General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Assembly overview – lock carrier
  1
• 1.2 Removing and installing lock carrier
  2
• 1.3 Detaching pressure hoses
  4
• 2 Wings
  7
• 2.1 Assembly overview - front wing
  7
• 2.2 Assembly overview - elbow
  8
• 2.3 Removing and installing front wing
  8
• 2.4 Front wing replacement part
  11
• 2.5 Removing and installing elbow
  11
• Bonnet, rear lid
  15
• 1 Bonnet
  15
• 1.1 Assembly overview - bonnet
  15
• 1.2 Assembly overview - bonnet stay
  16
• 1.3 Assembly overview – bonnet lock and release components
  17
• 1.4 Removing and installing bonnet
  17
• 1.5 Adjusting bonnet
  19
• 1.6 Removing and installing bonnet stay
  21
• 1.7 Removing and installing bonnet hinge
  22
• 1.8 Removing and installing bonnet lock
  23
• 1.9 Removing and installing arrester
  24
• 1.10 Removing and installing insulation
  25
• 2 Tank flap
  26
• 2.1 Assembly overview - fuel tank flap
  26
• 2.2 Removing and installing fuel tank flap
  26
• Front doors, door components, central locking
  29
• 1 Door
  29
• 1.1 Assembly overview - front door
  29
• 1.2 Assembly overview – door hinge
  31
• 1.3 Removing and installing inner door seal
  31
• 1.4 Removing and installing front door
  33
• 1.5 Adjusting door
  35
• 1.6 Adjusting striker pin
  35
• 1.7 Removing and installing door hinge
  36
• 1.8 Removing and installing door arrester
  38
• 1.9 Removing and installing striker pin
  38
• 2 Door components
  40
• 2.1 Assembly overview - window regulator
  40
• 2.2 Assembly overview - door handle and door lock
  41
• 2.3 Removing and installing window regulator
  41
• 2.4 Removing and installing window regulator motor
  43
• 2.5 Removing and installing lock cylinder housing
  45
• 2.6 Removing and installing door handle
  46
• 2.7 Removing and installing mounting bracket
  46
• 2.8 Removing and installing door lock
  47
• 3 Central locking
  49
• 3.1 Overview of fitting locations – central locking
  49
• 3.2 Assembly overview - ignition key to 2010
  50
• 3.3 Assembly overview - ignition key from 2010
  51
• 3.4 Removing and installing ignition key battery to 2010
  51
• 3.5 Removing and installing ignition key battery from 2010
  52
• Rear doors, door components
  54
• 1 Sliding door
  54
• 1.1 Assembly overview - guide rail
  54
• 1.2 Assembly overview – upper guide rail
  55
• 1.3 Removing and installing sliding door inner seals
  55
• 1.4 Removing and installing sliding door
  56
• 1.5 Adjusting sliding door
  58
• 1.6 Removing and installing guide rail
  66
• 1.7 Removing and installing upper guide rail
  67
• 2 Components of sliding door
  69
• 2.1 Assembly overview – components of sliding door
  69
• 2.2 Assembly overview - interior operating mechanism
  71
• 2.3 Assembly overview – additional lock
  72
• 2.4 Removing and installing upper roller guide
  72
• 2.5 Removing and installing lower roller guide
  73
• 2.6 Removing and installing hinge
  73
• 2.7 Removing and installing sliding door limit stop
  74
• 2.8 Removing and installing opening restrictor
  74
• 2.9 Removing and installing lock cylinder housing
  75
• 2.10 Removing and installing door handle
  75
• 2.11 Removing and installing mounting bracket
  75
• 2.12 Removing and installing door lock
  77
• 2.13 Removing and installing interior door handle
  78
• 2.14 Removing and installing additional lock at top
  80
• 2.15 Removing and installing striker pin
  81
• 2.16 Removing and installing striker pin
  82
• 2.17 Removing and installing guide wedge and slide
  82
• 3 Electric sliding door
  85
• 3.1 Assembly overview – sliding door
  85
• 3.2 Assembly overview - interior operating mechanism
  88
• 3.3 Assembly overview - guide rail
  89
• 3.4 Assembly overview – upper guide rail
  90
• 3.5 Removing and installing sliding door inner seal
  90
• 3.6 Removing and installing sliding door
  92
• 3.7 Adjusting sliding door
  94
• 3.8 Motor release mechanism
  101
• 3.9 Checking and adjusting tension of drive belt
  102
• 3.11 Removing and installing upper roller guide
  104
• 3.12 Removing and installing lower roller guide
  105
• 3.13 Removing and installing roller carriage
  105
• 3.14 Removing and installing sliding door limit stops
  107
• 3.17 Removing and installing lock cylinder housing
  110
• 3.18 Removing and installing door handle
  111
• 3.19 Removing and installing mounting bracket
  111
• 3.21 Removing and installing interior door handle
  115
• 3.22 Removing and installing pinch protection
  117
• 3.23 Removing and installing additional lock/upper power latching system
  118
• 3.24 Removing and installing striker pin
  119
• 3.26 Removing and installing guide wedge and slide
  121
• 3.27 Removing and installing guide rail
  122
• 3.28 Removing and installing upper guide rail
  123
• 3.29 Electric sliding door switch in B-pillar
  125
• 4 Right rear wing door
  127
• 4.1 Assembly overview - right rear wing door
  127
• 4.2 Assembly overview – door hinge
  129
• 4.3 Assembly overview – door arrester
  130
• 4.4 Assembly overview - upper door lock and lower guide
  131
• 4.5 Assembly overview - interior operating mechanism
  132
• 4.6 Assembly overview - door lock
  133
• 4.7 Removing and installing wing door inner seal
  133
• 4.8 Removing and installing rear right wing door
  134
• 4.9 Adjusting rear wing door
  136
• 4.10 Removing and installing door hinge
  142
• 4.11 Removing and installing door arrester
  143
• 4.12 Removing and installing - door upper lock and lower guide
  145
• 4.13 Removing and installing interior door handle
  147
• 4.14 Removing and installing door lock
  149
• 4.15 Removing and installing lock cylinder housing
  151
• 4.16 Removing and installing door handle
  151
• 4.17 Removing and installing mounting bracket
  152
• 4.18 Removing and installing upper striker pin
  153
• 4.19 Removing and installing centring pin and lower striker with centring pin
  154
• 5 Left rear wing door
  155
• 5.1 Assembly overview - left rear wing door
  155
• 5.2 Assembly overview - interior lock
  157
• 5.3 Assembly overview - door arrester with opening angle of 250°
  158
• 5.4 Removing and installing upper door lock
  158
• 5.5 Removing and installing lower door lock
  159
• 5.6 Removing and installing striker pin
  160
• 5.7 Removing and installing door opener
  160
• 5.8 Removing and installing interior lock
  160
• 5.9 Removing and installing door arrester with opening angle of 250°
  162
• 6 Cab door
  164
• 6.1 Assembly overview - cab door
  164
• 6.2 Assembly overview - hinges and hinge brackets
  166
• 6.3 Removing and installing cab door seal
  166
• 6.4 Removing and installing cab door
  168
• 6.5 Adjusting cab door
  170
• 6.6 Removing and installing hinges and hinge brackets
  172
• 6.7 Removing and installing door arrester
  173
• 6.8 Removing and installing housing
  174
• 6.9 Removing and installing door handle
  175
• 6.10 Removing and installing mounting bracket
  175
• 6.11 Removing and installing door lock
  176
• 6.12 Removing and installing interior door handle
  178
• 6.13 Removing and installing striker pin
  179
• Sunroof
  181
• 1 Sunroof with glass panel
  181
• 1.1 Function
  181
• 1.2 Assembly overview - sliding/tilting sunroof with glass panel
  182
• 1.3 Removing and installing sliding/tilting sunroof with glass panel
  182
• 1.4 Removing and installing sliding glass roof
  184
• 1.5 Removing and installing tilting arm
  185
• 1.6 Removing and installing sliding sunroof motor
  186
• 1.7 Removing and installing trim
  188
• Bumpers
  189
• 1 Bumper, front
  189
• 1.1 Assembly overview - front bumper cover
  189
• 1.2 Assembly overview - add-on parts
  191
• 1.3 Removing and installing front bumper cover, vehicles up to 2012
  191
• 1.4 Removing and installing front bumper cover, vehicles as of 2012
  193
• 1.5 Removing and installing front bumper carrier, vehicles up to 2012
  195
• 1.6 Removing and installing front bumper carrier, vehicles as of 2012
  196
• 1.7 Repairing front bumper cover
  198
• 2 Bumper, rear
  199
• 2.1 Assembly overview - rear bumper cover
  199
• 2.2 Assembly overview - rear bumper cover, add-on parts
  200
• 2.3 Assembly overview - steps
  201
• 2.4 Removing and installing rear bumper cover
  201
• 2.5 Removing and installing rear step
  203
• 2.6 Repairing rear bumper cover
  205
• Glazing
  206
• 1 Repair instructions
  206
• 1.1 Minimum curing period
  206
• 1.2 Repairing windscreen
  207
• 1.3 Installation instructions for bonded windows
  207
• 1.4 Preparing old undamaged window for glazing
  208
• 1.5 Preparing new windows for installing
  209
• 1.6 Preparing body flange for glazing
  210
• 1.7 Touching up paint damage
  210
• 1.8 Cleaning in the event of dirt caused by adhesive sealant
  211
• 2 Windscreen
  212
• 2.1 Assembly overview - windscreen
  212
• 2.2 Assembly overview - heated windscreen and rain sensor
  213
• 2.3 Removing and installing windscreen
  213
• 3 Side window
  218
• 3.1 Assembly overview - side window
  218
• 3.2 Removing and installing side window
  218
• 4 Movable section of sliding window
  222
• 4.1 Assembly overview – control mechanism for sliding window
  222
• 4.2 Removing and installing movable section of sliding window
  223
• 5 Rear windscreen
  226
• 5.1 Assembly overview – rear wing door window
  226
• 5.2 Removing and installing rear wing door window
  226
• 6 Rear sliding window
  230
• 6.1 Removing and installing rear sliding window
  230
• 7 Roof window
  233
• 7.1 Assembly overview - roof window
  233
• 7.2 Removing and installing roof window
  233
• 8 Front door window
  237
• 8.1 Assembly overview - front door window
  237
• 8.2 Removing and installing door window
  237
• 8.3 Adjusting door window
  238
• 8.4 Removing and installing side window
  239
• 9 Windows having threaded connections
  241
• 9.1 Assembly overview - rear vent window
  241
• 9.2 Assembly overview - cab rear door vent window
  242
• 9.3 Removing and installing rear vent window
  242
• 9.4 Removing and installing cab rear door vent window
  244
• Exterior equipment
  246
• 1 Radiator grille and front trim
  246
• 1.2 Assembly overview – radiator grille as of model year 2012
  247
• 2 Mouldings, trims, extensions
  253
• 2.1 Tool
  253
• 2.2 Assembly overview – headlight trim, up to model year 2011
  253
• 2.3 Removing and installing headlight trim, up to model year 2011
  254
• 2.4 Removing and installing air intake grille
  256
• 2.5 Removing and installing wing cover
  257
• 2.6 Removing and installing side panel trim
  257
• 2.7 Removing and installing number plate light trim
  258
• 2.8 Assembly overview - protective side strip
  262
• 3 Noise insulation
  264
• 3.1 Assembly overview - noise insulation
  264
• 3.2 Removing and installing noise insulation
  265
• 4 Drive assembly guard - Crafter 4MOTION with Achleitner all-wheel drive
  268
• 4.1 Drive assembly guard
  268
• 5 Exterior mirror
  271
• 5.1 Assembly overview - exterior mirror
  271
• 5.2 Removing and installing mirror glass, up to 2010
  275
• 5.3 Removing and installing mirror glass, from 2010
  276
• 5.4 Removing and installing auxiliary panoramic mirror, up to 2010
  278
• 5.5 Removing and installing auxiliary panoramic mirror, from 2010
  279
• 5.6 Removing and installing mirror housing
  280
• 5.7 Removing and installing exterior mirror (electrically adjustable)
  281
• 6 Wheel housing liner
  283
• 6.1 Tool
  283
• 6.2 Assembly overview - front wheel housing liner
  283
• 6.3 Removing and installing front wheel housing liner
  285
• 7 Lettering and emblems
  286
• 7.1 Assembly overview - rear emblem and trim panel
  286
• 7.2 Dimensions, lettering on rear
  286
• 7.3 Removing and installing rear emblem and trim panel
  289
• 7.4 Wing lettering - Crafter 4MOTION with Achleitner all-wheel drive
  291
• 8 Special add-on parts
  292
• 8.1 Wheel arch extensions - Crafter 4MOTION with Achleitner all-wheel drive
  292
• 8.2 Repair instructions
  292
• 8.3 Assembly overview - wheel housing extensions
  293
• 8.4 Removing and installing front bumper cover extension
  294
• 8.5 Removing and installing wing extension
  296
• 8.6 Removing and installing wing protective side moulding extension
  299
• 9 Towing bracket
  302
• 9.1 Tools
  302
• 9.2 Installation instructions
  302
• 9.3 Assembly overview - towing brackets
  302
• 9.4 Removing and installing rigid towing bracket
  305
• 9.5 Installation notes
  306
• 10 Spare wheel bracket
  307
• 10.1 Tools
  307
• 10.2 Assembly overview - spare wheel bracket
  307
• 10.3 Removing and installing spare wheel bracket
  308
• 11 Mudflap
  310
• 11.1 Tool
  310
• 11.2 Front mud flap
  310
• 11.3 Rear mud flap
  313
• 12 Load floor body
  315
• 12.1 Tools
  315
• 12.2 Contact corrosion
  316
• 12.3 Assembly overview - load floor body
  316
• 12.4 Assembly overview – luggage compartment floor and sideboard
  318
• 12.5 Sideboard
  319
• 12.6 Skid plate
  321
• 12.7 Rear skid plate
  323
• 12.8 Rear wing
  324