General body repairs, interior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working with pyrotechnic components
  1
• 1.3 Additional safety regulations for side airbag
  3
• 1.4 Additional safety instructions for curtain airbag
  4
• 1.5 Safety regulations for crash sensors (pressure sensors) for front side airbags
  5
• 1.7 Checking airbag securing parts after an accident
  7
• 1.8 Accident without airbag triggering
  7
• 1.9 Safety instructions for airbag
  7
• 1.10 Checking seat belts
  8
• 1.11 Check belt webbing
  8
• 1.12 Checking inertia reel (locking mechanism)
  9
• 1.13 Visually checking belt buckle
  10
• 1.14 Check operation of belt buckle
  10
• 1.15 Checking belt relays, and buckle tongues
  10
• 1.16 Checking securing parts and anchorage points after an accident
  10
• 1.17 Checking child seat anchors after an accident
  11
• 1.18 Safety instructions for automatic anti-dazzle interior mirror
  11
• 2 Repair notes
  12
• 2.1 Contact corrosion
  12
• 2.2 Routing and attachment of lines
  12
• Interior equipment
  13
• 1 Compartments, covers and trims
  13
• 1.1 Removing and installing glove compartment
  13
• 1.2 Removing and installing button for glove compartment
  15
• 1.3 Removing and installing lower airbag unit cover on front passenger side
  16
• 1.4 Removing and installing outer vent trim
  18
• 1.5 Removing and installing centre vent trim
  20
• 1.6 Removing and installing dash panel centre trim
  22
• 1.7 Removing and installing dash panel compartment
  23
• 1.8 Removing and installing centre dash panel compartment
  25
• 1.9 Removing and installing outer loudspeaker trim
  25
• 1.10 Removing and installing windscreen vent trim
  26
• 1.11 Removing and installing fuse box cover
  28
• 1.12 Removing and installing roof gallery storage compartment
  28
• 1.13 Removing and installing roof console and spectacles holder
  30
• 2 Equipment
  31
• 2.1 Assembly overview - sun visor
  31
• 2.2 Removing and installing grab handle
  31
• 2.3 Removing and installing sun visor
  36
• 3 Step insert
  39
• 3.1 Assembly overview - front step insert
  39
• 3.2 Assembly overview - sliding door step
  39
• 3.3 Assembly overview - Sliding door step seal
  41
• 3.4 Removing and installing front step insert
  41
• 3.5 Removing and installing sliding door step
  43
• 4 On inside
  46
• 4.1 Assembly overview - manual anti-dazzle interior mirror
  46
• 4.2 Assembly overview - interior mirror with rain and light sensor G397
  47
• 4.3 Removing and installing manual anti-dazzle interior mirror
  48
• 4.4 Repairing interior mirror retaining plate
  48
• 4.5 Removing and installing interior mirror with rain and light sensor G397
  50
• 4.6 Rain and light sensor G397
  51
• Passenger protection
  58
• 1 Seat belts
  58
• 1.1 Installation location overview - front seat belts and anchorage points
  58
• 1.2 Assembly overview - front three-point seat belt
  60
• 1.3 Assembly overview - rear seat belts
  61
• 1.4 Removing and installing front belt inertia reel
  61
• 1.5 Removing and installing front belt height adjuster
  62
• 1.6 Removing and installing belt end anchor
  64
• 1.7 Removing and installing front belt buckle
  65
• 1.8 Removing and installing belt inertia reel for double bench seat
  66
• 1.9 Removing and installing belt anchor for double bench seat
  66
• 1.10 Removing and installing outer belt buckle, double bench seat
  67
• 1.11 Removing and installing inner belt buckle, double bench seat
  67
• 1.12 Removing and installing outer belt anchor for double bench seat
  69
• 1.13 Removing and installing inner belt anchor for double bench seat
  69
• 2 Airbag system
  72
• 2.1 Overview of fitting locations - airbag system
  72
• 3 Airbag control unit
  73
• 3.1 Assembly overview - airbag control unit
  73
• 3.2 Removing and installing airbag control unit J234
  73
• 4 Driver's airbag
  76
• 4.1 Removing and installing airbag unit on driver side
  76
• 4.2 Removing and installing steering wheel
  79
• 4.3 Removing and installing return spring with slip ring
  80
• 5 Front passenger side airbag
  81
• 5.1 Removing and installing airbag unit on front passenger side
  81
• 6 Side airbag
  84
• 6.1 Removing and installing side airbags on driver and front passenger sides
  84
• 7 Curtain airbag
  87
• 7.1 Removing and installing curtain airbag in front seat area
  87
• 8 Airbag crash sensors
  91
• 8.1 Removing and installing front side airbag crash sensor
  91
• Trim, insulation
  94
• 1 Door trims
  94
• 1.1 Removing and installing front door trim, driver side
  94
• 1.2 Removing and installing comfort arm rest in front door
  96
• 1.3 Removing and installing comfort arm rest in front door
  98
• 1.4 Removing and installing rear right wing door trim
  100
• 1.5 Removing and installing rear left wing door trim
  102
• 1.6 Removing and installing cab door trim
  104
• 1.7 Removing and installing sliding door trim
  105
• 2 Dash panel
  108
• 2.1 Removing and installing dash panel
  108
• 2.2 Removing and installing foot well trim
  110
• 2.3 Removing and installing lower dash panel trim
  111
• 2.4 Removing and installing steering column trim
  111
• 2.5 Removing and installing lower centre trim
  112
• 2.6 Removing and installing centre console
  113
• 2.7 Removing and installing dash panel insert trim
  115
• 3 Removing and installing central tube for dash panel
  118
• 4 Interior trims
  121
• 4.1 Installation location overview - cab floor covering
  121
• 4.2 Installation location overview - passenger compartment floor covering
  123
• 4.3 Installation location overview - partition panel
  125
• 4.4 Assembly overview - B-pillar trim
  126
• 4.5 Assembly overview - front floor plate
  127
• 4.6 Removing and installing partition panel
  127
• 4.7 Removing and installing A-pillar trim
  129
• 4.8 Removing and installing A-pillar trim, vehicles with curtain airbag in cab
  130
• 4.9 Removing and installing B-pillar trim
  131
• 4.10 Removing and installing D-pillar trim
  133
• 4.12 Removing and installing front side panel trim
  136
• 4.13 Removing and installing rear side panel trim
  138
• 4.14 Removing and installing rear side panel trim, panel van
  140
• 4.15 Removing and installing side window trim
  141
• 4.16 Removing and installing left floor covering in cab
  142
• 4.17 Removing and installing right floor covering in cab
  142
• 4.18 Removing and installing front floor plate
  143
• 5 Luggage compartment trims
  146
• 5.1 Removing and installing lock carrier cover
  146
• 6 Roof trims
  148
• 6.1 Assembly overview – moulded headliner
  148
• 6.2 Removing and installing moulded headlining
  149
• Seat frames
  152
• 1 Front seats
  152
• 1.1 Assembly overview - seat frame
  152
• 1.2 Assembly overview - suspension seat
  153
• 1.3 Assembly overview - swivel seat
  155
• 1.4 Assembly overview - backrest frame
  156
• 1.5 Assembly overview - front double bench seat and seat padding
  156
• 1.6 Assembly overview - backrest and seat padding for double cab
  157
• 1.7 Removing and installing front seat with longitudinal adjustment
  158
• 1.8 Removing and installing front seat without longitudinal adjustment
  160
• 1.9 Seat frame trim
  162
• 1.10 Removing and installing seat padding
  164
• 1.11 Removing and installing front backrest frame
  165
• 1.12 Armrest on backrest frame
  166
• 1.13 Removing and installing front double bench seat and seat padding
  169
• 1.14 Removing and installing front seat box
  170
• 1.15 Removing and installing seat padding of front double bench seat
  171
• 1.16 Removing and installing front double backrest
  172
• 2 Rear seats
  174
• 2.3 Removing and installing 1st row passenger compartment seats
  175
• 2.4 Removing and installing armrest for bench seat
  176
• Seat - padding, covers
  180
• 1 Front seat covers and padding
  180
• 1.1 Assembly overview - front seat cover and padding
  180
• 1.2 Assembly overview - front backrest cover and padding
  182
• 1.3 Assembly overview - front double bench seat cover and padding
  183
• 1.4 Assembly overview - front double backrest cover and padding
  184
• 1.5 Removing and installing front seat cover and padding
  184
• 1.6 Removing and installing head restraint guide
  186
• 1.7 Removing and installing backrest cover panel
  187
• 1.8 Removing and installing front backrest cover and padding
  188
• 1.10 Removing and installing front double bench seat cover and padding
  191
• 1.11 Removing and installing cover and padding for front double backrest
  193
• 1.12 Replacing front seat heater elements
  196
• 2 Rear seat covers and padding
  198
• 2.1 Assembly overview - rear bench seat
  198
• 2.2 Removing and installing rear backrest cover and padding
  198
• 2.3 Removing and installing rear bench seat cover and padding
  200