General body repairs, interior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on vehicles with a start/stop system
  2
• 1.3 Safety measures when working with pyrotechnic components
  3
• 1.5 Additional safety regulations for side airbag
  5
• 1.6 Safety instructions for airbag
  6
• 1.7 Additional safety instructions for curtain airbag
  6
• 1.8 Deactivating the airbag
  7
• 1.9 Safety regulations for crash sensors (pressure sensors) for front side airbags
  7
• 1.13 Checking airbag securing parts after an accident
  10
• 1.14 Accident without airbag triggering
  10
• 1.15 Seat belts
  10
• 1.16 Checking seat belts
  11
• 1.17 Check belt webbing
  11
• 1.18 Checking inertia reel (locking mechanism)
  12
• 1.19 Visually checking belt buckle
  13
• 1.20 Check operation of belt buckle
  13
• 1.21 Checking belt relays, and buckle tongues
  13
• 1.22 Checking securing parts and anchorage points after an accident
  13
• 1.24 Checking child seat anchors after an accident
  14
• 2 Repair notes
  15
• 2.1 General repair instructions
  15
• 2.2 Contact corrosion
  15
• 2.3 Routing and attachment of lines
  15
• Interior equipment
  17
• 1 Compartments/covers
  18
• 1.1 Assembly overview - glove compartment, Transporter
  18
• 1.2 Assembly overview - roof console and storage compartment
  20
• 1.3 Assembly overview - telephone cradle, dash panel
  20
• 1.4 Removing and installing gap cover of steering column
  21
• 1.5 Removing and installing glove compartment, Multivan
  23
• 1.6 Removing and installing glove compartment, Transporter
  25
• 1.7 Removing and installing glove compartment cover
  27
• 1.8 Removing and installing dash panel storage compartment, Multivan
  29
• 1.10 Removing and installing dash panel speaker trim, Multivan
  32
• 1.11 Removing and installing dash panel speaker trim, Transporter
  34
• 1.12 Removing and installing additional dash panel console, Transporter
  35
• 1.14 Removing and installing dash panel storage net, Transporter
  41
• 1.15 Removing and installing bottle holder, Multivan
  42
• 1.16 Removing and installing ashtray with housing, cigarette lighter and drink holder, Multivan
  43
• 1.17 Removing and installing dash panel drink holder, Transporter
  44
• 1.18 Removing and installing dash panel middle trim, Multivan
  46
• 1.19 Removing and installing dash panel middle trim, Transporter
  48
• 1.20 Removing and installing storage compartment
  50
• 1.22 Removing and installing roof console, Multivan
  53
• 1.23 Removing and installing trim panel on rear side panel trim, Multivan
  55
• 1.24 Removing and installing rear ashtray with mounting frame, Multivan
  56
• 2 Equipment
  59
• 2.1 Assembly overview - coat hook, B-pillar
  59
• 2.2 Removing and installing sun visor
  60
• 2.3 Removing and installing grab handle, A-pillar
  61
• 2.4 Removing and installing grab handle, B-pillar
  61
• 2.5 Removing and installing grab handle, roof
  62
• 2.6 Removing and installing lashing points, roof
  63
• 2.7 Removing and installing lashing points, roof, 11.2006 ►
  65
• 2.8 Removing and installing front step insert
  66
• 2.9 Removing and installing rear step insert
  68
• 2.10 Removing and installing step insert, double cab
  70
• 3 On inside
  72
• 3.2 Assembly overview - »automatic« anti-dazzle interior mirror, with rain and light sensor G397
  74
• 3.3 Assembly overview - rain sensor G213
  75
• 3.6 Repairing interior mirror retaining plate
  77
• 3.9 Removing and installing rain and light sensor G397
  82
• 3.10 Repairing retaining plate for rain and light sensor G397
  83
• Passenger protection
  85
• 1 Seat belts
  86
• 1.1 Assembly overview - front seat belts, Multivan/Shuttle
  87
• 1.2 Assembly overview - front seat belts, Transporter
  88
• 1.3 Assembly overview - seat belts of outer seats in 2nd row, Shuttle
  89
• 1.4 Assembly overview - seat belts of outer seats in 2nd row, Kombi
  90
• 1.5 Assembly overview - seat belt of outer seat in 3rd row, Transporter
  91
• 1.6 Removing and installing front seat belts, Multivan/Shuttle
  91
• 1.7 Removing and installing front seat belts, Transporter
  93
• 1.8 Removing and installing seat belt of front double bench seat
  95
• 1.9 Removing and installing front belt height adjuster, Multivan/Shuttle
  96
• 1.10 Removing and installing front belt height adjuster, Transporter
  98
• 1.11 Removing and installing front belt buckle, height adjustable seat
  99
• 1.12 Removing and installing front belt buckle, swivel seat
  101
• 1.13 Removing and installing belt buckles of front double bench seat
  103
• 1.14 Removing and installing seat belt of individual seat in 2nd row, Multivan/Business
  104
• 1.15 Removing and installing seat belt of double bench seat in 2nd row, Transporter
  107
• 1.18 Removing and installing seat belts for outer seats in 2nd row, Shuttle
  112
• 1.19 Removing and installing seat belts for outer seats in 2nd row, Kombi
  114
• 1.21 Removing and installing belt buckle of individual seat in 2nd row, Transporter
  117
• 1.22 Removing and installing belt buckles of double bench seat in 2nd row, Transporter
  118
• 1.25 Removing and installing seat belt for outer seat in 3rd row, Transporter
  123
• 1.26 Removing and installing seat belts of 3-person bench seat, Multivan
  125
• 1.27 Removing and installing seat belts of 3-person bench seat, Transporter
  127
• 1.28 Removing and installing belt buckles of 3-person bench seat, Multivan
  129
• 1.29 Removing and installing belt end fittings of 3-person bench seat, Multivan
  130
• 1.30 Removing and installing belt buckles of 3-person bench seat, Transporter
  131
• 2 Child seat anchors
  134
• 2.1 Assembly overview - Top Tether retaining ring, Multivan/Business
  134
• 3 Airbag system
  135
• 3.1 Overview of fitting locations - front airbag system
  135
• 3.2 Overview of fitting locations - curtain airbag and crash sensors
  136
• 4 Airbag control unit
  137
• 4.1 Assembly overview - airbag control unit J234 , Multivan
  137
• 4.2 Assembly overview - airbag control unit J234 , Transporter
  138
• 4.3 Removing and installing airbag control unit J234 , Multivan
  138
• 4.4 Removing and installing airbag control unit J234 , Transporter
  141
• 5 Driver's airbag
  144
• 5.1 Removing and installing airbag unit on driver side
  144
• 5.2 Removing and installing airbag unit on driver side (multifunction)
  148
• 5.4 Removing and installing return spring with slip ring
  156
• 6 Front passenger side airbag
  157
• 6.1 Removing and installing airbag unit on front passenger side (Multivan)
  157
• 7 Side airbags
  171
• 7.1 Removing and installing side airbag on driver side and front passenger side, up to 2010
  171
• 7.2 Removing and installing side airbag on driver side and front passenger side, as of 2010
  174
• 7.3 Removing and installing side airbag of double bench seat
  176
• 8 Curtain airbags
  180
• 9 Deactivation switch
  188
• 10 Crash sensors
  190
• 10.1 Removing and installing crash sensors, sliding door side
  190
• 11 41-pin connector T41
  193
• 11.1 Checking and renewing 41-pin connector T41 plug housing and contacts
  193
• 12 Steering wheel
  197
• 12.1 Removing and installing steering wheel
  197
• Trim, insulation
  200
• 1 Front door trims
  200
• 1.1 Removing and installing front door trim, driver side
  200
• 1.2 Removing and installing front door trim, front passenger side
  202
• 1.3 Removing and installing front door trim, Transporter
  204
• 1.4 Removing and installing front door trim, postal and courier service vehicles
  206
• 2 Rear door trims
  210
• 2.1 Assembly overview - hardboard trim for sliding door
  210
• 2.2 Assembly overview - short hardboard trim for sliding door
  212
• 2.3 Assembly overview - high hardboard trim for sliding door
  213
• 2.4 Removing and installing rear wing door trim
  213
• 2.5 Removing and installing left rear wing door trim
  214
• 2.6 Removing and installing trim for double cab
  215
• 2.8 Removing and installing lower sliding door trim
  219
• 3 Dash panel
  221
• 3.1 Removing and installing footwell covers, Multivan
  221
• 3.2 Removing and installing footwell covers, Transporter
  224
• 3.3 Removing and installing covers on side of dash panel
  226
• 3.4 Removing and installing lower steering column cover, RHD vehicles
  227
• 3.5 Removing and installing steering column trim
  228
• 3.6 Removing and installing light switch trim
  230
• 3.7 Removing and installing right dash panel trim, Transporter
  232
• 3.8 Removing and installing trim on front passenger side, Transporter
  234
• 3.9 Removing and installing trim on front passenger side, Multivan
  236
• 3.10 Removing and installing left dash panel trim, Multivan
  238
• 3.11 Removing and installing left dash panel trim, Transporter
  240
• 3.12 Removing and installing left centre knee padding, Multivan
  241
• 3.13 Removing and installing right centre knee padding, Multivan
  243
• 3.14 Removing and installing right dash panel trim, Multivan
  244
• 3.15 Removing and installing right dash panel trim, Transporter
  245
• 3.16 Removing and installing centre footwell trim, Multivan
  247
• 3.17 Removing and installing centre footwell trim, Transporter
  249
• 3.18 Removing and installing dash panel, Multivan, Comfort version
  250
• 3.19 Removing and installing dash panel, Transporter
  257
• 4 Central tube for dash panel
  261
• 4.1 Removing and installing central tube for dash panel
  261
• 5 Interior trims
  267
• 5.1 Assembly overview - lower B-pillar trim bracket
  267
• 5.2 Assembly overview - front side panel trim, Multivan
  269
• 5.3 Assembly overview – partition, panel van
  271
• 5.4 Removing and installing A-pillar trim
  272
• 5.5 Removing and installing upper B-pillar trim, Multivan/Shuttle
  274
• 5.6 Removing and installing upper B-pillar trim, Transporter
  276
• 5.7 Removing and installing lower B-pillar trim, sliding door side
  278
• 5.8 Removing and installing upper C-pillar trim, Multivan
  280
• 5.9 Removing and installing upper C-pillar trim, Transporter
  281
• 5.10 Removing and installing upper D-pillar trim
  283
• 5.11 Removing and installing front side panel trim, Multivan
  285
• 5.12 Rear side panel trim, Multivan
  286
• 5.13 Removing and installing rear side panel trim, Transporter
  290
• 5.14 Removing and installing rear side panel trim, hardboard-type, Transporter
  292
• 5.15 Removing and installing sun blind
  293
• 5.16 Removing and installing rear bed plate
  295
• 6 Luggage compartment trims
  297
• 6.1 Assembly overview - upper rear lid trim
  297
• 6.2 Assembly overview - lower rear lid trim, hardboard-type
  298
• 6.3 Removing and installing rear lock carrier cover
  298
• 6.4 Removing and installing upper rear lid trim
  303
• 6.5 Removing and installing lower rear lid trim, up to 2010
  304
• 6.6 Removing and installing lower rear lid trim, as of 2010
  306
• 6.7 Removing and installing lower rear lid trim, hardboard-type, up to 2010
  309
• 6.8 Removing and installing lower rear lid trim, hardboard-type, as of 2010
  311
• 7 Roof trims
  313
• 7.1 Assembly overview - roof frame trim
  313
• 7.2 Assembly overview - moulded headliner, Multivan
  314
• 7.3 Removing and installing roof end strip
  314
• 7.4 Removing and installing moulded headliner for passenger compartment
  315
• 7.5 Front seat area moulded headliner
  317
• 8 Insulation
  320
• 8.1 Removing and installing floor covering in area of front seats
  320
• 8.3 Removing and installing front floor covering, wood-type, panel van
  324
• 8.4 Removing and installing rear floor covering, wood-type, panel van
  325
• 9 Fastening rings, seat rail system
  327
• 9.1 Assembly overview - fastening rings, Kombi and panel van
  327
• 9.2 Assembly overview - fastening rings, panel van
  329
• 9.3 Assembly overview - fastening ring on C-pillar
  330
• 9.4 Assembly overview - fastening ring, Multivan
  331
• 9.5 Assembly overview - sealing plugs Multivan, Camper and Kombi
  332
• 9.6 Assembly overview - seat rail systems
  333
• 9.7 Assembly overview - outer seat rail system
  334
• 9.8 Assembly overview - centre seat rail system
  335
• 9.9 Assembly overview - centre seat rail system, multifunction table
  336
• 9.10 Assembly overview - seat rail cover
  337
• 9.11 Assembly overview - lashing rails, panel van
  337
• 9.12 Removing and installing fastening rings, Kombi and panel van
  340
• 9.13 Removing and installing fastening rings, panel van
  341
• 9.14 Removing and installing fastening ring on C-pillar
  343
• 9.15 Removing and installing fastening ring, Multivan
  344
• 9.16 Removing and installing seat rail covers
  345
• 9.17 Removing and installing seat rail cover
  348
• Seat frames
  351
• 1 Front seats
  351
• 1.1 Assembly overview - double bench seat
  351
• 1.2 Removing and installing front seat
  353
• 1.3 Removing and installing front swivel seat
  357
• 1.4 Removing and installing adapter for front swivel seat
  360
• 1.5 Removing and installing swivel frame for front swivel seat
  363
• 1.6 Front double bench seat
  364
• 1.7 Removing and installing individual seat frame
  368
• 1.8 Front seat trims
  372
• 1.9 Removing and installing storage compartment on front seat frame
  377
• 1.10 Removing and installing armrest on front seat
  379
• 1.11 Seat lumbar support, electrical
  381
• 1.12 Removing and installing front seat cushion for height-adjustable front seat
  383
• 1.13 Removing and installing front seat cushion for front swivel seat
  385
• 1.14 Removing and installing double seat bench seat cushion
  387
• 1.15 Removing and installing front backrest
  388
• 1.16 Removing and installing front backrest, double bench seat
  392
• 2 Seats, 2nd row
  394
• 2.1 Assembly overview - trim of individual seat in 2nd row, Multivan/Business
  394
• 2.2 Assembly overview - individual seat in 2nd row, Multivan/Business
  396
• 2.3 Assembly overview - double bench seat in 2nd row, Transporter
  397
• 2.4 Assembly overview - 3-person bench seat in 2nd row, double cab
  399
• 2.5 Assembly overview - head restraint and head restraint guide, Multivan/Business
  400
• 2.6 Assembly overview - guide rail, Multivan/Business
  401
• 2.7 Assembly overview - drawer, Multivan/Business
  402
• 2.8 Removing and installing individual seats, Multivan/Business
  403
• 2.9 Removing and installing seat cushion of individual seat in 2nd row, Transporter
  404
• 2.12 Trims of individual seat in 2nd row, Multivan/Business
  409
• 2.13 Removing and installing trims of individual seat in 2nd row, Transporter
  419
• 2.14 Removing and installing trim of 3-person bench seat in 2nd row, double cab
  420
• 2.15 Removing and installing backrest of individual seat in 2nd row, Multivan/Business
  421
• 2.16 Removing and installing backrest of individual seat in 2nd row, Transporter
  424
• 2.17 Removing and installing backrest of double bench seat in 2nd row, Transporter
  426
• 2.20 Retrofitting individual seat in 2nd row (Kombi/Shuttle)
  432
• 3 Seats, 3rd row
  436
• 3.1 Assembly overview - 3-person bench seat, Transporter
  436
• 3.2 Removing and installing 3-person bench seat, Multivan
  438
• 3.3 Removing and installing front trim of 3-person bench seat, Multivan
  439
• 3.4 Removing and installing side trim of 3-person bench seat, Multivan
  441
• 3.5 Removing and installing rear trim of 3-person bench seat, Multivan
  442
• 3.6 Removing and installing seat cushion of 3-person bench seat, Multivan
  443
• 3.7 Removing and installing seat cushion of 3-person bench seat, Transporter
  444
• 3.8 Removing and installing backrest of 3-person bench seat, Multivan
  446
• 3.9 Removing and installing backrest of 3-person bench seat, Transporter
  447
• 3.10 Retrofitting 3-person bench seat in 3rd row, Kombi/Shuttle
  449
• 4 Seats, 3rd row (Business)
  453
• 4.1 Assembly overview - pneumatic lumbar support
  453
• 4.2 Removing and installing rear seat
  455
• 4.3 Removing and installing seat
  460
• 4.4 Removing and installing
  462
• 4.5 Removing and installing head restraint
  465
• 4.6 Removing and installing trim for head restraint adjuster
  468
• 4.7 Removing and installing backrest trim
  471
• 4.8 Removing and installing upper trim of front bench seat
  472
• 4.9 Removing and installing lower trim of front bench seat
  474
• 4.10 Removing and installing upper trim of rear bench seat
  475
• 4.11 Removing and installing lower trim of rear bench seat
  477
• 4.12 Removing and installing seat adjustment control element
  480
• 4.13 Removing and installing control element bracket
  485
• 4.14 Removing and installing seat belt
  487
• 4.15 Removing and installing belt buckle
  491
• 4.16 Removing and installing cover for centre console
  492
• 5 Table modules, Multivan/Business
  493
• 5.1 Removing and installing table module in seat rails
  493
• 5.2 Removing and installing table top, table module in seat rails
  495
• 5.3 Removing and installing drink holder, table module in seat rails
  496
• 5.4 Removing and installing ashtray, table module in seat rails
  497
• 5.5 Removing and installing drawer, table module in seat rails
  498
• 5.6 Removing and installing front trim, table module in seat rails
  500
• 5.7 Removing and installing rear trim, table module in seat rails
  501
• 5.9 Removing and installing rollers and support, table module in seat rails
  504
• 5.10 Removing and installing table module in sidewall
  506
• 5.11 Removing and installing table module in side panel
  507
• Seat - padding, covers
  510
• 1 Front seat covers and padding
  510
• 1.1 Assembly overview - seat heating element
  510
• 1.2 Assembly overview - backrest heater element
  512
• 1.3 Assembly overview - seat heater element, front double bench seat
  513
• 1.4 Assembly overview - backrest heater element, front double bench seat
  514
• 1.5 Cover and padding, front seat cushion
  514
• 1.7 Removing and installing front seat backrest cover and padding
  520
• 1.9 Removing and installing seat heating element
  528
• 1.10 Removing and installing backrest heating element
  530
• 1.11 Removing and installing seat heater element of front double bench seat
  531
• 1.12 Removing and installing backrest heater element of front double bench seat
  533
• 2 Seat covers and padding in 2nd row
  535
• 2.1 Removing and installing cover and padding of seat cushion in 2nd row, Multivan/Business
  535
• 2.8 Removing and installing 2nd row seat backrest, cushion cover and padding
  555
• 3 Third row seat covers and padding
  571
• 3.4 Removing and installing centre armrest, 3-person bench seat, Multivan
  580
• 3.5 Removing and installing cover and padding of backrest, 3-person bench seat, Transporter
  583
• 4 Cover and padding of seats in 3rd row (Business)
  587
• 4.1 Removing and installing seat cover and padding
  587
• 4.2 Removing and installing backrest cover and padding
  592