The continuous increasingly stringent regulations for CO2 fleet targets request further alternative and customer friendly solutions. High costs, reduced driving distances and missing infrastructures are some aggregative facts for end customer acceptance thus also for a broad market launch of ZEVs. Plug-in hybrids are meanwhile "state of the art" with partly "Zero Emission" operation mode and show already a good CO2 reduction potential. The project partners HyCentA Research GmbH, Magna Steyr Engineering AG & Co KG, Proton Motor Fuel Cell GmbH and Technische Universität Wien have developed a future vehicle solution for long driving ranges at zero emission within a national funded research project. The combustion engine of an existing ICE range extender shuttle van was substituted by a 25 kW PEM fuel cell system. The former utilized battery was reduced in size to decrease the overall weight of the vehicle. Approaches for the complete vehicle integration of the fuel cell range extender and the 70 MPa hydrogen storage system are presented. The high voltage architecture was newly developed and the thermal management has been re-designed. A two circuit coolant system fulfills the wide range of component demands with the possibility of fuel cell waste heat usage for cabin heating. Influences of the operation strategy on the energy and cost efficiency of the vehicle are shown and the optimization potentials will be outlined. The adaptive energy management algorithm and its influence on the fuel efficiency and driving range will be presented. It is highlighted that the vehicle setup combines the advantages of the battery and the fuel cell technology to compensate shortcomings like refueling duration, driving range and dynamic operation.