and thus to the kinematics of the occupants,
• Modifications to the wiring of the airbag system,
• Modifications to the system design (e.g. installation location of the sensors,
• Installation of parts in the vicinity of the outlets or inflation range (only tested retrofit solutions permissible),
reliable operation of the airbag, passengerairbag and belt tensioners can no longer be guaranteed. These components
should therefore only be used with the approval of the responsible department.
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

LT 25/LT35
Type
Panel
Van
Pickup
with
Single
cab
Chassis
with
Single
cab
Panel
Van
Pickup
with
Single
cab
Chassis
with
Single
cab
t
KG
2800
3200
3500
2800
3200
3500
2800
3200
3500
2800
3200
3500
2800
3200
3500
2800
3200
3500
wheelbase
mm
Stabilisatoren
frontaxle
rearaxle
center of
gravity
basic
vehicle
dimension
mm X
total
center of
gravity
vehicle
dimension
mm Y
3000 Standard Stabilizer 840 1000/1050
3000 Standard Stabilizer 805 1000/1050
3000 Standard Stabilizer 780 1000/1050
3550 Standard Stabilizer 840 1000/1050
3550 Standard Stabilizer 805 1000/1050
3550 Standard Stabilizer 805 1000/1050
maximum legal height
of center of gravity of
body
dimension
Standardequipment
1296
1226
1184
1366
1277
1226
1296
1236
1198
1333
1250
1202
1393
1293
1238
1430
1315
1253
with
Stabilizer
HA Z
1438
1346
1291
1510
1398
1333
1414
1340
1293
1488
1378
1315
1544
1418
1348
1590
1446
1368

Chassis
with
Single
cab
Chassis
with
Double
cab
Panel
Van
Pickup
with
single
cab
Chassis
with
Single
cab
Chassis
with
Single
cab
Chassis
with
Double
cab
LT 35/LT46
Type
Panel
Van
Pickup
with
Single
cab
Chassis
with
Single
cab
Chassis
with
Single
cab
2800
3200
3500
2800
3200
3500
3200
3500
3200
3500
3200
3500
3200
3500
3200
3500
t
KG
3500
4000
4600
3500
4000
4600
3500
4000
4600
3500
4000
4600
3550 Standard Stabilizer 780 1000/1050
3550 Standard Stabilizer 780 1000/1050
1307
1244
1204
1343
1268
1222
4025 Standard Stabilizer 840 1000/1050 1324
1252
4025 Standard Stabilizer 805 1000/1050 1335
1267
4025 Standard Stabilizer 805 1000/1050 1341
1271
4025 Standard Stabilizer 780 1000/1050 1255
1212
4025 Standard Stabilizer 780 1000/1050 1281
1232
wheelbase
mm
Stabilisatoren
frontaxle
rearaxle
3550 Standard Stabilizer
reinforced
3550 Standard Stabilizer
reinforced
3550 Standard Stabilizer
reinforced
3550 Standard Stabilizer
reinforced
center of
gravity
basic
vehicle
dimension
mm X
total
center of
gravity
vehicle
dimension
mm Y
805 1050/1100
770 1050/1100
770 1050/1100
725 1050/1100
1427
1349
1300
1471
1378
1322
1475
1381
1471
1385
1479
1391
1363
1310
1395
1335
maximum legal height
of center of gravity of
body
dimension
Standardequipment
1408
1313
1249
1486
1370
1292
1516
1387
1304
1409
1326
1266
with
Stabilizer
HA Z
1534
1419
1342
1614
1477
1385
1649
1498
1399
1514
1418
1349

Chassis
with
Double
cab
Panel
Van
Pickup
with
Single
cab
Chassis
with
Single
cab
Chassis
with
Single
cab
Chassis
with
Double
cab
3500
4000
4600
3500
4000
4600
3500
4000
4600
3500
4000
4600
3500
4000
4600
3500
4000
46000
3550 Standard Stabilizer
reinforced
4025 Standard Stabilizer
reinforced
4025 Standard Stabilizer
reinforced
4025 Standard Stabilizer
reinforced
4025 Standard Stabilizer
reinforced
4025 Standard Stabilizer
reinforced
725 1050/1100
805 1050/1100
770 1050/1100
780 1050/1100
725 1050/1100
725 1050/1100
1459
1359
1289
1504
1370
1286
1549
1407
1316
1555
1410
1318
1430
1340
1276
1462
1361
1290
1572
1457
1376
1651
1488
1387
1688
1521
1414
1695
1525
1416
1539
1435
1361
1575
1459
1377
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

1) Station wagon
a) If the passenger compartment is being ordered without standard seats, the station wagon will then generally be
provided ex works with 3 prepared mounting points for the first two rows of seats, including the single-sided
preparation for connecting the backrests of the standard seats at the contacting side wall with double and narrow triple
seat, respectively, at the wide triple seat, the two-sided connecting preparation.
Exception: Station wagons with 2 sliding doors. This variant is not provided with a prepared floor mounting points for the
first row of seats. For this reason, it is not possible to retrofit standard seats in this case.
(Note: Seats are also not available as standard!).
b) It is required to order the prepared floor mounting points for the 3rd row of seats, including the two-sided
connection preparation for the backrest of the wide triple seat bench at both side panels, with PR.-No. 3WE since they
are not available for the basic version.
Note: A retrofitting of the floor mounting points, including the both-sided connection preparation for the backrest of the
wide triple seat, in the 3rd row of seats is not possible.
c) However, if a double seat is ordered ex works for the 1st and / or 2nd row of seats, the 3rd floor mounting point
(which is not required) for the affected row(s) of seats will not be appropriately prepared. A subsequent upgrade to a
triple seat is possible (in front only onto a narrow triple seat), but is, however, extremely complicated! If an upgrade to a
wide triple seat (only for the 2nd row of seats) is to be realised, the connection preparation for the backrest on the
previous passage side of the double seat also has to be retrofitted.
d) For conventional single seats mounted in driving direction (not available ex works; to be supplied by the attachment
manufacturers) on the vehicle floor of the passenger compartment of the station wagon and/or the boot space of the
box-type delivery van, on the left and right of the side panels, a suggested solution for retrofitting the belt anchorage points
of three-point belts (to the left and right of the single seats on the vehicle floor and at the corresponding side panels) was
developed and tested by TÜV Rheinland [Testing and Research Laboratory of the Rhineland] in a sprinter. Since the
affected car-body areas are identical with that of the LT, the expert assessment No. 55110226-00, dated 19/10/1995, can
also be applied to the Volkswagen LT (LT 2). The attachment of the single seats on the vehicle floor are not dealt with.
The expert assessment is available on request (Fax 49-511-7983895).
2) Box-type delivery van
a) The boot space floor is not prepared to be equipped with station wagon standard seats. It is not possible to retrofit the
floor mounting points!
Note: A seat package is available ex works for all box-type delivery van versions with a narrow triple seat for the 1 st row of
seats!
b) Retrofitting of single seats performed by attachment manufacturers: See station wagon, item 1d).
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