General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier to 2011
  1
• 1.1 Assembly overview – lock carrier
  1
• 1.2 Removing and installing lock carrier
  2
• 1.3 Moving to and back from service position
  4
• 2 Lock carrier from 2011
  8
• 2.1 Assembly overview – lock carrier
  8
• 2.2 Removing and installing lock carrier
  9
• 2.3 Moving to and back from service position
  11
• 3 Wings on vehicles manufactured up to 2011
  18
• 3.1 Assembly overview - wing
  18
• 3.2 Assembly overview – additional wing cover
  19
• 3.3 Removing and installing wing
  19
• 3.4 Removing and installing wing bracket
  23
• 3.5 Removing and installing wing securing bracket
  24
• 4 Wings on vehicles manufactured as of 2011
  26
• 4.1 Assembly overview - wing
  26
• 4.2 Removing and installing wing
  27
• 4.3 Removing and installing wing bracket
  30
• 5 Bulkhead
  31
• 5.1 Assembly overview - plenum chamber bulkhead
  31
• 5.2 Assembly overview - plenum chamber bulkhead
  32
• 5.3 Assembly overview - plenum chamber cover
  34
• 5.4 Removing and installing plenum chamber cover
  34
• Bonnet, rear lid
  37
• 1 Bonnet
  37
• 1.1 Assembly overview - bonnet
  37
• 1.2 Assembly overview - bonnet lock and release components
  39
• 1.3 Removing and installing bonnet
  39
• 1.4 Adjusting bonnet
  41
• 1.5 Removing and installing bonnet lock on vehicles up to 2010
  44
• 1.6 Removing and installing bonnet lock on vehicles as of 2011
  45
• 1.7 Removing and installing bonnet release lever
  46
• 1.8 Removing and installing striker pin on vehicles as of 2011
  46
• 1.9 Removing and installing hinge
  47
• 1.10 Detaching Bowden cable
  48
• 1.11 Removing and installing insulation
  48
• 1.12 Removing and installing gas strut
  50
• 1.13 Releasing gas from gas strut
  52
• 2 Rear lid
  53
• 2.1 Assembly overview - rear lid
  53
• 2.2 Assembly overview – locking and release components
  55
• 2.4 Removing and installing rear lid
  58
• 2.5 Adjusting rear lid
  60
• 2.6 Removing and installing bonnet lock
  66
• 2.7 Removing and installing hinges
  68
• 2.8 Removing and installing striker pin
  70
• 2.9 Removing and installing latch carrier
  71
• 2.10 Removing and installing lock cylinder carrier
  75
• 2.11 Removing and installing exterior handle without lock cylinder, vehicles as of 2011
  75
• 2.12 Dismantling exterior handle without lock cylinder
  82
• 2.13 Removing and installing light strip
  87
• 2.14 Attachment of registration plate
  88
• 2.15 Removing and installing rear lid seal
  89
• 2.16 Removing and installing gas strut
  90
• 2.17 Releasing gas from gas strut
  92
• 3 Tank flap
  93
• 3.1 Assembly overview - fuel tank flap
  93
• 3.2 Assembly overview – tank flap locking unit
  94
• 3.3 Removing and installing fuel tank flap
  94
• 3.4 Removing and installing tank flap locking unit
  96
• Front doors, door components, central locking
  98
• 1 Rear door
  98
• 1.1 Assembly overview – door hinge
  98
• 1.2 Assembly overview – door hinges on postal and parcel delivery vehicles
  100
• 1.3 Removing and installing inner door seal
  102
• 1.4 Removing and installing outer door seal
  103
• 1.5 Removing and installing door hinge
  104
• 1.7 Greasing new door hinges
  108
• 1.8 Removing and installing front door
  108
• 1.9 Removing and installing front doors on postal and courier service vehicles
  110
• 1.10 Adjusting door
  111
• 1.11 Adjusting striker pin
  114
• 2 Door components
  115
• 2.1 Assembly overview - subframe
  115
• 2.2 Assembly overview - door handle and door lock
  116
• 2.3 Removing and installing subframe
  117
• 2.4 Removing and installing lock cylinder housing
  122
• 2.5 Removing and installing door handle
  124
• 2.6 Removing and installing door lock
  126
• 2.7 Installing mounting bracket
  127
• 3 Central locking
  128
• 3.1 Overview of fitting locations – central locking
  128
• 3.2 Assembly overview - ignition key to 2010
  130
• 3.3 Assembly overview - ignition key from 2010
  131
• 3.4 Assembly overview – ignition key with light
  132
• 3.5 Removing and installing ignition key battery to 2010
  132
• 3.6 Removing and installing ignition key battery from 2010
  133
• 3.7 Removing and installing battery for ignition key with light
  134
• Rear doors, door components
  136
• 1 Sliding door
  136
• 1.1 Assembly overview - sliding door roller guides
  136
• 1.2 Assembly overview – door arrester
  137
• 1.3 Assembly overview – guide rail cover
  137
• 1.4 Assembly overview – middle guide rail
  140
• 1.5 Removing and installing sliding door
  140
• 1.6 Adjusting sliding door
  143
• 1.7 Removing and installing hinge
  150
• 1.8 Removing and installing door arrester
  150
• 1.9 Removing and installing upper stop
  151
• 1.10 Removing and installing guide rail cover
  152
• 1.11 Removing and installing middle guide rail
  154
• 1.12 Removing and installing inner door seal
  157
• 1.13 Removing and installing top door seal on Caddy, short version
  158
• 1.14 Removing and installing top door seal on Caddy Maxi
  158
• 1.15 Removing and installing bottom door seal on Caddy, short version
  159
• 1.16 Removing and installing bottom door seal on Caddy Maxi
  159
• 2 Components of sliding door
  160
• 2.1 Assembly overview – sliding door locking and release components
  160
• 2.2 Assembly overview – remote release mechanism
  162
• 2.3 Assembly overview – mounting bracket
  162
• 2.4 Assembly overview - interior operating mechanism
  164
• 2.5 Removing and installing striker pin
  164
• 2.6 Removing and installing door lock
  165
• 2.7 Removing and installing exterior door handle
  166
• 2.8 Removing and installing remote release mechanism
  167
• 2.9 Removing and installing mounting bracket
  169
• 2.10 Removing and installing interior door handle
  170
• 3 Wing door
  173
• 3.1 Assembly overview – right wing door
  173
• 3.2 Assembly overview - rear left wing door
  174
• 3.3 Assembly overview – wing door hinges
  175
• 3.4 Removing and installing wing door
  175
• 3.5 Removing and installing rear wing door hinges
  177
• 3.6 Adjusting wing door
  179
• 3.7 Removing and installing wing door seal
  184
• 3.8 Removing and installing inner seal of wing door
  185
• 4 Components of rear wing door
  186
• 4.1 Assembly overview – locking and release components of rear wing door
  186
• 4.2 Assembly overview - release lever
  188
• 4.3 Assembly overview – remote release motor carrier
  189
• 4.4 Assembly overview – exterior door handle
  190
• 4.5 Removing and installing upper and lower striker pins
  190
• 4.6 Removing and installing upper lock
  191
• 4.7 Removing and installing lower lock
  192
• 4.8 Removing and installing release lever
  193
• 4.9 Removing and installing motor carrier part for remote release
  194
• 4.10 Removing and installing interior door handle
  196
• 4.11 Removing and installing exterior door handle
  196
• 4.12 Removing and installing light strip
  198
• 4.13 Removing and installing lock cylinder
  199
• Bumpers
  200
• 1 Front bumper cover to 2011
  200
• 1.1 Assembly overview – front bumper cover, standard equipment version
  200
• 1.2 Assembly overview – front bumper cover painted in vehicle colour
  202
• 1.3 Assembly overview – add-on parts, standard equipment version
  203
• 1.4 Assembly overview – add-on parts painted in vehicle colour
  204
• 1.5 Assembly overview - substructure components
  205
• 1.6 Assembly overview - front bumper carrier
  206
• 1.7 Removing and installing front bumper cover, standard equipment version
  206
• 1.8 Removing and installing front bumper cover painted in vehicle colour
  208
• 1.9 Repairing front bumper cover
  209
• 2 Front bumper cover from 2011
  210
• 2.1 Assembly overview - front bumper cover
  210
• 2.2 Assembly overview - front bumper cover, add-on parts
  212
• 2.3 Assembly overview - front bumper cover, add-on parts, »Cross Caddy«
  213
• 2.4 Assembly overview - front bumper cover, substructure components
  214
• 2.5 Assembly overview - front bumper carrier
  215
• 2.6 Assembly overview - parking aid and brackets in front bumper cover
  216
• 2.7 Removing and installing front bumper cover
  216
• 2.8 Repairing front bumper cover
  220
• 2.9 Installing brackets for parking aid system
  220
• 3 Bumper, rear
  225
• 3.1 Assembly overview - rear bumper cover
  225
• 3.2 Assembly overview - rear bumper cover for towing bracket
  227
• 3.3 Assembly overview - rear bumper cover, add-on parts
  228
• 3.4 Assembly overview - rear bumper cover, add-on parts, »Cross Caddy«
  229
• 3.5 Assembly overview - parking aid, brackets in rear bumper cover
  230
• 3.6 Assembly overview - bumper carrier with rear bumper cover
  232
• 3.7 Removing and installing rear bumper cover
  232
• 3.8 Removing and installing rear bumper cover for towing bracket
  235
• 3.9 Removing and installing bumper carrier with rear bumper cover
  237
• 3.10 Repairing rear bumper cover
  238
• 3.11 Installing brackets for parking aid system
  239
• Glazing
  244
• 1 Repair instructions
  244
• 1.1 Minimum curing period
  244
• 1.2 Window repair
  245
• 1.3 Installation instructions for bonded windows
  245
• 1.4 Preparing old undamaged windows for fitting
  246
• 1.5 Preparing new windows for installing
  247
• 1.6 Preparing body flange for glazing
  248
• 1.7 Touching up paint damage
  249
• 1.8 Cleaning in the event of dirt caused by adhesive sealant
  249
• 2 Windscreen
  251
• 2.1 Assembly overview - windscreen
  251
• 2.2 Dimensions for adhesive bead and glass/paint primer on windscreen
  252
• 2.3 Removing and installing windscreen
  252
• 3 Rear windscreen
  257
• 3.1 Assembly overview - rear window
  257
• 3.2 Dimensions for adhesive bead and glass/paint primer on rear window
  258
• 3.3 Removing and installing rear window
  258
• 4 Rear wing door window
  261
• 4.1 Assembly overview – rear wing door window
  261
• 4.2 Dimensions for adhesive bead and glass/paint primer on rear wing door window
  262
• 4.3 Removing and installing rear wing door window
  263
• 5 Side window
  265
• 5.1 Assembly overview – side window in sliding door
  265
• 5.2 Assembly overview - sliding window in sliding door
  267
• 5.3 Assembly overview – side window
  268
• 5.4 Assembly overview – side window
  269
• 5.5 Assembly overview - sliding window in side panel
  270
• 5.6 Assembly overview - movable section of sliding window
  271
• 5.7 Dimensions for adhesive bead and glass/paint primer on side window
  273
• 5.8 Removing and installing side window in sliding door
  275
• 5.9 Removing and installing sliding window in sliding door
  277
• 5.11 Removing and installing side window
  284
• 5.12 Removing and installing sliding window in side panel
  286
• 5.13 Removing and installing movable section of sliding window
  288
• 6 Front door window
  290
• 6.1 Assembly overview - front door window
  290
• 6.2 Assembly overview – window channel
  292
• 6.3 Removing and installing door window
  292
• 6.4 Removing and installing window regulator motor
  295
• 6.5 Removing and installing window channel
  296
• 7 Windows having threaded connections
  299
• 7.1 Assembly overview - front side window
  299
• 7.2 Assembly overview – vent wing
  299
• 7.3 Removing and installing front side window
  300
• 7.4 Removing and installing vent wing
  301
• Exterior equipment
  303
• 1 Radiator grille and front trim
  303
• 1.1 Assembly overview - radiator grille
  303
• 1.2 Removing and installing radiator grille up to 2011
  303
• 1.3 Removing and installing radiator grille on vehicles from 2011
  305
• 2 Mouldings, trims, extensions
  307
• 2.1 Assembly overview - protective side mouldings
  307
• 2.2 Assembly overview - protective side moulding, »Edition 30«
  308
• 2.3 Assembly overview - tunnel cross-piece
  309
• 2.4 Removing and installing protective side mouldings
  309
• 2.5 Removing and installing sill panel moulding, »Edition 30«
  311
• 2.6 Removing and installing decorative strip for light strip
  313
• 3 Noise insulation
  316
• 3.1 Assembly overview – noise insulation
  316
• 4 Decorative film
  319
• 4.1 Decorative film for rear wing door window
  319
• 4.2 Decorative film for rear bumper, »Edition 30«
  320
• 4.3 Decorative film on side member, »Cross Caddy«
  323
• 5 Roof railing
  326
• 5.1 Assembly overview - roof railing
  326
• 5.2 Removing and installing roof railing
  326
• 6 Exterior mirror
  332
• 6.1 Assembly overview - exterior mirror
  332
• 6.2 Assembly overview – insulation, sealing strip and fabric strip for exterior mirror
  333
• 6.3 Removing and installing mirror housing
  333
• 6.4 Removing and installing mirror glass
  335
• 6.5 Removing and installing exterior mirror
  335
• 7 Wheel housing liners
  338
• 7.1 Assembly overview - front wheel housing liner
  338
• 7.2 Assembly overview - rear wheel housing liner
  339
• 7.3 Removing and installing front wheel housing liner
  339
• 7.4 Removing and installing rear wheel housing liner
  341
• 8 Lettering and emblem
  343
• 8.1 Assembly overview – front emblem on radiator grille
  343
• 8.2 Dimensions - lettering and badges
  344
• 8.3 Removing and installing emblem in front bumper cover, vehicles up to 2011
  353
• 8.4 Removing and installing emblem, vehicles as of 2011
  353
• 9 Special add-on parts
  356
• 9.1 Assembly overview - special add-on parts, »Cross Caddy«
  356
• 9.2 Repair instructions
  358
• 9.3 Removing and installing trim insert for side member extension
  361
• 9.4 Removing and installing side member extension
  363
• 9.5 Removing and installing wheel housing extension for wing
  366
• 9.6 Removing and installing wheel housing extension for sliding door
  369
• 9.7 Removing and installing wheel housing extension for side panel
  372
• 9.8 Removing and installing front and rear door trim
  375
• 9.9 Removing and installing front spoiler
  377
• 9.10 Removing and installing rear spoiler
  380
• 10 Towing bracket
  383
• 10.1 Installation instructions for towing brackets
  383
• 10.2 Assembly overview – towing bracket up to 2008
  383
• 10.3 Assembly overview – towing brackets as of 2009
  385
• 10.4 Removing and installing towing bracket on vehicles up to 2008
  387
• 10.5 Removing and installing towing bracket on vehicles as of 2009
  390
• 11 Spare wheel mounting
  393
• 11.1 Assembly overview – spare wheel holder
  393
• 12 Roof load flap
  396
• 12.1 Assembly overview – roof load flap
  396
• 12.2 Assembly overview - cross member
  398
• 12.3 Removing and installing roof load flap
  398
• 12.4 Removing and installing roof load flap lock cover
  399
• 12.5 Removing and installing hinge
  400
• 12.6 Removing and installing gas strut
  401
• 12.7 Removing and installing seal
  404
• 12.8 Removing and installing roof load flap stop buffer on cross member
  405
• 12.9 Removing and installing cross member
  405
• 12.10 Adjusting cross member
  406
• 12.11 Removing and installing cross member attachments
  407