Conversion Guideline Opel Movano [ X62 ] Part 4 - Chapter 101-151 Edition: November 2012 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany
OPEL MOVANO (X62) CONTENTS Conversion Guideline - Part 4 CHAPTER DESCRIPTION: PAGE 101 POSITION OF ELECTRICAL GROUNDS 4 102 BATTERY LOCATION 9 103 ELECTRICAL CURRENTS AVAILABLE 10 104 * 6 PIN CONNECTOR FOR CONVERSIONS, “KPD” OPTION 12 105 * CAN BUS INTERFACE MODULE, “KC6” OPTION 18 106 CELL WIRING CONNECTION 27 107 ELECTRICAL CONNECTIONS 33 109 +12 V CURRENT DISTRIBUTION 35 110 ENGINE RUNNING INFORMATION 37 111 ACCELERATED IDLE, “UF3” OPTION 38 112 PARKING BRAKE INFORMAT
OPEL MOVANO (X62) CONTENTS Conversion Guideline - Part 4 CHAPTER DESCRIPTION: PAGE RECONSTRUCTING OPENING PANEL FUNCTIONS 77 135 REMOTE ENGINE START AND STOP 87 137 DEACTIVATION OF AIRBAGS AND SEAT BELT PRETENSIONERS 89 139 CONNECTION TO THE NEGATIVE BATTERY TERMINAL 90 140 CONNECTION TO THE POSITIVE BATTERY TERMINAL 92 141 ROUTING AIRBAG AND PRE-TENSIONER WIRING 96 98 133 * 149 * WIRING PRE-FIT FOR TRABUS 150 * ADDITIONAL LOCK WITH 3-BUTTON KEY 108 151 * STOP & START 111 *
OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS The vehicle has several electrical and electronic grounds. Before working on the vehicle, refer to chapter 107 “Electrical Connections”. The electricity sheets of the General Technical Conversion Guide must also be consulted before any modifications are made to the vehicle. An electrical ground, on a welded stud, is recommended for each additional piece of electrical equipment.
OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON DASHBOARD CROSS MEMBER 2 3 1 3 1: Ground MAM-32 2: Ground MAN-32 3: Do not use 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).
OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS IN THE ENGINE COMPARTMENT 4 1 2 3 1: Ground MW-32 2: Ground MAJ-12 3: Ground MAS-32 4: Do not use 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).
OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON THE PANEL VAN EXTREME REAR PILLAR 1 2 1: Ground MGA-7 2: Do not use 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).
OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON THE CHASSIS 1 2 1 2 1: Ground MAE 2: Do not use 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).
OPEL MOVANO (X62) 102 – BATTERY LOCATION The battery is located in the left-hand side door sill. To get to the battery, the plastic door sill trim needs to be removed. The battery is an L6 110 Ah battery. BATTERY LOCATION To connect anything to the battery, please refer to the “Connection to the positive battery terminal” and “Connection to the negative battery terminal” sheets. Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 103 – ELECTRICAL CURRENTS AVAILABLE The tables below show the different electrical currents available (in amps) depending on engine type and options. The vehicles come with a 110 Ah battery and a 180 A alternator. Warning: The value given is the worst-case-scenario average value available when the engine is running. The electrical equipment added is given priority over the vehicle’s basic additional electric heating (thermoplunger) and may thus jeopardise the vehicle’s comfort level.
OPEL MOVANO (X62) 103 – ELECTRICAL CURRENTS AVAILABLE CURRENTS AVAILABLE FOR REAR WHEEL DRIVE VERSIONS M9T (74 kW) Base CA M9T (92 kW) M9T (107 kW) Without accelerated idle 900 1000 1100 1200 DRL* 60 74 86 91 96 100 Without DRL* 72 87 99 104 108 113 Version Engine Base CA Base CA With accelerated idle (rpm) 1300 DRL* 60 74 86 91 96 100 Without DRL* 72 87 99 104 108 113 DRL* 60 74 86 91 96 100 Without DRL* 72 87 99 104 108 113 DRL* 60 74 86 91 96
OPEL MOVANO (X62) 104 – 6 PIN -CONNECTOR FOR CONVERSIONS, OPTION KPD This option is used to provide various electrical supply circuits including “engine running” information required for any added component using electrical power.
OPEL MOVANO (X62) 104 – 6 PIN -CONNECTOR FOR CONVERSIONS, OPTION KPD ASSIGNMENT OF 6 WAY-CONNECTOR Way number Assignment Way 1 (3ADJ) Accelerated idle control (wire cross section 0.5 mm²) Way 2 (BMT1) Way 3 (SBP4) Way 4 (MAN32) “Engine running” information Shared 10 A fuse Power supply + 12 V offloaded current (wire cross section 1 mm²) distribution Ground (wire cross section 1.
OPEL MOVANO (X62) 104 – 6 PIN -CONNECTOR FOR CONVERSIONS, OPTION KPD Fuse position for 6-way connector Power fuse F28 is located in the passenger compartment relay/fuse box (see chapter 118). Fuse F28 (10 Ampere) Relay position for the Option KPD The relay box for the KPD option is located in the right-hand side of the dashboard.
OPEL MOVANO (X62) 104 – 6 PIN -CONNECTOR FOR CONVERSIONS, OPTION KPD 2. The 2 way-connector in the B pillar The connector is located in the right-hand B pillar behind the plastic trim. This connector is identical to that which is described in Chapter 106th for the ‘WRF” option. There also the access to the connectors on the B-pillar is described. The maximum permanent current of this power supply must not exceed 40 A. This line is protected by 50A fuse F6 in the engine compartment interconnections unit.
OPEL MOVANO (X62) 104 – 6 PIN -CONNECTOR FOR CONVERSIONS, OPTION KPD Location of the 2-way connector fuse For further information see sheet 117-Engine Compartment Interconnections Unit. Fuse F6 (50A) Location of grounds associated with the “KPD” option The grounds (MAN32-A and MAN32-B) for the 6-way and 2-way connectors are grouped together on a single stud on the right-hand support of the dashboard cross member. GROUNDS MAN32-A MAN32-B Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 104 – 6 PIN -CONNECTOR FOR CONVERSIONS, OPTION KPD 3. Activation of the accelerated idle To activate the accelerated idle speed, way 1 of the 6-way connector must be grounded. EXAMPLE OF CONNECTION (ACCESSORY CONTROL) + 12V ACC A C D E 1 4 2 5 3 B A: +12 V accessory relay power supply B: Accessory control of the accelerated idle C: Way 1 of the 6-way connector D: Switch E: Relay with a freewheel diode N.B.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION It is an option for Converters. There is a need for this option mainly on following conversions: Camping-cars, emergency cars, integrated equipments as workshop vans or (nacelle) cranes/aerial platforms, refrigerated or vending vans. The electronic box transforms the CAN information into many signals useful for equipments which needs this information to work in relation with the car status.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION To recover the information from the interface module, the connection kit (part number 95514469 ) needs to be obtained (harness length: 600 mm). CONNECTION KIT For left-hand drive, the connection requires the storage box to be removed. N.B.: To make sure that each wire in the connection kit is correctly assigned, it is advisable to check the electrical continuity of the wiring before connection.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION Attention: If the vehicle is equipped with a digital tachograph, then pin 12 and pin 24 is not available at the 24-Pin connector (of the CAN-BUS Interfacemodul). All others information are still available.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION Description of unit input and output From these fields present at the entry to the CAN1, the unit can deliver 3 types of output data. 1) on the Bus CAN2 via 2 Fields: ADAP base 1 and ADAP base 2. 2) 8 binary outputs for relay controls 3) 2 PWM outputs (compatible with instrument panel): engine speed and vehicle speed +12V Batt.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION Name of Field: ADAP Base 1 Size (bits) Name Engine RPM 16 Driver request 8 Engine coolant Temp 8 Fuel consumption 8 Vehicle speed 16 MSB position LSB position Byte no. 1 – Bit no. 7 Byte no. 3 – Bit no. 7 Byte no. 4 – Bit no. 7 Byte no. 5 – Bit no. 7 Byte no. 6 – Bit no. 7 Byte no. 2 – Bit no. 0 Byte no. 3 – Bit no. 0 Byte no. 4 – Bit no. 0 Byte no. 5 – Bit no. 0 Byte no. 7 – Bit no.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION Name of Field: ADAP Base 2 Size (bits) Description Flashing Indicators (right/ left ) Hazard Light 1 1 ****fixed to zero**** 7 MSB position Byte no. 1 – Bit no. 0 Byte no. 2 – Bit no. 7 Byte no. 1 – Bit no.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION GENERIC DIAGRAM OF RELAY CONTROL BY BINARY OUTPUT D B F 1 2 A A: B: C: D: E: F: C 4 5 3 B E Complementary Adaptations Unit Dry contact output for information recovery Binary output to be relayed on the Complementary Adaptations Unit. The relay’s power supply must not be taken directly from the + battery.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION 8-WAY CONNECTOR Pin Description (+) Battery K line CAN L1 CAN H1 Ground Ground Ground Ground 1 2 3 4 5 6 7 8 24-WAY CONNECTOR Track No.
OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION Dimension: 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).
OPEL MOVANO (X62) 106 – CELL WIRING CONNECTION OPTION WRF Before working on the vehicle, refer to the chapter 107 “Electrical Connections”. This option WRF, which is available for the chassis cab and the platform cab, provides 2 stand-by connectors in the right-hand B pillar behind the plastic trim. These connectors provide “engine running” information, can be used to recreate the electrical functions of the van in a separate cell and provide power supplies.
OPEL MOVANO (X62) 106 – CELL WIRING CONNECTION OPTION WRF 2-WAY CONECTOR This connector is strictly identical to the one described in technical data chapter 104-Connector for the ‘’KPD’’ option adaptation. The maximum permanent current of this power supply must not exceed 40A. This line is protected by 50A fuse F6 in the engine interconnections unit.
OPEL MOVANO (X62) 106 – CELL WIRING CONNECTION OPTION WRF Location of the 2-way connector fuse for the ‘’WRF’’ option For further information see chapter 117 - Engine Interconnections Unit. Fuse(F6) 50A MAX FUSE 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).
OPEL MOVANO (X62) 106 – CELL WIRING CONNECTION OPTION WRF 16-WAY CONNECTOR ASSIGNMENT OF 16-WAY CONNECTOR N.B.: The width of the contact for ways 1, 8, 9 and 16 is 2.8 mm; the width for the other ways is 1.5 mm. Way number Assignment Way 1 (20BK) Analogue door closing control signal (wire cross section 2 mm²) Way 2 (87T) Logical boot lock switch information signal (wire cross section 0.
OPEL MOVANO (X62) 106 – CELL WIRING CONNECTION OPTION WRF Important: The signals for ways 1, 2, 9 and 16 can only be used to control standard locking (panel van locks) and are only suitable for 3 locks. For any other use, a relay has to be used. For ways 11 and 13, if a relay is used, a panel switch should be added to replace the 13M link. (See courtesy light sheet). Ways 7 and 8 are protected by a single 10 A fuse (F28). The accumulated currents of the 2 lines must not exceed 8 A.
OPEL MOVANO (X62) 106 – CELL WIRING CONNECTION OPTION WRF Locally remove the door entry seal on the "B" pillar side. check that the clips on the interior trim are in place. Lever with a flat tool to unhook the lower section of the trim If necessary, put the clip back into its housing before reassembly. Retrieve the connector from the joint Before final reassembly of the trim and the door seal, Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 107 – ELECTRICAL CONNECTIONS 1. General Overview Before carrying out any operations, it is imperative that the battery’s negative terminal be disconnected. The negative terminal should only be reconnected after ensuring that all the disconnected elements have been reconnected (especially the steering wheel controls). As the vehicle is multiplexed, any change to the wiring may cause the vehicle to malfunction or to break down.
OPEL MOVANO (X62) 107 – ELECTRICAL CONNECTIONS 3. Anti-lock braking system (ABS) Under no circumstances may a power cable be fitted less than 100 mm from any component of the ABS system (ABS unit, ECU, wiring and sensors). In addition, for the anti-lock braking system (ABS) to function correctly, notwithstanding any specific agreement, we advise against servicing the brake contactor on the pedal assembly. The ABS wiring may not be extended. 4.
OPEL MOVANO (X62) 109 – +12 V CURRENT DISTRIBUTION Before working on the vehicle, refer to chapter 107 “Electrical Connections”. The +12 V current distribution power supply is a power supply that can be temporarily unavailable to save the battery. An energy management system constantly checks the battery charge status. Connecting electrical accessories while the engine is off will discharge the battery. Do not exceed the maximum power consumption.
OPEL MOVANO (X62) 109 – +12 V CURRENT DISTRIBUTION LOCATION OF ACCESSORY SOCKETS ON THE DASHBOARD LOCATION OF ACCESSORY SOCKETS ON THE LOAD COMPARTMENT 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).
OPEL MOVANO (X62) 110 – ENGINE RUNNING INFORMATION Before working on the vehicle, refer to chapter 107 “Electrical Connections”. In the event of a lot of electrical power being taken, the electrical assessment may have an adverse effect on the battery charge. The power take-off therefore needs to be conditioned with the engine running information.
OPEL MOVANO (X62) 111 – ACCELERATED IDLE, “UF3” OPTION The accelerated idle function is used to increase the vehicle’s idle speed to give more power and/or electrical energy. The standard vehicle idle is 800 rpm. The accelerated idle’s default value is 1,000 rpm. This value may be set to between 1,000 and 2,000 rpm in 100 rpm increments. This is done using the “Clip” diagnostics tool in the Opel dealer network.
OPEL MOVANO (X62) 112 – PARKING BRAKE INFORMATION Before working on the vehicle, refer to chapter 107 “Electrical Connections”. The parking brake information is grounded when the brake is applied. This connection can be accessed on the handbrake. HANDBRAKE 2 1 1: Handbrake 2: Handbrake cable 3: Handbrake cable (disconnected) 2 3 Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 112 – PARKING BRAKE INFORMATION To recover this information, it must be sent using a relay with a free wheel diode.
OPEL MOVANO (X62) 113 – WIRING INSTALLATION Before working on the vehicle, refer to chapter 107 “Electrical Connections”. PANEL VAN WIRING LOCATIONS 9 8 7 6 12 5 10 4 7 3 11 1 13 2 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).
OPEL MOVANO (X62) 113 – WIRING INSTALLATION CHASSIS CAB WIRING LOCATIONS 8 7 6 5 10 4 3 11 12 7 1 2 13 N° 1 2 3 4 5 6 7 8 9 10 11 12 13 N.B.
OPEL MOVANO (X62) 114 – ABS WIRING INSTALLATION Additional power cables may not be installed less than 100 mm from any ABS system components (ECU, wiring and sensors), electronic units or ECUs. ROUTING OF WIRING AND BRAKE PIPES (wiring in green, pipes and others in blue) 2 3 4 1 4 4 1: Central and rear section ABS wiring (in green) 2: Front section ABS wiring (in green) 3: ABS unit and ECU 4: ABS sensors N.B.: Modifications are not permitted to ABS wiring.
OPEL MOVANO (X62) 115 – INSTALLATION OF ELECTRICAL COMPONENTS 13 2 1 3 12 4 11 10 5 9 6 8 7 N° 1 2 3 4 5 6 (option) 7 8 (option) 9 10 (option) 11 (bus option) 12 (option) 13 DESCRIPTION BFRH (passenger compartment fuse-relay box) BIM (engine interconnections unit) Thermoplunger unit USM (Undercoat Switching Module) Control unit: voltage power supply control Injection computer BVR ECU (robotised gearbox) Front wheel drive ABS/ESP hydraulic unit BVR ECU (robotised gearbox) Rear wheel drive Airba
OPEL MOVANO (X62) 117 – ENGINE INTERCONNECTIONS UNIT (BIM) The engine interconnections unit can be found to the left of the engine compartment in front of the shock absorber mounting. This unit contains the power supply fuse board and the protection and switching unit (UPC). POSITION OF UNIT IN THE ENGINE COMPARTMENT Warning: These indications are given for information purposes only. Changing a fuse or connecting electrically to a UPC connection is prohibited.
OPEL MOVANO (X62) 117 – ENGINE INTERCONNECTIONS UNIT (BIM) INTERIOR OF THE ENGINE INTERCONNECTIONS UNIT Fuse Type Rating Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse 40 A 50 A 50 A 70 A Connection BP8 BP9 BP23 BP91 F8 Maxi Fuse 70 A BP11 F9 F10 F10 F11 F11 F11 F12 F13 F14 F15 F16 F16 Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse Maxi Fuse 70 A 50 A 40 A 40 A 50 A 60 A 40 A 60 A 60 A 70 A 40 A 50 A BP12 F1 F2 F3 F4 F5 F6 F7 BP71 BP7
OPEL MOVANO (X62) 117 – ENGINE INTERCONNECTIONS UNIT (BIM) PROTECTION AND SWITCHING UNIT 1 2 10 3 4 5 12 6 7 8 9 16 17 18 19 22 23 Fuse Type Rating Conn. F1 Min. Fuse 7.5 A F2 Min. Fuse 7.5 A F3 Min. Fuse 10 A F4 Min. Fuse 10 A F5 Min. Fuse 20 A F6 F7 F8 Min. Fuse Min. Fuse Min. Fuse 10 A 10 A 25 A F9 Min. Fuse 30 A F10 F11 Min. Fuse - 10 A - LPD LPDA LPG LPGA CPDB CPD CPG 8E 8F RPG RPD BP14 14L 14K AP25 - F12 Min.
OPEL MOVANO (X62) 118 – PASSENGER COMPARTMENT FUSE-RELAY BOX (BFRH) Before working on the vehicle, refer to chapter 107 “Electrical Connections”. This fuse-relay box is located under the dashboard, on the left above the driver’s feet (left-hand drive vehicles) or above the passenger’s feet (right-hand drive vehicles). To access it, the access flap must be removed.
OPEL MOVANO (X62) 118 – PASSENGER COMPARTMENT FUSE-RELAY BOX (BFRH) Fuse Type Rating 5 Mini Fuse 5 A 6 Mini Fuse 30 A 7 Mini Fuse 25 A 8 Mini Fuse 5 A 9 Mini Fuse 10 Mini Fuse 5 A 11 Mini Fuse 10 A 12 Mini Fuse 5 A 13 Mini Fuse 15 A 14 Mini Fuse 5 A 15 Mini Fuse 20 A 16 Mini Fuse 20 A 17 Mini Fuse 15 A 18 Mini Fuse 5 A 19 Mini Fuse 15 A 20 Mini Fuse 21 Mini Fuse 10 A 22 Mini Fuse 10 A 23 Mini Fuse 5 A 24 Mini Fuse 10 A 25 Mini
OPEL MOVANO (X62) 120 – MULTIPLEXED CAN NETWORK (CONTROLLER AREA NETWORK) The multiplexed network enables the ECUs to exchange their data. It complies with the CAN protocol and is connected to the diagnostic socket. Modifications to the multiplexed network are not permitted. CAN ARCHITECTURE Splice - A Cockpit ECU 645 USM 1337 Splice - B Airbag ECU 756 TDB 247 KC6 1664 Aircon TBD 319 ABR/ESP 118 Inj. ECU 120 Diag.
OPEL MOVANO (X62) 122 – LIGHTS AND SIGNALLING LIGHT INFORMATION Before working on the vehicle, refer to chapter 107 “Electrical Connections”. 1. Right or left front lamps The information is available directly on the front lamp connectors in the engine compartment.
OPEL MOVANO (X62) 122 – LIGHTS AND SIGNALLING LIGHT INFORMATION 2. Front fog lamps The information is available on the connection located under the bumper. CONNECTOR POSITION ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Way 1 Right fog lamp Way 2 Left fog lamp Way 3 Ground Important: Each of these connections must only be used to control one single automotive relay; no power available. Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 122 – LIGHTS AND SIGNALLING LIGHT INFORMATION 3. Right or left tail lights 3.1. Panel van The information is available directly on the tail light connectors in the loading area. CONNECTOR POSITION ASSIGNMENT OF CONNECTOR WAYS Way number N.B.: Assignment Way 1 Turn signal light Way 2 Side light Way 3 Brake lamp Way 4 Ground Way 5 Fog lamp Way 6 Reversing lamp A consumer with the same power as the trailer bulbs can be connected to each of the connections.
OPEL MOVANO (X62) 122 – LIGHTS AND SIGNALLING LIGHT INFORMATION 3.2. Chassis cab, chassis double cab and platform cab The information is available directly on the tail light connectors on the extreme rear cross member. CONNECTOR POSITION ASSIGNMENT OF CONNECTOR WAYS Way number N.B.
OPEL MOVANO (X62) 122 – LIGHTS AND SIGNALLING LIGHT INFORMATION 3.3. Versions with trailer coupling connector All chassis cabs and panel vans with the trailer coupling option (“VR2” option) have this connector. POSITION OF THE CONNECTOR ON PANEL VANS ASSIGNMENT OF CONNECTOR WAYS 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).
OPEL MOVANO (X62) 122 – LIGHTS AND SIGNALLING LIGHT INFORMATION Way number Assignment Way 1 Trailer presence information Way 2 Reverse lamp (21 W) Way 3 Left side light (5 W) Way 4 Left turn signal light (21 W) Way 5 Brake lamp (42 W) Way 6 Right turn signal light (21 W) Way 7 Right side light (5 W) Way 8 Vehicle fog lamp feedback Way 9 Ground Way 10 Fog lamp (21 W) Way 1: Detection of a turn signal fault (audible alarm if bulb out).
OPEL MOVANO (X62) 123 – DAYTIME RUNNING LIGHTS Option T3W Daytime running lights increase visibility of the vehicle during daylight. The running lights option automatically switches on the dipped beam lights when the vehicle starts up, depending on legislation in the country where the vehicle is sold. When the ignition is on, the headlights come on and instrument illumination is subdued. The daytime running lights switch off when the ignition is switched off.
OPEL MOVANO (X62) 124 – SWITCH INSTALLATION Before working on the vehicle, refer to chapter 107 “Electrical Connections. Depending on the version, one or more spaces for switches may be provided on the side part and/or the centre left of the dashboard.
OPEL MOVANO (X62) 125 – 16-WATT SIDE INDICATORS, OPTION UZB The side indicators are located at the bottom of the door mirrors. Vehicles (shorter than 6 metres) are fitted with side indicators with 5 W bulbs as standard in the side mirrors. When the regulations so require, vehicles that are longer than 6 metres must use 16 W bulbs in their side indicators. The "UZB" option meets this requirement. For more information, see also Chapter 36.
OPEL MOVANO (X62) 126 – INSTALLATION OF AN ADDITIONAL BATTERY 1. The standard starter battery The standard battery is located under the left side of the driver's cab. The covering of the step must remove to get to the battery BATTERY BEHIND LEFT STEPBOARD The battery box is screwed to the floor and can also extend completely down. Before that, the battery should be removed. Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 126 – INSTALLATION OF AN ADDITIONAL BATTERY 2. The additional battery A special battery tray should be used according to the size of the battery. It is to be attached under the body. We recommend that you use the mountings of the main battery tray on the left-hand side as your model. The battery will therefore be fitted from underneath the body. For installation of an additional battery, space is provided under the right-hand cab door sill, visible in zone 2 in the drawing below.
OPEL MOVANO (X62) 126 – INSTALLATION OF AN ADDITIONAL BATTERY RIGHT HAND DOOR SILL 1 2 1 Zone to be cut out from the stamped part for access to the additional battery terminals in the right-hand cab side sill 2 Radius required regardless of the cut-out The side sill panel may be cut out to allow access to the positive and negative terminals (see 1). The maximum authorized cut-out must not exceed the limit of the stamped part. The cut-out will be done with the radii in the corners (see 2).
OPEL MOVANO (X62) 127 – DRIVER’S SEAT BELT WARNING The vehicle comes with an audible seat belt warning as standard for the driver’s seat. If the driver's seat is changed, this feature can be replaced or potentially neutralized. The seat belt stalk has a mechanical contact switch that reads the presence of the seat belt buckle. This contact switch is directly connected to the airbag ECU. The contact connections are on the 6-way connector under the seat.
OPEL MOVANO (X62) 127 – DRIVER’S SEAT BELT WARNING To activate the audible seat belt warning, a stalk fitted with an opening contact switch should be used, which should be connected to the connector using ways 1 and 2 of the 6-way connector. The presence of the seat belt is detected when the contact switch is open. To deactivate the audible seat belt warning, ways 1 and 2 of the 6-way connector need to be connected by a shunt.
OPEL MOVANO (X62) 128 – EXTENDED REAR WIRING, “UNF” OPTION The “UNF” option provides special rear wiring that is 650 mm longer, which is necessary for extension of the rear overhang. This excess length is wound on the chassis. The additional length enables extension of the overhang depending on the version: - Platform cab: 1,690 mm - Single wheel chassis cab: 1,500 mm - Twin wheel chassis cab: 950 mm COIL LOCATION ON THE CHASSIS Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 129 – MODIFIABLE ECU SETTINGS Some ECU settings can be changed using the diagnostics tool (TECH2) in the Opel dealer network. Prior to any modification, the ECU in question must be fully reconfigured. After modification, the vehicle must still comply with the legislation and standards in force in the country of sale.
OPEL MOVANO (X62) 129 – MODIFIABLE ECU SETTINGS Modifiable function North South No light Light With Without Consumption unit (ADAC) (In line with legislation) Litres/100 kilometres Miles/Gallon Kilometres/1 litre Odometer unit (In line with legislation) Kilometres Miles Seat belt unfastened warning Active Inactive Language (dashboard display) By country Vehicle service range Without Configured Free Overspeed warning signal (In line with legislation/depending on country) Active Inactive Beep
OPEL MOVANO (X62) 129 – MODIFIABLE ECU SETTINGS Airbags ECU Modifiable function Settings that can be modified using CLIP Passenger-side front airbag Active Inactive Side airbag for driver Active Inactive Passenger-side side airbag Active Inactive Driver’s front pretensioner Active Inactive Driver’s front pretensioner Active Inactive Driver’s 2nd row pretensioner Active Inactive Passenger’s 2nd row pretensioner Active Inactive For some of the functions, please refer to the relevant sheet.
OPEL MOVANO (X62) 131 – INTERIOR LIGHTING Before working on the vehicle, refer to chapter 107 “Electrical Connections”. 1. Energy recovery conditions The progressive ground on connectors is a delayed analogue signal. Under no circumstances may this signal be relayed. Excess consumption of no more than 2 A (24 W) may be taken from the rear zone and double cab lighting. No excess consumption is feasible for front and right-hand side courtesy lights (sliding side door).
OPEL MOVANO (X62) 131 – INTERIOR LIGHTING 2. Location of lighting and connector way assignments DRIVER'S SEAT LIGHTING ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Way 1 (BPT2) Delayed +12 V power supply (wire cross section 0.5 mm²) Way 2 (13L) Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.5 mm²) Way 3 (NAM) Ground (wire cross section 0.5 mm²) Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 131 – INTERIOR LIGHTING REAR PANEL VAN LIGHTING AND DOUBLE CAB LIGHTING Van Chassis Cab ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Way 2 (13M) Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.35 mm²) Way 3 (MG) Permanent ground (wire cross section 0.35 mm²) Way 4 (BPT2) Delayed +12 V power supply (wire cross section 0.35 mm²) Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 131 – INTERIOR LIGHTING ROOF CONNECTOR Van Chassis Cab ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Way C5 (13M) Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.35 mm²) Way B7 (BPT2) Delayed +12 V power supply (wire cross section 0.35 mm²) Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 131 – INTERIOR LIGHTING RIGHT-HAND SIDE DOOR LIGHTING ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Way 2 (13M) Progressive active ground when door opens and digressive when door closes or +APC (wire cross section 0.35 mm²) Way 3 (NAM) Permanent ground (wire cross section 0.35 mm²) Way 4 (BPT2) Delayed +12 V power supply (wire cross section 0.35 mm²) Warning: The wires cannot be retrieved in the connector as there is no double exit.
OPEL MOVANO (X62) 132 – ELECTRIC PLUG FOR COUPLING The first-fit electric plug for the coupling and the one available from after-sales are 13-pin type. Assignment of the pins is standardised. Electrical switches are built into the plug. They are activated depending on the opening or closing of the coupling plug hood. The SW1 switch indicates the presence or absence of the trailer to the vehicle ECUs. The SW2 switch enables the vehicle ECUs to automatically disconnect the rear fog lamp.
OPEL MOVANO (X62) 132 – ELECTRIC PLUG FOR COUPLING ASSIGNMENT OF CONNECTOR TRACKS 8 9 7 1 10 SW2 2 11 6 3 12 Way number SW1 4 5 13 Assignment Way 1 Left turn signal light Way 2 Rear fog lamp Way 3 Ground (10 A max) Way 4 Right turn signal light Way 5 Right side light Way 6 Brake lights Way 7 Left side light Way 8 Reversing lamp Way 9 Not wired Way 10 Not wired Way 11 Not wired Way 12 Not wired Way 13 Ground (10 A max) SW1 Trailer presence SW1 Rear fog lamp disconnec
OPEL MOVANO (X62) 132 – ELECTRIC PLUG FOR COUPLING SW1 ELECTRICAL DIAGRAM 151I 1 UCH 2 3 3 4 1: Passenger Compartment Control Unit (UCH) 2: SW1 switch 3: Coupling plug, track 3 4: Ground SW2 ELECTRICAL DIAGRAM 9Q 1 2 UCH 9P 3 2 1: Passenger Compartment Control Unit (UCH) 2: SW2 switch 3: Coupling plug, track 2 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).
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS 1 – Installation or modification of front door panel switches (Front wheel drive version with " Easytronic " automatic robotized gearbox). Before working on the vehicle, refer to chapter 107 “Electrical Connections”. On front wheel drive vehicles, the presence of an automatic robotized, or "Easytronic", gearbox imposes the presence of a front driver door.
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS Without knowing the type of transformation made, Opel cannot provide detailed mechanical installation recommendations. Nevertheless, the adapter must comply with the following technical recommendations: Switch installation and associated transformation: The door switch information must be associated with the automatic robotized gearbox for the driver door.
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS The connection may be made at the adaptor connector (front door latch UCH) located under the instrument panel or on the front door wiring (depending on the characteristics of the transformation). 1 A SideView 2 1 : Adaptor connector: front door latch 2 : Door switch signal: channel A 4 UCH 1 It will be necessary to reconfigure the UCH in the Opel network to indicate the presence of the door to it (using the CLIP diagnostics tool).
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS Switch characteristics: The switch must be: - “Open" in "driver door open" position - “Closed" in " door closed" position On mass production vehicles fitted with a front door, the switch is integrated in the latch: Letters localize the channels on the latch connector Figures localize the channels on the harness Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS Procedure to verify correct operation after transformation: The following procedure is used to check the correct operation of the automatic robotized gearbox and therefore that of the driver door switch assembly. The service must be verified directly using: - Triggering of the buzzer noise. - The electric measurement linked to starting the electric pump.
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS Operator action: - Open the driver door. Check: - During activation of the electric pump (2 to 10 seconds), check that a consumed battery current greater than 17A is obtained (for information, activation of electric pump emits a characteristic noise during operation). Verification of the buzzer operation: Initial vehicle configuration required: Engine running, foot on the brake, first gear engaged and driver door open.
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS 2 – Installation of the front door latch (geometric position) Striker Door latch Striker 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).
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS Important dimensions to be respected for correct operation of the assembly 14 4,2 25,6 27,5 8,5 Striker Door latch 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).
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS 3 – Installation of the sliding side or rear door latch 3 1 3 1 4 2 Example of latch installation on mass production rear hinged doors 1 Right rear hinged door 2 Door latch 3 Left rear hinged door 4 Striker 2 4 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).
OPEL MOVANO (X62) 133 – RECONSTRUCTING OPENING PANEL FUNCTIONS Important dimensions to be respected for correct operation of the assembly 25,7 15,9 11,2 14 27,5 4 2 It may be necessary to reconfigure the UCH in the Opel network to indicate the presence or not of a door to it (using the CLIP diagnostics tool).
OPEL MOVANO (X62) 135 – REMOTE ENGINE START AND STOP It is possible to double the engine start and stop control. It is the job of the converter to take into account all the aspects associated with safe operation and to ensure: - the quality of the connections. - that the wires added have the same cross sections as the original wires; or even larger if called for by the length of the wires added. - that relays closed at rest are used if the cut-offs in these lines are executed via relays.
OPEL MOVANO (X62) 135 – REMOTE ENGINE START AND STOP ASSIGNMENT OF CONNECTOR WAYS 1 2 3 4 5 6 104AA Way number Assignment Way 1 (BP12) Protected 12 V power supply, red wire with cross section 5 mm² Way 2 - Way 3 (D) Start-up, beige wire with cross section 5 mm² Way 4 (A) Primary ignition supply, yellow wire with cross section 5 mm² Way 5 - Way 6 (S) Current distribution power supply, yellow wire with cross section 5 mm² To start the engine (starter solenoid control), activate way 3 with th
OPEL MOVANO (X62) 137 – DEACTIVATION OF AIRBAGS AND SEAT BELT PRETENSIONERS Depending on the customer’s requirements, an airbag or seat belt pretensioner may need to be deactivated. This can be done using the Opel diagnostics tool in the Opel dealer network. An airbag or pretensioner that has been deactivated can be reactivated at any time. After modification, the vehicle must still comply with the legislation and standards in force in the country of sale.
OPEL MOVANO (X62) 139 – CONNECTION TO THE NEGATIVE BATTERY TERMINAL Before working on the vehicle, refer to chapter 107 “Electrical Connections”. 1. General recommendations The wiring used must allow the negative battery terminal block to be removed (tightening torque 8 Nm ± 15%). Tighten at the recommended torque of 8 Nm ± 15%. Leave threading of at least one thread free after tightening. NEGATIVE BATTERY TERMINAL 1 1: Additional wiring (must be black) connected to the negative battery terminal 2.
OPEL MOVANO (X62) 139 – CONNECTION TO THE NEGATIVE BATTERY TERMINAL 3. Wiring duct WIRING PATH IN BATTERY TRAY 2 1 1: Additional wiring 2: Cable duct (diameter 40), grommet to be fitted UNDER-BODY WIRING PATH 1 2 3 4 1: Cable duct (diameter 40), grommet to be fitted 2: Brake pipes 3: Additional wiring 4: Under-body electrical wiring Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 140 – CONNECTION TO THE POSITIVE BATTERY TERMINAL Before working on the vehicle, refer to chapter 107 “Electrical Connections”. Depending on the electrical assessment, the power take-off may be conditioned with the engine running information. 1. General recommendations The wiring used must allow the positive battery terminal block to be removed (tightening torque 8 Nm ± 15%).
OPEL MOVANO (X62) 140 – CONNECTION TO THE POSITIVE BATTERY TERMINAL 2. Connection to M6 stud Make sure there is good contact (flatness) with the terminal. Crimping must be done in accordance with terminal manufacturer guidelines. Tighten at the recommended torque of 8 Nm ± 15% and leave at least one spare thread after tightening. The fuse holder should be properly attached to avoid any vibrations and damage to its surroundings (e.g. risk of noise, corrosion).
OPEL MOVANO (X62) 140 – CONNECTION TO THE POSITIVE BATTERY TERMINAL 3. Connection using the midi fuse locations Two locations are provided for midi-type fuses. For this, special M5 studs from the supplier MTA must be used. The following fuses may be used: 30 A midi fuse; 40 A midi fuse. Tighten at the recommended torque of 5 Nm ± 15% for the M5 studs and leave at least one spare thread after tightening.
OPEL MOVANO (X62) 140 – CONNECTION TO THE POSITIVE BATTERY TERMINAL 4. Wiring protection Use a category 3 resin, lightweight felt or tape-type protection in the engine compartment and in the under-body and category 1 to 3 for the other sections not subjected to high temperatures (see “Wiring” sheet). Since the split annular sheathing type protection is abrasive and may cause corrosion (paint wear) and noise (in hollow bodies) it must be immobilised.
OPEL MOVANO (X62) 141 – ROUTING AIRBAG AND PRE-TENSIONER WIRING No intervention or modification must be made to elements relating to the vehicle's passive safety. The airbag and seatbelt pre-tensioner wire is an integral part of the vehicle's passive safety system units.
OPEL MOVANO (X62) 141 – ROUTING AIRBAG AND PRE-TENSIONER WIRING In blue, the wiring and sensitive units which make up the vehicle's passive safety system: Right-hand drive version Note: For more information, also see Chapter 32, 137 and the General conversion recommendations 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).
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS Before working on the vehicle, refer to the “Electrical Connections” sheet.
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS POWER SUPPLY PLATE (777AB) Fuse Amperage [A] Connection F3 50 BP59 F4 40 BP8 ABS UCE F5 50 BP9 Additional heating relay 1 F6 50 BP23 Purpose-built body conversion / F7 70 BP91 Additional heating relay F8 70 BP11 Rear lights, passenger compartment relay/fuse box, Diesel heater resistor F9 70 BP12 Passenger compartment relay/fuse box Function F1 F2 BUS X62 X62 BUS 16-Seater BUS FUSE PLATE (260BA) Fuse Amperage [A] Connectio
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS 2. Right-side dashboard area connectors: The optional relay/fuse box (BFRO) is located on the right-hand side (left- and right-hand drive) It is attached to the right-hand flange of the dashboard beam. Unit 107-32A is used to connect the dashboard wiring to child transport interconnection wiring. This connector is on standby and coiled in the right-side dashboard wiring.
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS BFRO = Optional Relay/Fuse Box (1016) 2 1 20A BUZZER (638AA) (À diode) 20A 5 40A (À diode) (À diode) 20A (À diode) 3 20A 4 Part Function 70A 6 (À diode) (À diode) Connection 1 Sliding door 1790 2 Boot lid 142 3 Bus heated seat 1399 4 Bus ESP 1524 5 A/C info 652 6 BCM + battery feed 1760 7 + load shed accessory feed 1155 70A (À diode) 7 3.
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS CONNECTOR 108-32A - ALLOCATION OF CHANNELS Connection Cable [mm²] 1 38AH 2 2 38MT 0.5 3 38AJ 1 + Electric Fan Motor Control feed Speed 2 4 38AK 1 + Electric Fan Motor Control feed Speed 3 5 BT2 0.5 + timed battery feed 2 6 LPDB 0.5 + Side Light feed Right-side Coupling via Coupling Module 7 MAN 0.
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS CONNECTOR 642-32A - ALLOCATION OF CHANNELS OF Connection Cable [mm²] 1 LPD 0.5 + Side Light feed Right-side Coupling via Coupling Module 2 103P 0.5 Right-side headlight actuator control 2 MAN 0.5 Right-side dashboard cross member electrical earth 103R 0.5 Right-side headlight actuator control 4 8 103N 0.5 Right-side headlight actuator control 1 9 103Q 0.5 Right-side headlight actuator control 3 10 SP8 0.
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS 4. B-pillar connectors The connectors are located in the right-hand B pillar behind the plastic trim. This connection operation requires the removal of the B pillar trim (see chapter 104 - “KPD” or Opel repair manual). 5 3 1 2 Part Function 4 Connection No.
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS ALLOCATION OF CHANNELS OF CONNECTOR 384-32B 2 Pin Connection Cable [mm²] 1 Function 1 BP23 7 12V protected + battery feed Passenger compartment 4 2 BP59 7 12V protected + battery feed Electric door fuse Note: The maximum permanent current of these power supplies must not exceed 40A. These lines are protected by 50A F6 (BP23) and F3 (BP59) fuses in the engine compartment interconnections unit (777).
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS CONNECTOR BH-32A - ASSIGNMENT OF CHANNELS Pin Connection Cable Function [mm²] A1 BT1 2.5 + timed battery feed 1 A2 103P 0.5 Right-side headlight actuator control 2 A3 103Q 0.5 Right-side headlight actuator control 3 A4 LPDB 0.5 + Side light feed Right-side coupling via coupling Module A5 38MT 0.5 Relay 1 control motor running A6 5GK 0.5 Selector contact signal 1 A7 62A 0.5 Left-side door striker plate control A8 151R 0.
OPEL MOVANO (X62) 149 – WIRING PRE-FIT FOR TRABUS CONNECTOR BH-32A - ASSIGNMENT OF CHANNELS Pin Connection Cable Function [mm²] C7 133P 0.5 Door sill deployment light control C8 13M 0.
OPEL MOVANO (X62) 150 – ADDITIONAL LOCK WITH 3-BUTTON KEY On conversions with an additional opening element in the rear area, it is possible to incorporate an additional electric lock, activated by the Master's original central locking. To do so, the Master must be equipped with the 'SOP03' option (3-button door opening system). It may be necessary to modify the configuration of the remote control.
OPEL MOVANO (X62) 150 – ADDITIONAL LOCK WITH 3-BUTTON KEY For a non-Opel electric lock, the electrical actuator properties set out in the table below must be complied with. 16-way connector Pin Function 1 Analogue door closing control signal 2 2 Logical boot lock switch information signal 0.35 3 Delayed +12 V 2 A power supply for interior lights, controlled by the passenger compartment ECU (UCH) 0.5 4 Left lateral side light 3A power supply 0.
OPEL MOVANO (X62) 150 – ADDITIONAL LOCK WITH 3-BUTTON KEY Note: The width of the contacts for channels 1, 8, 9 and 16 is 2.8mm; the width for the other pins is 1.5mm. Function Pin Nominal I (A) per engine Peak I (A) per engine I / output (A) U (V) / T (°C) Ref. Rear door unlocking 1 2.7 (x3) 3.5 8.1 11.5 / 23° Rear door locking 9 2.7 (x3) 3.5 8.1 11.5 / 23° Locking 16 1.4 (x3) 4.2 11.5 / 23° Note: Subject to errors and technical amendments.
OPEL MOVANO (X62) 151 – STOP & START The 'STOP & START' (= S&S) option controls the automatic stopping of the engine when the vehicle stops and automatic restarting when a deliberate restart is detected, in order to optimise fuel consumption and pollution. The 'STOP & START' option is available on 2.3 dci engines (M9T front- and rear-wheel drive, 100hp and 125hp. The 'STOP & START' option is incompatible with the following options: M1F (chapter 63.
OPEL MOVANO (X62) 151 – STOP & START 2. Convertibility conditions recommendations and restrictions 2.1. Recommendations and restrictions The 'STOP & START' option is not compatible with some conversions which require constant power (electrical or mechanical) from the vehicle. 2.2. Vehicle servicing Before carrying out any servicing on the vehicle, the battery must be disconnected (to avoid the S&S causing the engine to start unexpectedly). 2.3.
