Opel Movano X62 2010 Conversion Manualline
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Opel Movano X62 2010 Conversion Manualline

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Conversion Guideline
NEW Movano X62
Part 4 - Chapter 101-141
Version:
August 2010
GME Engineering
Special Vehicle Development / Light Commercial Vehicles
Rüsselsheim / Germany

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Summary of Contents for Opel Movano X62 2010

  • Page 1 Conversion Guideline NEW Movano X62 Part 4 - Chapter 101-141 Version: August 2010 GME Engineering Special Vehicle Development / Light Commercial Vehicles Rüsselsheim / Germany...

  • Page 2: Table Of Contents

    OPEL MOVANO (X62) CONTENTS CHAPTER DESCRIPTION: PAGE POSITION OF ELECTRICAL GROUNDS BATTERY LOCATION ELECTRICAL CURRENTS AVAILABLE ADAPTATION CONNECTOR, “KPD” OPTION CONVERSION UNIT, “KC6” OPTION ELECTRICAL CONNECTIONS +12 V CURRENT DISTRIBUTION ENGINE RUNNING INFORMATION ACCELERATED IDLE, “UF3” OPTION PARKING BRAKE INFORMATION...

  • Page 3: 101 Position Of Electrical Grounds

    OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS The vehicle has several electrical and electronic grounds. Before working on the vehicle, refer to the “Electrical Connections” sheet. The electricity sheets of the General Technical Conversion Guide must also be consulted before any modifications are made to the vehicle.
  • Page 4 OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON DASHBOARD CROSS MEMBER 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...
  • Page 5 OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS IN THE ENGINE COMPARTMENT 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...
  • Page 6 OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON THE PANEL VAN EXTREME REAR PILLAR 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...
  • Page 7 OPEL MOVANO (X62) 101 – POSITIONS OF ELECTRICAL GROUNDS ELECTRICAL GROUNDS ON THE CHASSIS 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...

  • Page 8: 102 Battery Location

    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”...

  • Page 9: 103 Electrical Currents Available

    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.
  • Page 10 OPEL MOVANO (X62) 103 – ELECTRICAL CURRENTS AVAILABLE CURRENTS AVAILABLE FOR REAR WHEEL DRIVE VERSIONS Without With accelerated idle (rpm) Engine Version accelerated idle 1000 1100 1200 1300 DRL* Base Without DRL* (74 kW) DRL* Without DRL* DRL* Base Without DRL*...

  • Page 11: 104 Adaptation Connector, "Kpd" Option

    OPEL MOVANO (X62) 104 – 6 PIN- and 2 PIN-CONNECTOR, OPTION KPD Before working on the vehicle, refer to the “Electrical Connections” sheet. This option provides: - A stand-by connector in the dashboard area. - A stand-by connector in the right-hand B pillar (lateral zone).
  • Page 12 Way 5 Reserve Way 6 Reserve The counterpart to this connector is available from the Opel dealer network under part number 8200773547. CONNECTION KIT N.B.: The permanent accumulated currents of the following 2 ways must not exceed 8 A: - Way 2: "Running Engine"...
  • Page 13 OPEL MOVANO (X62) 104 – 6 PIN- and 2 PIN-CONNECTOR, OPTION KPD 2. B pillar connector The connector is located in the right-hand B pillar behind the plastic trim. LOCATION ASSIGNMENT OF CONNECTOR WAYS Way number Assignment +12 V direct battery power supply for maximum consumption of 40 A (wire cross Way 1 (BP23) section 7 mm²).
  • Page 14 OPEL MOVANO (X62) 104 – 6 PIN- and 2 PIN-CONNECTOR, OPTION KPD Important: This power supply is connected directly to the battery. The vehicle is therefore not protected by the energy management system. Risk of battery draining. The counterpart to this connector is already fitted to the wiring but it is still necessary to obtain the...
  • Page 15 OPEL MOVANO (X62) 104 – 6 PIN- and 2 PIN-CONNECTOR, OPTION KPD EXAMPLE OF CONNECTION (ACCESSORY CONTROL) + 12V ACC A: +12 V accessory relay power supply B: Accessory control of the accelerated idle C: Way 1 of the 6-way connector...

  • Page 16: 105 Conversion Unit, "Kc6" Option

    OPEL MOVANO (X62) 105 – CAN BUS- INTERFACE MODULE, “KC6” OPTION Before working on the vehicle, refer to the “Electrical Connections” sheet. The interface module is available as an option on all versions. This module can be used to recover certain information that is available on the multiplexed network.

  • Page 17: 107 Electrical Connections

    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).
  • Page 18 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.

  • Page 19: 109 +12 V Current Distribution

    OPEL MOVANO (X62) 109 – +12 V CURRENT DISTRIBUTION Before working on the vehicle, refer to the “Electrical Connections” sheet. 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.
  • Page 20 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...

  • Page 21: 110 Engine Running Information

    OPEL MOVANO (X62) 110 – ENGINE RUNNING INFORMATION Before working on the vehicle, refer to the “Electrical Connections” sheet. 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.

  • Page 22: 111 Accelerated Idle, "Uf3" Option

    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. For an idle value between 1,000 and 1,300 rpm, the vehicle can be running (except for vehicles with a robotized gearbox in which case the vehicle must be stopped).

  • Page 23: 112 Parking Brake Information

    OPEL MOVANO (X62) 112 – PARKING BRAKE INFORMATION Before working on the vehicle, refer to the “Electrical Connections” sheet. The parking brake information is grounded when the brake is applied. This connection can be accessed on the handbrake. HANDBRAKE 1: Handbrake...
  • Page 24 112 – PARKING BRAKE INFORMATION To recover this information, it must be sent using a relay with a free wheel diode. For example, the following OPEL parts may be used: 40 Amp relay, Cartier Reference: 20240041 20 Amp relay, Cartier Reference: 29201041...

  • Page 25: 113 Position Of Wiring Installation

    OPEL MOVANO (X62) 113 – WIRING INSTALLATION Before working on the vehicle, refer to the “Electrical Connections” sheet. PANEL VAN WIRING LOCATIONS Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of...
  • Page 26 OPEL MOVANO (X62) 113 – WIRING INSTALLATION CHASSIS CAB WIRING LOCATIONS N° DESCRIPTION Front bumper wiring Door sill light wiring Engine wiring Dashboard wiring Multimedia wiring Front door, sliding door wiring Additional side light wiring Rear pad wear indicator wiring...

  • Page 27: 114 Abs Wiring Installation

    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. For more information, see also Chapter 69 ROUTING OF WIRING AND BRAKE PIPES...

  • Page 28: 115 Installation Of Electrical Components

    OPEL MOVANO (X62) 115 – INSTALLATION OF ELECTRICAL COMPONENTS MARKING 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 6 (option) BVR ECU (robotised gearbox) Front wheel drive...

  • Page 29: 117 Engine Interconnections Unit

    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).
  • Page 30 OPEL MOVANO (X62) 117 – ENGINE INTERCONNECTIONS UNIT (BIM) INTERIOR OF THE ENGINE INTERCONNECTIONS UNIT Fuse Type Rating Function Connection Maxi Fuse 40 A ABS ECU Maxi Fuse 50 A BP23 Conversion Maxi Fuse 50 A Additional heating relay 1...
  • Page 31 OPEL MOVANO (X62) 117 – ENGINE INTERCONNECTIONS UNIT (BIM) PROTECTION AND SWITCHING UNIT 16 17 18 19 Fuse Type Rating Conn. Function Min. Fuse 7.5 A Right side light LPDA Min. Fuse 7.5 A Left side light LPGA CPDB Min. Fuse...
  • Page 32 OPEL MOVANO (X62) 117 – ENGINE INTERCONNECTIONS UNIT (BIM) Fuse Type Rating Conn. Function Min. Fuse 25 A BP14 ABS power supply Min. Fuse 30 A Windscreen wiper Min. Fuse 10 A AP25 Airbag PIS (primary ignition supply) Gearbox ECU power supply Min.

  • Page 33: Passenger Compartment Fuse-Relay Box

    OPEL MOVANO (X62) 118 – PASSENGER COMPARTMENT FUSE-RELAY BOX (BFRH) Before working on the vehicle, refer to the “Electrical Connections” sheet. 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).
  • Page 34 OPEL MOVANO (X62) 118 – PASSENGER COMPARTMENT FUSE-RELAY BOX (BFRH) Connec- Fuse Type Rating Function tion Mini Fuse << BP 69 >> dashboard Mini Fuse << BP 3 >> UCE Habitacle (CPE, SUPCPE), BFR Mini Fuse << BP 77 >> UCE Habitacle + Bat sécurité...

  • Page 35: 120 Multiplexed Can Network

    TERMINAL IMPEDANCE PRIVATE CAN N.B.: Control of the multiplexed network is only possible using the “Clip” diagnostics tool in the OPEL / VAUXHALL network. If one of the ECUs is replaced, configuration needs to be carried out using the “Clip”...

  • Page 36: 122 Lights And Signalling Light Information

    OPEL MOVANO (X62) 122 – LIGHTS AND SIGNALLING LIGHT INFORMATION Before working on the vehicle, refer to the “Electrical Connections” sheet. 1. Right or left front lamps The information is available directly on the front lamp connectors in the engine compartment.
  • Page 37 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...
  • Page 38 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...
  • Page 39 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...
  • Page 40 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.
  • Page 41 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...

  • Page 42: 123 Daytime Running Lights

    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. The running lights function can be activated or deactivated using the Opel diagnostics tool in the Opel dealer network.

  • Page 43: 124 Switch Installation

    OPEL MOVANO (X62) 124 – SWITCH INSTALLATION Before working on the vehicle, refer to the “Electrical Connections” sheet. 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.

  • Page 44: 16-Watt Side Indicators

    OPEL MOVANO (X62) 125 – 16-WATT SIDE INDICATORS, OPTION UZB Vehicles (shorter than 6 metres) are fitted with side indicators with 5 W bulbs as standard. All complete vehicles with a total length of over six metres must be equipped with side marker lamps and 16 W side indicators in compliance with EU Directive 76 / 756 / EEC.

  • Page 45: 126 Installation Of An Additional Battery

    OPEL MOVANO (X62) 126 – INSTALLATION OF AN ADDITIONAL BATTERY A space is set aside under the right-hand cab side sill. A special battery tray should be used according to the size of the battery. It is to be attached under the body.

  • Page 46: 127 Driver's Audible Seat Belt Warning

    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.
  • Page 47 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.

  • Page 48: 128 Extended Rear Wiring, "Unf" Option

    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:...

  • Page 49: 129 - Modifiable Ecu Settings

    OPEL MOVANO (X62) 129 – MODIFIABLE ECU SETTINGS Some ECU settings can be changed using the diagnostics tool 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.
  • Page 50 OPEL MOVANO (X62) 129 – MODIFIABLE ECU SETTINGS Settings that can be modified using Modifiable function CLIP Rain/light sensor detection threshold: - Northern countries and Great Britain North - Other countries South (In line with legislation in the country of sale)
  • Page 51 OPEL MOVANO (X62) 129 – MODIFIABLE ECU SETTINGS Modifiable function Settings that can be modified using CLIP Active Passenger-side front airbag Inactive Active Side airbag for driver Inactive Active Passenger-side side airbag Inactive Active Driver’s front pretensioner Inactive Active Driver’s front pretensioner...

  • Page 52: 131 Interior Lighting

    OPEL MOVANO (X62) 131 – INTERIOR LIGHTING Before working on the vehicle, refer to the “Electrical Connections” sheet. 1. Energy recovery conditions The progressive ground on connectors is a delayed analogue signal. Under no circumstances may this signal be relayed.
  • Page 53 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) Progressive active ground when door opens and digressive when door closes or Way 2 (13L) +APC (wire cross section 0.5 mm²)
  • Page 54 OPEL MOVANO (X62) 131 – INTERIOR LIGHTING REAR PANEL VAN LIGHTING AND DOUBLE CAB LIGHTING Chassis Cab ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Progressive active ground when door opens and digressive when door closes or Way 2 (13M) +APC (wire cross section 0.35 mm²) Way 3 (MG) Permanent ground (wire cross section 0.35 mm²)
  • Page 55 OPEL MOVANO (X62) 131 – INTERIOR LIGHTING ROOF CONNECTOR Chassis Cab ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Progressive active ground when door opens and digressive when door closes or Way C5 (13M) +APC (wire cross section 0.35 mm²) Way B7 (BPT2) Delayed +12 V power supply (wire cross section 0.35 mm²)
  • Page 56 OPEL MOVANO (X62) 131 – INTERIOR LIGHTING RIGHT-HAND SIDE DOOR LIGHTING ASSIGNMENT OF CONNECTOR WAYS Way number Assignment Progressive active ground when door opens and digressive when door closes or Way 2 (13M) +APC (wire cross section 0.35 mm²) Way 3 (NAM) Permanent ground (wire cross section 0.35 mm²)

  • Page 57: 132 Electric Plug For Trailerhitch

    The trailer coupling wiring is available in the Opel dealer network under part number 93168508 for vehicles fitted with a rear parking sensor or under part number 93168511 for vehicles not fitted with a rear parking sensor.
  • Page 58 OPEL MOVANO (X62) 132 – ELECTRIC PLUG FOR COUPLING ASSIGNMENT OF CONNECTOR TRACKS Way number 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...
  • Page 59 OPEL MOVANO (X62) 132 – ELECTRIC PLUG FOR COUPLING SW1 ELECTRICAL DIAGRAM 151I 1: Passenger Compartment Control Unit (UCH) 2: SW1 switch 3: Coupling plug, track 3 4: Ground SW2 ELECTRICAL DIAGRAM 1: Passenger Compartment Control Unit (UCH) 2: SW2 switch 3: Coupling plug, track 2 Note: Subject to errors and technical amendments.

  • Page 60: 135 Remote Engine Start And Stop

    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.
  • Page 61 OPEL MOVANO (X62) 135 – REMOTE ENGINE START AND STOP ASSIGNMENT OF CONNECTOR WAYS 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...

  • Page 62: 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.

  • Page 63: 139 Connection To The Negative Battery Terminal

    OPEL MOVANO (X62) 139 – CONNECTION TO THE NEGATIVE BATTERY TERMINAL Before working on the vehicle, refer to the “Electrical Connections” sheet. 1. General recommendations The wiring used must allow the negative battery terminal block to be removed (tightening torque 8 Nm ±...
  • Page 64 OPEL MOVANO (X62) 139 – CONNECTION TO THE NEGATIVE BATTERY TERMINAL 3. Wiring duct WIRING PATH IN BATTERY TRAY Additional wiring Cable duct (diameter 40), grommet to be fitted UNDER-BODY WIRING PATH 1: Cable duct (diameter 40), grommet to be fitted...

  • Page 65: 140 Connection To The Positive Battery Terminal

    OPEL MOVANO (X62) 140 – CONNECTION TO THE POSITIVE BATTERY TERMINAL Before working on the vehicle, refer to the “Electrical Connections” sheet. 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 ±...
  • Page 66 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.
  • Page 67 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;...
  • Page 68 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”...

  • Page 69: 141 Routing Airbag And Pre-Tensioner Wiring

    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.
  • Page 70 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.

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