Special Applications Guide - Service || MV-1

Transcription

SPECIAL APPLICATIONS
GUIDE
JUNE 2014
Copyright 2014 by Mobility Ventures LLC
No part of this manual may be reproduced in any form, by photostat, microfilm, xerography, or any other means, or incorporated into any information retrieval system,
electronic or mechanical, without the written permission of Mobility Ventures LLC. MV-1 is a registered trademark of Mobility Ventures LLC. Mobility Ventures is a trademark of
Mobility Ventures LLC. The MV-1 is covered by U.S. Patent No. D615,456. Other patents pending.
1
TABLE OF CONTENTS
CONTENTS
INTRODUCTION .......................................................................................................................................................................................... 5
TECHNICAL SPECIFICATIONS ................................................................................................................................................................. 6
Cooling System ...................................................................................................................................................................................... 6
Engine Displacement & Cylinders .......................................................................................................................................................... 6
Engine Dimensions ................................................................................................................................................................................ 6
Fuel/Air System ..................................................................................................................................................................................... 7
Air Conditioner ...................................................................................................................................................................................... 7
Axle/Differential .................................................................................................................................................................................... 7
Alternator & Battery .............................................................................................................................................................................. 8
Frame ..................................................................................................................................................................................................... 8
Brake System ......................................................................................................................................................................................... 8
Service Brake Caliper (Front) ............................................................................................................................................................. 8
Service Brake Rotor (Front) ............................................................................................................................................................... 8
Service Brake Caliper (Rear) .............................................................................................................................................................. 9
Service Brake Rotor (Rear) ................................................................................................................................................................ 9
Master Cylinder and Brake System Capacities ......................................................................................................................... 9
Steering System ..................................................................................................................................................................................... 9
Transmission .......................................................................................................................................................................................... 9
Wheels and Tires ................................................................................................................................................................................. 10
Vehicle Payload ................................................................................................................................................................................... 10
OVERALL VEHICLE DIMENSIONS - Standard Measurement Spec Sheet .................................................................................................. 11
Roof Bow Locations ............................................................................................................................................................................. 13
Center of Gravity Side View ................................................................................................................................................................. 13
Center of Gravity Top View ................................................................................................................................................................. 14
2
Mobility Ventures LLC
To - Table of Contents
MV-1 Special Applications Guide
Close Up of Center of Gravity .............................................................................................................................................................. 14
Center of Gravity Dimensional View ................................................................................................................................................... 15
Driver’s Seat “H-Point” Dimensional View .......................................................................................................................................... 15
Factory-Installed Jump Seat “H-Point” Dimensional View .................................................................................................................. 16
Third Row Bench Seat “H-Point” Dimensional View ........................................................................................................................... 16
VEHICLE MASS AND DISTRIBUTION ......................................................................................................................................................... 17
CHASSIS SPECIFICATIONS ......................................................................................................................................................................... 18
Suspension & Brake Information ......................................................................................................................................................... 18
Frame & Chassis Dimensions ............................................................................................................................................................... 19
CNG Chassis Top View with Body Mount Measurements ............................................................................................................... 19
CNG Chassis Side View with Overall Frame Height ......................................................................................................................... 20
CNG Chassis Front View with Wheel Mounting Surface Cross Car Measurement.......................................................................... 20
CNG Chassis Rear View with Wheel Mounting Surface Cross Car Measurement ........................................................................... 21
Gasoline Chassis Top View with Dimensions .................................................................................................................................. 22
Gasoline Chassis Side View ............................................................................................................................................................. 22
BODY SPECIFICATIONS ............................................................................................................................................................................. 23
Interior Dimensions ............................................................................................................................................................................. 23
Reference Diagram .......................................................................................................................................................................... 23
A-Pillar Section ................................................................................................................................................................................ 24
B-Pillar Section ................................................................................................................................................................................ 25
C-Pillar Section ................................................................................................................................................................................ 26
Liftgate Opening .............................................................................................................................................................................. 27
Center Cut Body Side – CNG............................................................................................................................................................ 28
Center Cut Body Side – Gasoline ..................................................................................................................................................... 29
Floor Dimensions with Jump Seat ................................................................................................................................................... 30
Floor Dimensions without Jump Seat.............................................................................................................................................. 31
Driver’s Seat Mounting Configuration ................................................................................................................................................. 32
Top View of Front Floor at Driver’s Seat ......................................................................................................................................... 32
Side View of Front Floor .................................................................................................................................................................. 34
3
Module Identification and Location Under Driver’s Seat ................................................................................................................ 34
Interior Restrictions and Safety Precautions ....................................................................................................................................... 35
Instrument Panel Dimension Views..................................................................................................................................................... 37
Exterior Body Panel Dimensions.......................................................................................................................................................... 41
Fenders and Quarter Panels ............................................................................................................................................................ 41
Overall Body Measurement ............................................................................................................................................................ 42
Front Door Outer Panel Dimensions ............................................................................................................................................... 43
Rear Door Outer Panel Dimensions ................................................................................................................................................ 43
Liftgate Dimensions ......................................................................................................................................................................... 43
Hood Dimensions ............................................................................................................................................................................ 44
Roof Dimensions ............................................................................................................................................................................. 45
WIRING HARNESSES – ROUTING AND LOCATION .................................................................................................................................... 46
Auxiliary Power Outlet Jumper (APOJ) Harness .................................................................................................................................. 46
Battery Harness ................................................................................................................................................................................... 47
Body Harness ....................................................................................................................................................................................... 48
Cargo Lamp Harness ............................................................................................................................................................................ 49
Chassis Harness CNG ........................................................................................................................................................................... 50
Chassis Harness GAS ............................................................................................................................................................................ 52
Engine Harness .................................................................................................................................................................................... 54
Forward Lamp Harness ........................................................................................................................................................................ 56
Headliner Harness ............................................................................................................................................................................... 57
HVAC Harness ...................................................................................................................................................................................... 58
Instrument Panel Harness ................................................................................................................................................................... 59
Liftgate Harness/Liftgate Bezel Jumper Harness ................................................................................................................................. 62
Power Ramp Harness .......................................................................................................................................................................... 63
Ramp Actuator Harness ....................................................................................................................................................................... 64
Steering Column Harness .................................................................................................................................................................... 65
Transmission Harness .......................................................................................................................................................................... 66
Underhood Harness ............................................................................................................................................................................. 67
4
INTRODUCTION
The purpose of this guide is to provide technical design information to aftermarket upfitters and special purpose
application specialists who will be working on a Mobility Ventures LLC MV-1. This information will provide guidance
for upfitters so they can complete their installations without violating the safety, noise, or emissions certifications of
the vehicle.
Any failures which occur from the installation or use of Non-Genuine Parts and accessories not supplied by Mobility Ventures are not
covered by the MV-1 Vehicle Warranty. This also includes the alteration or misuse of any original Vehicle equipment. Any vehicle
found to be altered from its original design will be subject to Mobility Ventures voiding the Vehicle Warranty on the affected
components.
While Mobility Ventures may participate with the integration of, or provide technical information for the development of
aftermarket installations or accessories, Mobility Ventures in no way assumes warranty liability for these items. It is important that
the upfitter advise customers that these installations are not warranted by Mobility Ventures.
NOTE: This guide should be used in conjunction with the correct model year MV-1 service manual to ensure that the
most current procedures and specifications are being used in any vehicle modification.
This guide identifies many of the physical parameters which must be maintained in order to ensure the structural and
performance integrity of the final product.
WARNING
ALWAYS follow the guidelines described in this document when making modifications to any MV-1.
REASON: Failure to follow the guidelines described in this document may result in compromised performance and
conditions which potentially could be hazardous to the user. The responsibility and consequences of nonconformance to the guidelines listed in this document will rest with the aftermarket manufacturers or upfitters.
NOTE: Failure to follow the guidelines described herein may negate the safety, noise, or emissions certification
compliance of Mobility Ventures LLC and/or its suppliers. In that case, the aftermarket equipment installer will be
responsible for the certification, including affixing any certification labels as required by 49CFR Parts 566, 567 and
568.
This guide applies only to modifications to a completed vehicle sold by Mobility Ventures LLC.
The Mobility Ventures LLC MV-1 has been certified at Gross Vehicle Weight Rating (GVWR) of 6,600 Pounds (2993
Kilograms) and Gross Axle Weight Ratings (GAWR) of 3600 Pounds (1633 Kilograms) in the front and 3600 Pounds
(1633 Kilograms) in the rear. Aftermarket equipment must be added to the vehicle in a manner so these limits are not
exceeded during use. In addition, the vehicle is certified to meet the specific safety, noise, and emissions
requirements for the vehicle in the GVWR class. Therefore, the aftermarket vehicle manufacturer or upfitter is not
permitted to modify or alter the GVWR or GAWR of the vehicle.
Measurements in this guide are provided for reference and are shown in millimeters and inches. The dimensions provided must be
regarded as guidelines since dimensions may vary slightly between vehicles of the same model, due to manufacturing tolerances or
earlier repair work. Use tolerances of +/- 2mm. Measuring methods utilized for this guide were CAD reference, Trammel style and
Tape measuring (shop measurements) showing edge-to-edge dimensions of parts in the orientation they normally reside on the
vehicle. This guide is not to be used for collision repair or as a guarantee of dimensional integrity of any part used on the MV-1
vehicle. Mobility ventures reserves the right to modify dimensions shown at any time without prior public notification.
5
TECHNICAL SPECIFICATIONS
COOLING SYSTEM
RADIATOR TYPE
LIQUID CROSS-FLOW
COOLING SYSTEM CAPACITY / GAS
17.4 QUARTS / 16.4 LITERS
COOLING SYSTEM CAPACITY / CNG
17.7 QUARTS / 16.7 LITERS
COOLING FAN TYPE
TWO SPEED, TWIN ELECTRIC COOLING FANS
CAP PRESSURE
16 PSI / 110 KPA
THERMOSTAT
195 DEGREES FAHRENHEIT / 90 DEGREES CELSIUS
NORMAL OPERATING
TEMPERATURE
205 DEGREES FAHRENHEIT / 96 DEGREES CELSIUS
ENGINE DISPLACEMENT & CYLINDERS
DISPLACEMENT
281 CUBIC INCHES / 4.6 LITERS
NUMBER OF CYLINDERS
8
FIRING ORDER
1-3-7-2-6-5-4-8
BORE
3.55 INCHES / 90.2 MILLIMETERS
STROKE
3.54 INCHES / 90 MILLIMETERS
OIL PRESSURE AT 2,000 RPM
(NORMAL OPERATING
TEMPERATURE)
40-75 PSI / 275-517 KPA
ENGINE DIMENSIONS
OVERALL HEIGHT
OVERALL LENGTH
OVERALL WIDTH
MASS
451 POUNDS / 205 KILOGRAMS
6
FUEL/AIR SYSTEM
AIR INDUCTION
NATURALLY ASPIRATED
AIR FILTER
PAPER FILTER ELEMENT
FUEL PUMP – GAS
ELECTRONIC FUEL PUMP IN STEEL TANK
GASOLINE TANK CAPACITY
24 GALLONS / 90.8 LITERS
CNG FUEL PRESSURE
3600 PSI / 24,821 KPA
CNG TANK TYPE
THREE TYPE 3 ALUMINUM CYLINDERS WRAPPED WITH GRAPHITE FIBER
CNG TOTAL CAPACITY
21.6 GGE (GASOLINE GALLON EQUIVALENT)
CNG TANK TEMPERATURE RATING
BETWEEN -40 AND 180 DEGREES F / -40 TO 82 DEGREES C
AIR CONDITIONER
MANUFACTURER
EVANS TEMPCON
SYSTEM CAPACITY
28 OUNCES OF R134A REFRIGERANT
AXLE/DIFFERENTIAL
REAR SUSPENSION TYPE
DE DION TUBE REAR SUSPENSION
REAR DIFFERENTIAL
MANUFACTURER
AMERICAN AXLE
AXLE RATIO
3.45:1
REAR HALF SHAFTS
GKN
REAR AXLE FLUID CAPACITY
1.1 QUARTS (1 LITER)
REAR AXLE FLUID TYPE
75W90 SYNTHETIC AXLE LUBRICANT WITH LIMITED SLIP ADDITIVE
7
ALTERNATOR & BATTERY
BATTERY TYPE
EXIDE 12 VOLT
COLD CRANKING AMP RATING
(CCA)
750 AMPS @ 0 DEGREES FAHRENHEIT / -17 DEGREES CELSIUS
COLD CRANKING AMP RATING
(CCA)
850 AMPS @ 32 DEGREES FAHRENHEIT / 0 DEGREES CELSIUS
RESERVE
174.5 MINUTES
ALTERNATOR MANUFACTURER
DENSO
ALTERNATOR OUTPUT
134 AMPS AT 1800 RPM AT 32 DEGREES FAHRENHEIT / 0 CELSIUS
SUPPLIER / MANUFACTURER
GLOBAL AUTOMOTIVE
TYPE
WELDED STEEL BOX SECTION
WELDED CROSS MEMBERS
6
BOLTED CROSS MEMBERS
2
FRAME
BRAKE SYSTEM
Service Brake Caliper (Front)
BWI
CALIPER TYPE
SINGLE PISTON HYDRAULIC
CALIPER DESIGN
CAST IRON HOUSING WITH ALUMINUM PISTON
Service Brake Rotor (Front)
BWI
DIAMETER
NOMINAL THICKNESS
MINIMUM THICKNESS (DISCARD)
8
Service Brake Caliper (Rear)
BWI
CALIPER TYPE
SINGLE PISTON HYDRAULIC WITH INTEGRAL PARKING BRAKE
CALIPER DESIGN
CAST IRON HOUSING WITH ALUMINUM PISTON (41.3 MM)
Service Brake Rotor (Rear)
BWI
DIAMETER
NOMINAL THICKNESS
MINIMUM THICKNESS
Master Cylinder and Brake System Capacities
BRAKE FLUID TYPE
DOT 3 BRAKE FLUID
MASTER CYLINDER CAPACITY
16.4 OUNCES (481.9 MILLILITERS)
TOTAL BRAKE SYSTEM CAPACITY
1.09 QUARTS (1.03 LITERS)
STEERING SYSTEM
POWER STEERING PUMP
TRW HYDRAULIC PUMP
STEERING GEAR
TRW HYDRAULIC RACK AND PINION
C FACTOR
2.141 INCH / 54.4 MM LINEAR TRAVEL PER STEERING WHEEL
REVOLUTION
STEERING FLUID CAPACITY
15.0 OUNCES (440 MILLILITERS)
STEERING FLUID TYPE
MERCON® 5 POWER STEERING FLUID
TRANSMISSION
FORD MOTOR COMPANY
MODEL
4R75E FOUR SPEED AUTOMATIC WITH OVERDRIVE
FLUID TYPE
MERCON® LV TRANSMISSION FLUID
TRANSMISSION FLUID CAPACITY
13.9 QUARTS (13.2 LITERS)
9
WHEELS AND TIRES
TIRE SUPPLIER / MANUFACTURER
CONTINENTAL TIRE
SIZE & RATING
P235/65R17 108 LD
OPERATING PRESSURE
41 PSI / 253 KPA
WHEEL SUPPLIER /
MANUFACTURER
HAYES – LEMMERZ
WHEEL SIZE
17 X 6.5 INCHES (STEEL WHEEL)
WHEEL MOUNTING
SIX (6) M12 STUDS ON A 115MM DIAMETER MOUNTING CIRCLE
WHEEL OFFSET
52MM OUTBOARD FROM CENTER LINE OF WHEEL
VEHICLE PAYLOAD
CNG VEHICLE PAYLOAD
1350 POUNDS (613.35 KILOGRAMS)
GASOLINE VEHICLE PAYLOAD
1545 POUNDS (700.80 KILOGRAMS)
10
OVERALL VEHICLE DIMENSIONS - STANDARD MEASUREMENT SPEC SHEET
G2
I1
H
I2
G1
D
K
E
SPEQ-038
Wheelbase:
Length:
Height:
Width:
Turning Circle:
Access Door Useable Width:
Access Door Useable Height:
Interior Height, Rear Wheelchair Position:
Interior Height, Forward Wheelchair Position:
Overall Interior Floor Length:
Interior Width at B-Pillars:
Vehicle Ground Clearance (minimum):
Ramp Extension – Short Deployment:
Ramp Extension – Long Deployment:
Useable Ramp Width:
Ramp Angle – Short Deployment (Manual):
Ramp Angle – Short Deployment (Power):
Ramp Angle – Long Deployment:
Track:
Head Room:
Hip Room:
Leg Room:
Shoulder Room:
Cargo Volume Index:
Curb Weight:
Gross Vehicle Weight Rating (GVWR)
Gross Axle Weight Rating Front (GAWR Front)
Gross Axle Weight Rating Rear (GAWR Rear)
11
A
B
C1
C2
D
E
F
G1
G2
H
I1
I1
I2
Front & Rear
Front / Rear
Front / Rear
Front / Rear
Front / Rear
122 in.
205 in.
75 in.
79.4 in.
42.8 ft.
36 in.
56 in.
59.5 in.
58.3 in.
81.5 in.
64.5 in.
6 in.
52.5 in.
87 in.
30 in.
1:4.1 ratio
1:4.4 ratio
1:6 ratio
68.3 in.
41.7/41.9 in.
63/63.8 in.
42/46 in.
64.7/ 62.4 in.
3099 mm
5207 mm
1905 mm
2017 mm
13045 mm
914 mm
1422 mm
1511 mm
1481 mm
2070 mm
1638 mm
152 mm
1334 mm
2210 mm
762 mm
Gasoline
36.4 ft3
1031 liters
CNG
Gasoline
CNG
3
K
29.1 ft
5055 lbs.
5250 lbs.
6600 lbs.
3600 lbs.
3600 lbs.
1735 mm
1059/1064 mm
1600/1621 mm
1067/1168 mm
1643/1585 mm
824 liters
2293 kg
2381 kg
2994 kg
1633 kg
1633 kg
SPEQ-001
REAR WHEEL
OPENING WIDTH:
36.1” (917mm)
BODY TO GROUND
CLEARANCE:
6” (152.4mm)
REAR WHEEL OPENING
TO GROUND HEIGHT:
34.8” +/-0.5”
(885mm +/-12mm)
DIMENSION IS
AVERAGE FRONT
TO REAR
DIMESIONS WITHOUT
WHEEL LINER INSTALLED
LX
78” +/-0.5”
(1982mm +/-12mm)
FRONT WHEEL
OPENING WIDTH:
35” (889mm)
FRONT WHEEL OPENING
TO GROUND HEIGHT:
34.5” +/-0.5”
(875mm +/-12mm)
DIMESIONS WITHOUT
WHEEL LINER INSTALLED
12
OVERALL VEHICLE
HEIGHT TO GROUND:
STD
77” +/-0.5”
(1958mm +/-12mm)
ROOF BOW LOCATIONS
18.5”
(471mm)
37.4”
(950mm)
25.4”
(644mm)
SPEQ-002
CENTER OF GRAVITY SIDE VIEW
CENTER OF
GRAVITY
SPEQ-003
13
CENTER OF GRAVITY TOP VIEW
CENTER OF
GRAVITY
SPEQ-004
CLOSE UP OF CENTER OF GRAVITY
CENTER OF GRAVITY LOCATED
7.4” (188mm) ABOVE THE FLOOR,
34.9” (887mm) FORWARD OF THE
THIRD ROW SEAT PANEL
1.2” (31mm) LEFT OF THE CENTER
LINE OF THE VEHICLE
CENTER OF
GRAVITY
SPEQ-005
14
CENTER OF GRAVITY DIMENSIONAL VIEW
CENTER OF GRAVITY LOCATED
7.4” (188mm) ABOVE THE FLOOR,
34.9” (887mm) FORWARD OF THE
THIRD ROW SEAT PANEL
1.2” (31mm) LEFT OF THE CENTER
LINE OF THE VEHICLE
CENTER OF
GRAVITY
SPEQ-005
DRIVER’S SEAT “H-POINT” DIMENSIONAL VIEW
A
B
SPEQ-007
A - (DISTANCE TO DRIVER’S FALSE FLOOR) = 17” (434mm)
B - (DISTANCE TO B-PILLAR TRIM) = 3.4” (86mm)
CENTER OF DRIVER IS 19.2” (488mm) FROM C/L OF VEHICLE
MEASUREMENTS ARE TAKEN WITH THE
SEAT MID WAY BETWEEN UP AND DOWN,
AND 2” (50mm) FORWARD OF FULL REAR
SPEQ-006
15
FACTORY-INSTALLED JUMP SEAT “H-POINT” DIMENSIONAL VIEW
A
B
SPEQ-008
A - (DISTANCE TO THE REAR EDGE OF B-PILLAR TRIM) = 12.7” (323mm)
B - (DISTANCE TO THE RAMP FLOOR SURFACE) = 20.1” (511mm)
CENTER OF SECOND ROW OCCUPANT IS 19.2” (488mm) FROM C/L OF VEHICLE
THIRD ROW BENCH SEAT “H-POINT” DIMENSIONAL VIEW
B
A
SPEQ-009
A - (DISTANCE TO RAMP FLOOR SURFACE) = 21.1” (537mm)
B - (DISTANCE TO LEADING EDGE OF C-PILLAR TRIM) = 10.1” (257mm)
CENTER OF THIRD ROW SEAT OUTBOARD OCCUPANTS IS 20” (510mm)
FROM C/L OF VEHICLE. CENTER OF CENTER OCCUPANT IS ON THE
C/L OF VEHICLE.
16
VEHICLE MASS AND DISTRIBUTION
THE FOLLOWING CHART IDENTIFIES THE AVERAGE WEIGHTS MEASURED ON THE MV-1. MASS WAS CALCULATED AT
CURB WEIGHT (FULL FUEL TANK(S), ALL FLUIDS TOPPED, NO PASSENGERS)
MV-1 CNG VEHICLE
LEFT FRONT MASS
1412.875 POUNDS (640.869 KILOGRAMS)
RIGHT FRONT MASS
LEFT REAR MASS
RIGHT REAR MASS
TOTAL MASS
MV-1 GASOLINE VEHICLE
LEFT FRONT MASS
RIGHT FRONT MASS
LEFT REAR MASS
RIGHT REAR MASS
TOTAL MASS
17
CHASSIS SPECIFICATIONS
SUSPENSION & BRAKE INFORMATION
FRONT SUSPENSION
FRONT SUSPENSION TYPE
SLA INDEPENDENT FRONT SUSPENSION
FRONT SPRING TYPE
COIL
FRONT ABSORBER STYLE
STANDARD HYDRAULIC SHOCK ABSORBER
STEERING GEAR TYPE
RACK AND PINION
REAR SUSPENSION
REAR SUSPENSION TYPE
DE DION REAR TUBE SUSPENSION
LEVEL CONTROL
AIR ASSISTED REAR SHOCKS WITH AUTOMATIC LEVEL CONTROL (ALC)
REAR SPRING TYPE
REAR STEEL LEAF SPRINGS
REAR AXLE TYPE
INDEPENDENT REAR AXLE SHAFTS
BRAKE SYSTEM
BRAKE LAYOUT
4 WHEEL DISC BRAKES
SAFETY EQUIPMENT
ANTI-LOCK BRAKES (ABS), STABILITY CONTROL, TRACTION CONTROL, DYNAMIC
REAR PROPORTIONING SYSTEM
18
FRAME & CHASSIS DIMENSIONS
CNG Chassis Top View with Body Mount Measurements
BODY MOUNT A
BODY MOUNT B
BODY MOUNT C
BODY MOUNT D
BODY MOUNT E
FRONT OF
VEHICLE
LENGTH FROM
FRONT MOST
POINT OF FRONT
BUMPER
WIDTH TO
CENTER LINE
OF VEHICLE
HEIGHT TO
GROUND
(OF COMPLETE
VEHICLE)
13.7”
(348mm)
58.6”
(1488mm)
93.1”
(2366mm)
128”
(3250mm)
177.3”
(4503mm)
25”
(634mm)
26.4”
(670mm)
29.5”
(750mm)
29.6”
(753mm)
27.8”
(705mm)
20.9”
(531mm)
11.7”
(298mm)
11.2”
(285mm)
9”
(229mm)
23.8”
(604mm)
A
B
C
D
E
SPEQ-010
BODY MOUNT LOCATIONS
L=LENGTH FROM FRONT, W=WIDTH TO CENTER
LINE, AND H=HEIGHT TO GROUND.
A
L=503MM, W=634MM, H=795MM
B
L=1643MM, W=670MM, H=558MM
C
L=2520MM, W=750MM, H=542MM
D
L=3405MM, W=752MM, H=484MM
E
L=4657MM, W=704MM, H=854MM
19
CNG Chassis Side View with Overall Frame Height
SPEQ-011
14”
(356mm)
DIMENSIONS FROM THE LOWEST POINT OF FRAME RAIL TO THE
HIGHEST POINT OF THE FRAME RAIL AT THE FRONT AND REAR
17.6”
(436mm)
CNG Chassis Front View with Wheel Mounting Surface Cross Car Measurement
72.6”
(1844mm)
SPEQ-012
MEASURED FROM FRONT
WHEEL MOUNTING SURFACE
20
CNG Chassis Rear View with Wheel Mounting Surface Cross Car Measurement
SPEQ-013
72.2”
(1833mm)
MEASURED FROM REAR
WHEEL MOUNTING SURFACE
21
46.4”
(1178mm)
54.4”
(1381mm)
37.4”
(950mm)
FRONT OF
VEHICLE
198”
(5030mm)
SPEQ-014
Gasoline Chassis Top View with Dimensions
FRAME WIDTH DIMENSIONS
DIMENSION A AT THE FRONT SECTION
950MM
DIMENSION B AT THE CENTER SECTION
1381.5MM
DIMENSION C AT THE REAR SECTION
1178MM
OVERALL LENGTH BUMPER TO BUMPER
5022MM
Gasoline Chassis Side View
SPEQ-015
22
BODY SPECIFICATIONS
INTERIOR DIMENSIONS
Reference Diagram
THE FOLLOWING DIAGRAMS ARE BASED ON THIS ILLUSTRATION SHOWING WHERE THE VIRTUAL CUTS WERE MADE IN
THE BODY. PLEASE SEE RELATED DIAGRAMS TO FOLLOW WITH DIMENSIONS TAKEN AT EACH POINT.
A PILLAR
SECTION
B PILLAR
SECTION
C PILLAR
SECTION
SPEQ-016
23
A-Pillar Section
A PILLAR SECTION
MEASUREMENT TAKEN
FROM THE CENTER OF
THIS ARC TO THE CENTER
OF THE SAME ARC ON THE
OTHER SIDE
63”
(1601mm)
67.3”
(1709mm)
MEASUREMENT TAKEN
FROM THE CENTER OF
THIS ARC TO THE CENTER
OF THE SAME ARC ON THE
OTHER SIDE
SPEQ-043
CONVERSIONS
MILLIMETERS
INCHES
1560
61.417
1621
63.819
24
B-Pillar Section
B PILLAR SECTION
MEASUREMENT TAKEN
FROM THE CORNER OF
THIS SLOT TO THE CORNER
OF THE SAME SLOT ON THE
OTHER SIDE
58.2”
(1477mm)
66.7”
(1693mm)
MEASUREMENT TAKEN
FROM THE CENTER OF
THIS SLOT TO THE CENTER
OF THE SAME SLOT ON
THE OTHER SIDE
66.6”
(1691mm)
MEASUREMENT TAKEN
FROM THE CENTER OF
THIS HOLE TO THE CENTER
OF THE SAME HOLE ON THE
OTHER SIDE
SPEQ-044
CONVERSIONS
MILLIMETERS
INCHES
1416
55.748
1615
63.583
1552
61.102
25
C-Pillar Section
C PILLAR SECTION
MEASUREMENT TAKEN
FROM THE CENTER OF
THIS HOLE TO THE CENTER
OF THE SAME HOLE ON THE
OTHER SIDE
MEASUREMENT TAKEN
FROM THE BOTTOM EDGE
OF THIS SLOT TO THE
BOTTOM EDGE OF THE
SAME SLOT ON THE
OTHER SIDE
57.9”
(1472mm)
68.3”
(1736mm)
68.7”
(1745mm)
MEASUREMENT TAKEN
FROM THIS SURFACE TO
THE SAME SURFACE ON THE
OTHER SIDE
SPEQ-045
CONVERSIONS
MILLIMETERS
INCHES
1387
54.606
1603
63.110
1602
63.071
26
Liftgate Opening
MEASUREMENT TAKEN
FROM THIS HORIZONTAL
SURFACE
MEASUREMENT TAKEN
FROM THIS EDGE TO
THE SAME EDGE ON
THE OTHER SIDE
42.4”
(1076 mm)
42.7”
(1084mm)
47.3”
(1202mm)
MEASUREMENT TAKEN
FROM THIS HORIZONTAL
SURFACE
MEASUREMENT TAKEN
FROM THIS SURFACE TO
THE SAME SURFACE ON
THE OTHER SIDE
SPEQ-017
CONVERSIONS
MILLIMETERS
INCHES
1018
40.079
1203
47.362
1150
45.276
27
Center Cut Body Side – CNG
MEASURED FROM THE
MIDDLE OF THE C-PILLAR
ROOF BOW, VERTICALLY
TO THE FLOOR (WITHOUT
RAMP MODULE)
MEASURED FROM THE
MIDDLE OF THE B-PILLAR
TO THE FLOOR
MEASURED FROM THIS
EDGE OF THE FRONT
TO THE TRANSMISSION
HUMP
34.3”
(872mm)
49.4”
(1255mm)
60.1”
(1526mm)
62.9”
(1597mm)
MEASURED FROM THE
CNG TANK ACCESS COVER
SPEQ-047
28
MEASURED FROM THIS
HORIZONTAL SURFACE OF
THE REAR ROOF BOW
Center Cut Body Side – Gasoline
MEASURED FROM THE
MIDDLE OF THE B-PILLAR
TO THE FLOOR
MEASURED FROM THE
MIDDLE OF THE C-PILLAR
TO THE FLOOR (WITHOUT
RAMP MODULE)
MEASURED FROM THIS
EDGE OF THE FRONT
TO THE TRANSMISSION
HUMP
44.6”
(1134mm)
49.4”
(1255mm)
62.9”
(1597mm)
60.1”
(1526mm)
SPEQ-046
MEASURED FROM THIS
HORIZONTAL SURFACE OF
THE REAR ROOF BOW
VERTICALLY TO THE FLOOR
CONVERSIONS
MILLIMETERS
INCHES
1307
51.457
1436
56.536
1631
64.213
872
34.331
29
Floor Dimensions with Jump Seat
A = JUMP SEAT IN DOWN POSITION 12” (305mm)
B = JUMP SEAT IN STOWED POSITION 24.4” (620mm)
A
B
SPEQ-018
48”
(1220mm)
48.6”
(1235mm)
68.3”
(1734mm)
44.4”
(1127mm)
25.8”
(665mm)
SPEQ-019
MEASUREMENTS TAKEN
AT Q-STRAINT
MEASUREMENT TAKEN
FROM A POWER RAMP
30
CONVERSIONS
MILLIMETERS
INCHES
325
12.795
635
25.000
1240
48.819
1211
47.677
1709
67.283
1115
43.898
661
26.024
Floor Dimensions without Jump Seat
40.7” (1035mm) SEAT FORWARD
32.7” (830mm) SEAT BACK
SPEQ-020
CONVERSIONS
MILLIMETERS
INCHES
956
37.638
1155
45.472
31
DRIVER’S SEAT MOUNTING CONFIGURATION
Top View of Front Floor at Driver’s Seat
SEAT ATTACHMENT
STUDS - M10 x 40
SEAT ATTACHMENT
BOLTS - M10 x 45
13.8”
(350mm)
15.7”
(400mm)
SPEQ-021
32
SEAT ATTACHMENT
STUDS - M10 x 40
SEAT ATTACHMENT
BOLTS - M10 x 45
13.8”
(350mm)
15.7”
(400mm)
SPEQ-021
CONVERSIONS
350MM
13.779 INCHES
400MM
15.748 INCHES
33
Side View of Front Floor
CONVERSION - 124MM = 4.882 INCHES.
4.9”
(124mm)
SPEQ-023
Module Identification and Location Under Driver’s Seat
CAUTION: Be aware of all module
locations and do not alter their
configuration.
REASON: Any modifications to
location or fluid protection can result
in module failure.
RCM MODULE
ABC MODULE
YAW-LAT SENSOR
RCM = Restraint Control Module / Air Bag
SPEQ-024
ABC = Auxiliary Body Controller / Primary Ramp Control
Yaw/Lat Sensor = Data for Traction/ Stability Control
34
INTERIOR RESTRICTIONS AND SAFETY PRECAUTIONS
AT NO TIME SHOULD THE FLOOR SHEET METAL BE ALTERED, DRILLED, SCREWED IN TO, OR OTHERWISE
COMPROMISED AROUND THE AREA WHERE THE FUEL TANK(S) ARE HOUSED. THIS IS TRUE FOR BOTH THE CNG
POWERED MV-1 AS WELL AS THE GASOLINE MODEL. ANY SCREW POINT PENETRATING THE SHEET METAL LEAVES THE
VEHICLE VULNERABLE FOR A POSSIBLE FUEL LEAK IN THE EVENT OF AN IMPACT.
WARNING
ALWAYS be aware of fuel tank mounting and
fuel line routing when considering rear
compartment installations. NEVER alter the
sheet metal surrounding the CNG or gasoline
fuel tanks, and DO NOT drill into sheet metal.
REASON: Altering or drilling into the sheet
metal can create a safety hazard and may result
in tank damage.
SPEQ-025
ALSO USE CAUTION WHEN CONSIDERING FLOOR MOUNTED ITEMS. THE FLOORING BETWEEN THE B-PILLAR AND THE
C-PILLAR IS ALL PART OF THE RAMP CARTRIDGE AND PENETRATING THE FLOOR MAY RESULT IN IMPROPER RAMP
OPERATION AND/OR DAMAGE. DO NOT DRILL INTO THIS SECTION OF THE INTERIOR FLOOR.
35
CAUTION: DO NOT drill
into the top of the ramp
flooring.
REASON:
The
ramp and/
MV-1 Special
Applications
Guide
MAIN WIRING
HARNESS
FLOOR ACCESS
CAPS
Q-STRAINT
TRIM CAPS
FRONT CAM
Q-STRAINT
TRACK
JUMPER
HARNESS
MANUAL
FENCE
FRONT FENCE &
HINGE ASSEMEBLY
MANUAL RAMP
TOOL ACCESS
DOOR EDGE
ROLLER
FRAME
THRESHOLD
REAR CAM
CAUTION
TAPE
OUTER RAMP
THRESHOLD
REAR FENCE &
HINGE ASSEMEBLY
OUTER RAMP PLATE WITH
ANTI-SKID MATERIAL
36
SPEQ-048
INSTRUMENT PANEL DIMENSION VIEWS
SPEQ-026
I/P FRONT VIEW
SPEQ-027
I/P LEFT SIDE VIEW
37
SPEQ-028
I/P RIGHT SIDE VIEW
SPEQ-029
I/P REAR VIEW
38
SPEQ-030
DASH PANEL WITH BEAM STRUCTURE
SPEQ-031
39
10.4”
(265mm)
9.8”
(250mm)
7”
(179mm)
20.8”
(528mm)
SPEQ-039
9.1”
(232mm)
DASH PANEL WITH BEAM STRUCTURE AND CENTER STACK MEASUREMENTS
A
WIDTH ACROSS TOP OF BRACKET = 250MM
B
WIDTH ACROSS CENTER OF BRACKET = 265MM
C
WIDTH ACROSS BOTTOM OF BRACKET = 232MM
D
HEIGHT OF TOP OF BRACKET = 179MM
E
BRACKET HEIGHT TO THE NORMAL SURFACE OF THE FLOOR STRUCTURE =
518MM
40
EXTERIOR BODY PANEL DIMENSIONS
Fenders and Quarter Panels
A
D
B
E
C
F
A
FENDER HEIGHT AT WHEEL OPENING
B
FENDER LENGTH
C
QUARTER PANEL LENGTH AT FEATURE LINE
D
WHEEL OPENING TO TOP OF ROOF
E
TOP OF ROOF TO FASCIA MATING SURFACE
F
BUMPER TO BUMPER LENGTH
14.9”
(378mm)
45.4”
(1153)
54.1”
(1375mm)
41.1”
(1044mm)
49.2”
(1249mm)
205”
(5207mm)
SPEQ-032
DIMENSION “E” IS MEASURED
TO THIS SURFACE
CHART
CODE
MEASUREMENT
METRIC
ENGLISH
A
371MM
14.6 IN.
B
FENDER LENGTH
1054 MM
41.5 IN.
C
1409 MM
55.5 IN.
D
462 MM
18.2 IN.
E
1245 MM
49 IN.
41
Overall Body Measurement
A
D
B
E
C
F
A
B
FENDER LENGTH
C
D
E
F
BUMPER TO BUMPER LENGTH
14.9”
(378mm)
45.4”
(1153)
54.1”
(1375mm)
41.1”
(1044mm)
49.2”
(1249mm)
205”
(5207mm)
SPEQ-032
DIMENSION “E” IS MEASURED
TO THIS SURFACE
42
Front Door Outer Panel Dimensions
62.8”
(1595mm)
40.6”
(1030mm)
36.6”
(930mm)
SPEQ-033
CHART
CODE
MEASUREMENT
METRIC
ENGLISH
A
FRONT DOOR OVERALL HEIGHT
1589 MM
62.5 IN.
B
FRONT DOOR HEIGHT AT BELT LINE
1012 MM
39.84 IN.
C
FRONT DOOR LENGTH
927 MM
36.5 IN.
Rear Door Outer Panel Dimensions
62.6”
(1589mm)
40.8”
(1037mm)
SPEQ-034
42.1”
(1070mm)
CHART
CODE
MEASUREMENT
METRIC
ENGLISH
A
REAR DOOR OVERALL HEIGHT
1586 MM
62.4 IN.
B
REAR DOOR HEIGHT AT BELT LINE
1005 MM
39.6 IN.
C
REAR DOOR LENGTH
1102 MM
43.4 IN.
Liftgate Dimensions
43
48.9”
(1242mm)
47.6”
(1208mm)
29”
(736mm)
51.8”
(1317mm)
SPEQ-035
CHART
CODE
MEASUREMENT
METRIC
ENGLISH
A
LIFTGATE WIDTH
1314 MM
51.7 IN.
B
LIFTGATE HEIGHT AT BELT LINE
731 MM
28.8 IN.
C
LIFTGATE OVERALL HEIGHT
1317 MM
52.6 IN.
Hood Dimensions
61.2”
(1555mm)
66.1”
(1680mm)
34.9”
(886mm)
SPEQ-036
CHART
CODE
MEASUREMENT
METRIC
ENGLISH
A
LENGTH OF HOOD AT CENTER LINE
908 MM
35.75 IN.
B
WIDTH OF HOOD ACROSS REAR OF HOOD PANEL
1666 MM
65.6 IN.
C
WIDTH OF HOOD ACROSS FRONT OF HOOD PANEL
1550 MM
61 IN.
44
Roof Dimensions
54.5”
(1382mm)
FRONT OF
VEHICLE
46.1”
(1170mm)
107.3”
(2725mm)
MEASUREMENT TAKEN
ALONG CENTER LINE
OF ROOF
SPEQ-037
CHART
CODE
MEASUREMENT
METRIC
ENGLISH
A
LENGTH OF ROOF AT CENTER LINE OF ROOF PANEL
2668 MM
105 IN.
B
WIDTH OF ROOF ACROSS THE REAR OF ROOF PANEL
1183 MM
45.57 IN.
C
WIDTH OF ROOF ACROSS THE FRONT OF ROOF PANEL
1368 MM
53.86 IN.
45
WIRING HARNESSES – ROUTING AND LOCATION
AUXILIARY POWER OUTLET JUMPER (APOJ) HARNESS
Locator Number
Description
1
APOJ-BD1
2
APOJ1
46
BATTERY HARNESS
Locator Number
Description
1
POS Batt Terminal
2
NEG Batt Terminal
3
BA-UH1
4
Generator BA1
5
Generator battery positive
6
Starter Ground
7
Starter Solenoid
8
Starter B+
9
Chassis Ground
47
BODY HARNESS
Locator Number
Description
1
BD1 Tail lamp
2
APOJ-BD1 Inline
3
BD2 Speaker
4
BD-LG1 Inline
5
BD3 Speaker
6
SS149 Splice saver #149
7
BD4 Tail lamp
8
BD5 Auxiliary power outlet
9
BD-IP1 Inline
48
CARGO LAMP HARNESS
Locator Number
Description
1
CL-HL1 Inline
2
CL1 Cargo lamp
49
CHASSIS HARNESS CNG
Locator Number
Description
1
CH1 RR Wheel speed sensor
2
CH2 RR marker lamp
3
CH3 ALC pump
4
CH14 Shutoff valve tank 3
5
CH4 LR marker lamp
6
7
CH5 ALC module
8
CH6 LR Wheel speed sensor
9
G128 Chassis ground
10
CH7 Fuel pump control module
11
CH16 Pressure sensor tank 1
12
13
CH18 Temp sensor tank 1
14
G121 ABS to chassis ground
50
Locator Number
Description
15
CH19 Pressure regulator
16
CH11 ABS module
17
CH12 LF Wheel speed sensor
18
CH-UH2 Inline
19
CH-UH1 Inline
20
CH13 RF Wheel speed sensor
51
CHASSIS HARNESS GAS
Locator Number
Description
1
CH1 RR Wheel speed sensor
2
CH2 RR marker lamp
3
CH3 ALC compressor
4
CH4 LR marker lamp
5
CH5 ALC module
6
CH6 LR Wheel speed sensor
7
G128 Chassis ground
8
CH7 Fuel pump control module
9
CH8 Evap vent valve
10
CH9 Fuel tank pressure sensor
11
CH10 Fuel pump
12
G121 ABS to chassis ground
13
CH11 ABS module
14
CH12 LF Wheel speed sensor
52
Locator Number
Description
15
CH-UH2 Inline
16
CH-UH1 Inline
17
CH13 RF Wheel speed sensor
53
ENGINE HARNESS
Locator Number
Description
1
EN1 Crankshaft position (CKP) sensor
2
EN2 A/C compressor coil
3
EN3 Radio interference capacitor
4
EN-UH1 Inline
5
EN4 ETC
6
EN5 Fuel injector
7
EN6 COP
8
EN7 Fuel injector
9
EN8 COP
10
EN9 Fuel injector
11
EN10 COP
12
EN11 Fuel injector
54
Locator Number
Description
13
EN12 COP
14
EN13 Pass side UHO2
15
EN14 Knock sensor
16
EN15 Evap canister purge valve
17
EN16 DR side UHO2
18
EN17 PCM
19
EN18 Fuel injector
20
EN19 COP
21
EN20 Fuel injector
22
EN21 COP
23
EN22 Fuel injector
24
EN23 COP
25
EN24 Fuel injector
26
EN25 COP
27
EN26 EGR
28
EN27 CHTS jumper
29
EN28 Radio interference capacitor
30
EN29 Camshaft position (CMP) sensor
31
EN30 Oil pressure switch
32
FIJ1 CNG fuel injector jumper harness
33
FIJ2 CNG fuel injector jumper harness
55
FORWARD LAMP HARNESS
Locator Number
Description
1
FL1 Impact sensor
2
FL2 Horns
3
FL3 Side marker
4
FL4 Park/turn lamp
5
FL5 Head lamp
6
FL-UH1 Inline
7
FL6 Head lamp
8
FL7 Park/turn lamp
9
FL8 Side marker
10
G129 Ground eyelet
11
FL9 Impact sensor
56
HEADLINER HARNESS
Locator Number
Description
1
HL-IP1 Inline
2
HL1 Dome lamp
3
HL2 Dome lamp
4
HL3 Dome lamp
5
HL4 Dome lamp
6
CL-HL1 Inline
57
HVAC HARNESS
Locator Number
Description
1
HV1 Recirculation door actuator
2
HV2 Evaporator thermostat
3
G122 Ground eyelet
4
HV3 Defrost/panel actuator
5
HV4 Blower motor resistor
6
HV5 Blower motor resistor
7
HV6 Blower motor
8
HV7 Defrost/Floor actuator
9
HV-IP1 Inline
58
INSTRUMENT PANEL HARNESS
Locator Number
Description
1
HL-IP1 Inline
2
IP1 RF Speaker
3
IP-RF1 Inline
4
SS114 Splice saver
5
IP-RP2 Inline
6
SS133 Splice saver
7
IP2 Ambient light sensor
8
IP-RR1b Inline
9
IP-RR1a Inline
10
IP3 Auxiliary power outlet (APO) RF
11
IP4 Radio
12
IP5 Lower mux assy
13
IP6 upper mux assy
14
IP7 HVAC control
59
Locator Number
Description
15
IP8 Instrument panel cluster (IPC)
16
IP9 Auxiliary power outlet (APO) LF
17
IP10 LF Speaker
18
IP11 Passive anti theft system (PATS)
19
IP12 Multifunction switch
20
IP13 Clockspring
21
IP14 Ignition switch
22
IP15 Dimmer switch backlighting
23
IP16 Headlamp switch
24
IP17 Auxiliary body control (ABC) module
25
26
IP19 Power seat elevation switch
27
28
29
IP22 Yaw/Lat Sensor
30
IP23 Drivers seat belt switch
31
G116 Body ground
32
IP-RP1 Inline
33
IP-LR1a Inline
34
IP-LR1b Inline
35
IP24 Drivers seat belt pretensioner
36
IP25 Restraint control module (RCM)
37
IP26 Restraint control module (RCM)
38
IP-LF1 Inline
39
IP27 Auxiliary power outlet (APO)
40
IP28 Park brake switch
41
IP29 Data link connector (DLC)
42
IP-UH1 Inline
43
IP-SC1 Inline
44
IP30 Steering angle sensor
45
IP31 Smart junction box (SJB)
46
60
Locator Number
Description
47
48
49
HV-IP1 Inline
50
BD-IP1 Inline
61
LIFTGATE HARNESS/LIFTGATE BEZEL JUMPER HARNESS
Liftgate Harness
Locator Number
Description
1
BD-LG1
2
LG1 Heated back glass
3
LG2 Heated back glass
4
LG3 Wiper motor
5
LG4 CHMSL
6
LG5 Liftgate latch actuator
7
LG6 Liftgate latch ajar switch
8
LBJ-LG1 Inline
Liftgate Bezel Jumper Harness
Locator Number
Description
9
LBJ-LG1 Inline
10
LBJ1 liftgate release switch
62
POWER RAMP HARNESS
Locator Number
Description
1
IP-RP1 Inline
2
RP2 Ramp motor
3
RP3 Ramp position switch
63
RAMP ACTUATOR HARNESS
Locator Number
Description
1
IP-RP2 Inline
2
RP1 Short deploy actuator
64
STEERING COLUMN HARNESS
Locator Number
Description
1
SC1 Brake shift interlock
2
SC2 Overdrive off switch
3
IP-SC1 Inline
65
TRANSMISSION HARNESS
Locator Number
Description
1
TR-UH1 Inline
2
TR1 Trans
3
TR2 O2 Sensor
4
TR3 O2 Sensor
5
TR4 OSS
6
TR5 Range sensor
7
TR6 TSS
8
TR7 PCM
66
UNDERHOOD HARNESS
Locator Number
Description
1
UH1 Washer pump
2
UH2 Smart junction box
3
4
5
UH5 APP Sensor
6
UH6 brake on/off switch (BOO)
7
UH7 Front wiper motor
8
IP-UH1 Inline
9
FL-UH1 Inline
10
UH8 PCM
11
TR-UH1 Inline
12
CH-UH2 Inline
13
CH-UH1 Inline
14
UH9 MAF
15
UH10 Cooling fan motor 1
67
Locator Number
Description
16
UH11 Cooling fan motor 2
17
G120,G123 Chassis Ground
18
UH12 A/C pressure sensor
19
UH13 Battery POS to fuse links
20
BA-UH1 Inline
21
UH16 CNG IPT sensor (*CNG)
22
UH14 Water temp valve
23
EN-UH1 Inline
24
UH17 EGR Valve (*CNG)
25
EN26-UH inline to EGR connector (*CNG)
26
UH15 Brake fluid level switch
68

Special Applications Guide - Service || MV-1

Transcription

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