LEVC VN5 2021 User manual

LEVC VN5
Conversion Manual
Date of publication: 07/2020

Table of contents
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1  General Information 3
1.1  About This Publication ...................................................................................................................... 3
1.2  About This Manual ............................................................................................................................. 3
1.3  Commercial and Legal Aspects ........................................................................................................ 4
1.4  Contact Information ........................................................................................................................... 7
1.5  Conversion Homologation................................................................................................................. 7
1.6  Electromagnetic Compatibility (EMC) .............................................................................................. 8
1.7  Vehicle Duty Guidelines..................................................................................................................... 8
1.8  Dismantling and De-Pollution ........................................................................................................... 9
1.9  Jacking ................................................................................................................................................ 9
1.10  Lifting................................................................................................................................................. 10
1.11  Noise Vibration and Harshness (NVH)............................................................................................ 10
1.12  Vehicle Transportation Aids and Vehicle Storage......................................................................... 11
1.13  Load Space Dimensions.................................................................................................................. 13
1.14  Load Distribution.............................................................................................................................. 14
2  Body and Paint 19
2.1  Body .................................................................................................................................................... 19
2.2  Drill Zones........................................................................................................................................... 20
2.3  Racking Systems................................................................................................................................ 26
2.4  Load space.......................................................................................................................................... 27
2.5  Load Space Panels............................................................................................................................. 28
2.6  Body Closures .................................................................................................................................... 29
2.7  Interior Trim ........................................................................................................................................ 31
2.8  Seats.................................................................................................................................................... 32
2.9  Glass, Frames and Mechanisms....................................................................................................... 33
2.10  Supplementary Restraint System (SRS) ........................................................................................ 33
2.11  Seat belt Systems............................................................................................................................. 37
2.12  Roof ................................................................................................................................................... 38
2.13  Corrosion Prevention....................................................................................................................... 39
2.14  Frame and Body Mounting .............................................................................................................. 39
3  Electrical 41
3.1  High Voltage System.......................................................................................................................... 41
3.2  Wiring Installation .............................................................................................................................. 42
3.3  Communications Network ................................................................................................................. 46
3.4  Charging System................................................................................................................................ 50
3.5  12V Battery and Cables ..................................................................................................................... 52
3.6  Climate Control System..................................................................................................................... 53
3.7  Instrument Panel, Displays and Operator Controls ........................................................................ 53
3.8  Horn ..................................................................................................................................................... 54
3.9  Electronic Engine Controls ............................................................................................................... 54

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3.10  Information and Entertainment System ......................................................................................... 54
3.11  Instrument Panel, Displays and Operator Controls ...................................................................... 53
3.12  Phone Connectivity.......................................................................................................................... 55
3.13  Exterior Lights .................................................................................................................................. 56
3.14  Interior Lights ................................................................................................................................... 56
3.15  Cruise Control .................................................................................................................................. 56
3.16  Lane Departure Warning.................................................................................................................. 56
3.17  Handles, Locks, Latches and Entry Systems ................................................................................ 57
3.18  Fuses and Relays ............................................................................................................................. 58
3.19  Antennas ........................................................................................................................................... 66
3.20  Electrical Connectors and Connections ........................................................................................ 67
3.21  Ground Connections........................................................................................................................ 68
3.22  Windshield Wipers ........................................................................................................................... 69
4  Chassis 70
4.1  Suspension ......................................................................................................................................... 70
4.2  Wheels and Tyres ............................................................................................................................... 70
4.3  Brake System...................................................................................................................................... 72
5  Powertrain 74
5.1  Engine ................................................................................................................................................. 74
5.2  Cooling System .................................................................................................................................. 74
5.3  Accessory Drive ................................................................................................................................. 75
5.4  Exhaust System.................................................................................................................................. 75
5.5  Fuel System ........................................................................................................................................ 76
5.6  Gasoline Particulate Filter ................................................................................................................. 76

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About This Publication
This Conversion Manual is the latest publication for the LEVC 2021 VN5.
Review this manual in full before starting any conversion.
The conversion Manual is a live document which can be viewed on the LEVC website at:
https://www.levc.com/corporate/technical-information-center/
Make sure you are viewing the latest available version of this document.
NOTE
For additional information or technical support contact [email protected].
About This Manual
Introduction
This guide is published by LEVC to provide general descriptions and advice for vehicle
converters.
Certain modifications may invalidate legal approvals and application for re-certification may be
necessary.
Modifications to the vehicle which do not meet the guideline standards in this publication may
severely impact vehicle performance, stability, function, reliability and reduce customer
satisfaction. They could also lead to mechanical or structural failure.
Not all information in this manual applies to all territories.
NOTE
For additional information or technical support contact [email protected].
How To Use This Manual
This manual covers vehicle conversion procedures. The manual is divided into five parts relating
to different areas of the vehicle:
– General Information
– Body
– Electrical
– Chassis
– Powertrain
In some sections of this manual it may refer you to see additional sections for information, links
have been provided. These links are in blue text. This manual is also designed to be used as a

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printed document, where there are links page numbers have been added, which will help guide
you to the start of the section which contains the relevant information. There is also an
alphabetical index at the back of the manual. As with the contents pages you will be able to link
to sections. To do this just click on the page number.
All left and right handed references to the vehicle are taken from a position sitting in the driver
seat looking forward unless otherwise stated.
Important Safety Instructions
Appropriate conversion procedures are essential for the safe, reliable operation of all vehicles
as well as the personal safety of the individual carrying out the work. This manual cannot
possibly anticipate all such variations and provide advice or cautions as to each. Anyone who
does not follow the instructions provided in this manual must first establish that they
compromise neither their personal safety nor the vehicle integrity by their choice of methods,
tools or components.
WARNINGS, CAUTIONS and NOTES are used throughout this manual to highlight areas of
safety concern, potential damage to the vehicle or additional information.
WARNING
'Warning' text is used if there is a risk of injury.
CAUTION
'Caution' text is used if there is a risk of damage.
NOTE
Note text gives advice or further information.
Technical Information
Additional technical information can be requested from LEVC, for example in the form of:
– 2D Engineering Drawing PDF files
– 3D CAD data in STEP format
– LEVC Portal access to workshop information
NOTE
For additional information or technical support contact [email protected].
Commercial and Legal Aspects
Terminology
Converter refers to any re-seller altering the vehicle by converting the body and adding or
modifying any equipment not originally specified and/or supplied by LEVC.
Unique component refers to non-LEVC specified or after sale components or equipment not
covered by your LEVC warranty.

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Warranty on LEVC Vehicles
Contact The National Sales Company in the country where the vehicle will be registered for
details of the terms of any applicable LEVC warranty.
The Converter should warrant its design, materials and construction for a period at least equal
to any applicable LEVC warranty.
The Converter must ensure that any alteration made to a vehicle or component does not reduce
the safety, function, or durability of the vehicle or any component.
The Converter shall be solely responsible for any damage resulting from any alteration made by
the Converter or any of its agents to a LEVC Vehicle component.
The Converter releases LEVC from all claims by any third party for any cost or loss (including
any consequential damages) arising from work performed by a Converter unless LEVC has
given its prior written consent to such liability.
Whole Vehicle Type Approval
The objective of the 2007/46/EC Whole Vehicle Type Approval (WVTA) legislation or applicable
local legislation is to ensure that new vehicles, components and separate technical units put on
the market provide a high level of safety and environmental protection. This will help to ensure
that all vehicles are not damaged by the fitting or converting of certain parts or equipment, after
they have been placed on the market or entered service.
Converters are advised to check if the installation of additional parts require either Type
Approval or Individual Vehicle Approval before the vehicle is registered.
– Type Approval requires a Conformity of Production (CoP) inspection to be carried out at the
conversion location to demonstrate that all vehicles of the same type will conform to the type
approved specification.
– IVA requires inspection of an individual vehicle to establish compliance.
NOTE
Factory fitted LEVC parts are covered by the Certificate of Conformity (CoC)
Legal and Vehicle Type Approval
All components embodied on LEVC vehicles are approved to the applicable legal requirements.
LEVC vehicles have Type Approval for the intended marketing territories.
LEVC vehicles have Type Approval for many territories, although the vehicles shown in this
manual are not necessarily released in all territories.
NOTE
For additional information or technical support contact [email protected].

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Significant changes to the vehicle may affect its legal compliance. Strict adherence to the
original design intent for brakes, weight distribution, lighting, occupant safety and hazardous
materials compliance is mandatory.
Alternative Type Approval
If significant changes are made the Converter must negotiate with the relevant authority. Any
changes to the vehicle operating conditions must be advised to the customer.
Legal Obligations and Liabilities
The Converter should consult with its legal advisor on any questions concerning its legal
obligations and liabilities.
General Product Safety Requirement
The Converter shall ensure that any vehicle it places in the market complies with the European
General Product safety Directive 2001/95/EC (as amended periodically) or applicable local
legislation. The Converter shall also ensure that any alteration it makes to a LEVC vehicle or
component does not reduce its compliance with the European General Product Safety Directive.
The Vehicle Converter shall release LEVC from all liability for damages resulting from:
– failure to comply with the advice given in this manual.
– faulty design, production, installation, assembly or alteration not originally specified by
LEVC.
– failure to comply with the basic fit for purpose principles inherent in the original product.
Care Points
– Do not exceed the gross vehicle mass.
– The position of the center of gravity is changed when masses are added or removed from
the vehicle. This may influence the steering characteristics, handling behavior and the brake
performance.
– Do not change the tyre size or load rating.
– Do not modify the brake system.
– Do not modify, drill, cut or weld any suspension components, specifically the steering gear
system, subframe or anti-roll bars, springs or shock absorbers including mounting brackets.
– Do not modify or remove heat shields. Ensure adequate heat shields are maintained.
Maintain sufficient clearance to hot parts. Keep in mind that excessive heat can build up
from the exhaust system, in particular from the catalytic converter and from the Gasoline
Particulate Filter (GPF).
– When modifying the vehicle, ensure that the driver field of view is maintained.
– The travel and function of pedals must not be restricted.
– Do not remove labels provided with the original vehicle. Ensure appropriate visibility. Do not
change original location or remove warning labels provided with the original vehicle that are
in view of the driver. Ensure that labels remain in full view and not obstructed by any
modification.
– Do not route any electrical cables with the Anti-lock Brakes System and Traction Control
System cables. There is a risk of extraneous signal being passed between cables. It is
recommended to not attach electrical cables to existing harnesses or pipes.

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– Modifications to the restraints system are not allowed. Do not make changes to, or relocate
the Supplementary Restraint System (SRS) components or wiring.
– Attachments or modifications to the driver's cabin area of the vehicle may affect the airbag
deployment timing and result in uncontrolled deployment.
– Drilling the frame and body structure must be conducted following the guidelines in Body,
page 19 and Frame and Body Mounting, page 39.
– Make sure that reinforcements are installed to maintain the integrity of the original body
structure when adding steps, grab handles or similar modifications.
– The vehicle must not be used for the purposes of towing, it must not be fitted with a tow bar
or any towing equipment.
Product Liability
The Converter shall be liable for any product liability (whether for death, personal injury, or
property damage) arising from any alteration to a LEVC vehicle or component made by the
Converter or any of its agents. LEVC shall not be liable for any such liability (except as provided
by law).
The Converter or equipment manufacturer is liable for the:
– Operational reliability and road-worthiness of the vehicle to its original intent
– Operational reliability and road-worthiness of any component or conversion, not listed in
original LEVC documentation
– Operational reliability and road-worthiness of the vehicle as a whole (for example the body
changes and/or additional equipment must not have a negative effect on the driving, braking
or steering characteristics of the vehicle)
– Subsequent damage resulting from the conversion or attachment and installation of unique
components, including unique electrical or electronic systems
– Functional safety and freedom of movement of all moving parts (for example axles, springs,
shafts, steering mechanisms and brakes)
– Functional safety and freedom of the tested and approved flexibility of the body and integral
chassis structure
Contact Information
NOTE
For additional information or technical support contact [email protected].
Conversion Homologation
The Vehicle Converter must observe any statutory rules and regulations and is responsible for
obtaining any homologation certification required.
NOTE
For additional information or technical support contact [email protected].

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Electromagnetic Compatibility (EMC)
WARNING
Do not mount any transceiver, microphones, speakers, or any other similar
item on or near any airbag covers, on the side of the seats. Strong
electromagnetic interference could cause the airbags to deploy.
CAUTION
Do not fasten antenna cables to original vehicle wiring, fuel pipes and brake pipes.
Keep antenna and power cables at least 100 mm from any electronic modules and
airbags.
The vehicle has been tested and certified to electromagnetic compatibility legislation (UNECE
Regulation 10 or applicable local legislation). Ensure that any additional equipment installed on
the vehicle complies with applicable local legislation and other requirements.
Radio Frequency (RF) transmitter equipment (for example: cellular telephones, amateur radio
transmitters) may only be fitted to the vehicle if they are tested and do not affect the operation of
the vehicle. There are no special provisions or conditions for installations or use.
For EMC on Blue Light conversions with rear view cameras please contact LEVC.
NOTE
For additional information or technical support contact [email protected].
Vehicle Duty Guidelines
It is necessary to take into account the customer needs and the anticipated vehicle duty cycles
of the modified vehicle. The vehicle must not be modified beyond its capabilities to fulfill the
roles required by the customer.
Conversion Affect on Range and Performance
Any conversion may affect the range and performance depending on the aerodynamics and the
weight added by the conversion.
NOTE
For additional information or technical support contact [email protected].
It is advisable to control the weight, but without deteriorating other vehicle attributes and
functions (especially those related to safety and durability).
Vehicle Ride and Handling Attributes
WARNING
Do not exceed the gross vehicle mass

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Conversions to the vehicle that change the center of gravity may affect the ride and handling
attributes.
NOTE
All vehicles should be evaluated for safe operation prior to sale.
Dismantling and De-Pollution
Environmental and recycling aspects must be integrated in the development process of new
components and vehicles.
A Dismantling and De-Pollution manual is available from LEVC which provides more information
on this.
NOTE
For additional information or technical support contact [email protected].
Jacking
The Jacking points must be kept clear for use. Do not obstruct these areas.
The vehicle jack supplied with the vehicle must be accessible and stored in a safe place in the
vehicle. If a spare wheel or tyre inflation kit is supplied, it must also be accessible.

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Lifting
WARNING
When lifting the vehicle with a two post lift for the removal of the engine or
subframes, make sure the vehicle is secured to the lift using vehicle retention
straps to prevent tilting. Failure to follow these instructions may result in
personal injury.
Noise Vibration and Harshness (NVH)
Noise levels must not be deteriorated by the conversion.
Exterior noise
Make sure any powertrain/exterior related NVH is not affected by the conversion.
The exterior noise level of the converted vehicle has to be verified if changes are made near to
the following components:
– powertrain
– exhaust
– air intake system
– tyres
Interior noise
Reinforce panels and structures as appropriate to avoid vibrations. Consider the installation of
sound deadening material on panels to reduce interior noise.

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Vehicle Transportation Aids and Vehicle Storage
Claims arising from deterioration caused by incorrect storage, maintenance or handling are not
the responsibility of LEVC. Vehicle Converters must determine their own procedures and
precautions, particularly where vehicles are stored in the open, because they may be exposed
airborne contaminants.
Storage Precautions
CAUTION
Disconnect the 12 volt battery if the vehicle is to be stored for more than 7 days.
CAUTION
Make sure that the protective covers are not removed from an incomplete vehicle
until the conversion is started.
CAUTION
Make sure that components removed during conversion are kept clean and dry.
CAUTION
Make sure that components removed during conversion are refitted to the same
vehicle.
– The windscreen wipers should be set to the service position and lifted off of the glass.
– Increase normal tire pressure by 0.5 bar.
– Keep the parking brake disengaged during storage. Switch the electronic parking brake off
before disconnecting the 12 volt battery. This will allow the vehicle to be moved by hand
around a workshop.
– Install suitable wheel chocks to prevent roll away.
Where possible, vehicles should be stored in an enclosed, dry, well-ventilated area. This area
must be on firm, well drained ground which is free of long grass or weeds and where possible
protected from direct sunlight.
Vehicles must not be parked near, under foliage or close to water as additional protection may
be necessary for certain areas of the vehicle.
Long Term Storage
The wiper blades should be removed and placed inside the vehicle. Make sure the wiper arms
are prevented from resting on the windscreen.
Wheel trims (where fitted) should be removed and stored in the vehicle.
Release the electronic parking brake and chock the wheels.
Set Recirculation in the climate controls to the "open" position to provide ventilation.

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Where protective film has been applied at manufacturing it must be left on the vehicle until
prepared for delivery but must be removed after a maximum storage period of six months (film
is date stamped to indicate required removal date).
Make sure that the bonnet and all windows and doors are completely closed and the vehicle is
locked.
12 volt Battery Storage
CAUTION
Do not use a fast charging function to charge the 12 volt battery. Only use a modern
battery charger with controlled charging voltage.
CAUTION
Do not connect an external battery or battery charger directly to the 12 volt battery.
Only use the 12 volt charging points located in the engine compartment.
CAUTION
Do not connect another vehicle to the 12 volt battery or the 12 volt charging points. It
is not possible to jump start another vehicle from your vehicle. This procedure can
cause a fuse to fail on your vehicle.
NOTE
If the 12 volt battery and the high voltage battery are discharged, then the two
batteries must be charged. The 12 volt battery must have a minimum state of charge
before the high voltage battery can be charged.
The 12 volt battery should be disconnected, but not removed from the vehicle
To make sure the battery is maintained correctly and to assist in preventing premature failure, it
is necessary to check and recharge the battery monthly while a vehicle is not in use. Where a
12 volt battery is left below its optimum charge level for any length of time, it may result in
premature failure of the battery.
HV Battery Storage
To minimise high voltage battery deterioration during prolonged storage of the vehicle (longer
than one month), a charge level of approximately 80% is recommended, as indicated on the
driver's display.
– If the state of charge is high, run the vehicle until approximately 80% remains.
– If the state of charge is low, charge the high voltage battery until a level of approximately
80% is reached.
While in storage, especially when storing for longer than 6 months, periodically check the
charge level in the driver's display. If the level is below 70%, charge the battery to approximately
80% again.

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NOTE
Choose the coolest location possible for the vehicle in order to minimise deterioration
of the high voltage battery during long-term storage. Preferably indoors, or in the
shade in warmer climates.
Regular Checks
Perform these checks once a month:
– Check the vehicle is clean
– Remove any external contamination
– Check the 12 volt battery charge - recharge if necessary
– Check the HV battery charge level in the driver's display - if it is below 70% charge to 80%
– Check the tyre condition
Perform these checks every 3 months:
– Check the interior for condensation
– Run the petrol range extender
Transportation
CAUTION
Do not tow the vehicle. If you tow the vehicle, you will cause damage to the electric
drive motor in the vehicle.
NOTE
The vehicle must only be transported with all four wheels off the ground.
Load Space Dimensions
1 Side load space door aperture height - 1,200 mm
2 Rear load space doors aperture height - 1,272 mm

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3 Rear load space door aperture width - 1,275 mm
4 Load space height - 1,372 mm
5 Load space length - 2,447 mm
6 Load space width between wheel arches - 1,275 mm
7 Load space width maximum - 1,526 mm
8 Step height - 640
Load Distribution
Maximum weights and Centre of Gravity (CoG) limits
Maximum gross vehicle weight of the vehicle* 2900 Kg
Maximum axle weight** 1500 Kg
Maximum CoG height (Z) (measured from the
ground)
795 mm
Maximum difference of CoG lateral position 4%
* The maximum gross vehicle weight of the vehicle includes the vehicle, all passengers, cargo
and any modifications or conversions to the original vehicle.
** The weight measured at the front or rear axle must not exceed the maximum axle weight.
Centre of Gravity Position
The position of the center of gravity is changed when masses are added or removed from the
vehicle. This may influence the steering characteristics, handling behavior and the brake
performance.
It is important to check that the centre of gravity position has not moved beyond acceptable
limits once extra equipment is fitted, or if weight has been removed for example.
Centre of Gravity (CoG) Lateral Position
The center of mass of any additional equipment must be located within the wheelbase of the
vehicle.
Avoid one-sided load distribution. Uneven load distribution could result in unacceptable handling
and braking characteristics.
The lateral position of the CoG can be calculated using the following procedure:
1. Weigh the vehicle under each wheel on a horizontal surface.
2. Add the mass weighed at the front right wheel to the mass weighed at the rear right wheel to
give the total right side mass. Do the same for the left front and left rear wheel to give the
total left side mass.
3. Compare the total right side mass to the total left side mass. The difference between the two
values must not exceed the maximum difference of CoG lateral position stated in the table
above.

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Centre of Gravity (CoG) Height (Z)
The CoG Height influences axle weights while braking and roll stability.
The highest acceptable limit for the CoG Height (Z) is stated in the table above and can be
calculated using the method below.
Centre of Gravity Height Test Procedure
WARNING
It is the responsibility of the converter that the following Centre of Gravity Test
Procedure is undertaken in a safe and controlled manner and that suitable
equipment is used throughout the procedure.
Use four weighing scales, one under each wheel of the vehicle.
The vehicle is to be first weighed and measured in a horizontal position. Then the front wheels
are to be raised to three different heights and weights and measurements taken again each
time.
NOTE
The higher the front of the vehicle is lifted the more accurate the results will be. This
will be restricted by physical limitations of the ground clearance of the vehicle, the
height of the roof, the equipment used and environment.
NOTE
This procedure can also be repeated raising the rear wheels for increased accuracy.
For the best possible accuracy the following preparations should be made:
– fix wheel travel using solid shocks or spring fixes for example
– Increase tyre pressure to maximum allowed value
– remove all moving loads from the vehicle or make sure that they are securely fixed in place
– close the vehicle doors
To calculate the Centre of Gravity Height (Z) follow the procedure below.

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Centre of Gravity Height Calculation
Measurements Required Measurements Taken
1st 2nd 3rd
Wheelbase WB mm
Front Axle Weight mVkg
Rear Axle Weight mHkg
Total Mass mG= mV+ mHkg
Inclined Vehicle
Front Axle Weight m'Vkg

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Measurements Required Measurements Taken
1st 2nd 3rd
Rear Axle Weight m'Hkg
Height (Lift) H mm
Inclination Angle * α deg
Centre of Gravity Height ** Z mm
Values (Horizontal)
Centre of Gravity (CoG) height (from the ground) Z
Wheelbase WB
Front axle weight mV
Rear axle weight mH
Total vehicle weight mG
Radius of the tyre rtyre
Values (Inclined)
Centre of Gravity (CoG) height (from the vehicle axle centre line) ZSP
Front axle weight m'V
Rear axle weight m'H
Total vehicle weight m'G
Height (lift) H
Angle of incline α

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Centre of Gravity Longitudinal Position
The longitudinal position of the Centre of Gravity can be found by weighing the vehicle at it's
wheels in a horizontal position, using the formulas below.

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Body
Body Structure - General Information
CAUTION
Before you drill into the vehicle, you must examine the Drill Zones, page 20
document. This will help you to avoid damage to other components.
When you do the conversion:
– Do not damage the structural integrity of the vehicle.
– Do not drill into closed sections or extrusions
– Make sure that the weight of the additional components added is distributed evenly.
– All fasteners installed through the floor, side or roof must be sealed to prevent water ingress.
Use an LEVC approved sealant.
Welding
CAUTION
Do not weld the vehicle structure. The aluminum structure is riveted and bonded.
Heat from welding will damage the adhesive.
Cooling and air intakes
Do not install components that will decrease the air flow through the front grilles 3. If you
decrease the air flow it will cause the vehicle to over heat and restrict the engines air intake 2.
Do not install components that will decrease air flow through the cowl vent screen 1. If you
decrease the air flow it will reduce the performance of the climate control system.