General body repairs, interior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety measures when working with pyrotechnic components
  2
• 1.4 Safety instructions for airbag
  4
• 1.5 Safety regulations for crash sensors (pressure sensors) for front side airbags
  4
• 1.6 Deactivating the airbag
  5
• 1.8 Additional safety regulations for side airbag
  6
• 1.9 Additional safety instructions for curtain airbag
  6
• 1.10 Safety regulations for crash sensors (pressure sensors) for front side airbags
  7
• 1.12 Checking airbag securing parts after an accident
  9
• 1.13 Accident without airbag triggering
  10
• 1.14 Checking seat belts
  10
• 1.15 Check belt webbing
  10
• 1.16 Checking inertia reel (locking mechanism)
  12
• 1.17 Visually checking belt buckle
  12
• 1.18 Check operation of belt buckle
  12
• 1.19 Checking belt relays, and buckle tongues
  13
• 1.20 Checking securing parts and anchorage points after an accident
  13
• 2 Repair notes
  15
• 2.1 General repair instructions
  15
• 2.2 Contact corrosion
  15
• 2.3 Routing and attachment of lines
  15
• 3 Hazard classification of high-voltage system
  17
• Interior equipment
  18
• 1 Compartments/covers
  18
• 1.1 Overview of fitting locations – compartments/covers
  18
• 1.2 Assembly overview – dash panel cover on driver side
  19
• 1.3 Assembly overview - steering column trim
  20
• 1.4 Assembly overview – glove compartment
  22
• 1.5 Assembly overview - storage compartment in headliner
  23
• 1.6 Assembly overview - handbrake lever boot
  24
• 1.7 Removing and installing cup holder
  25
• 1.8 Removing and installing dash panel cover on driver side
  26
• 1.9 Removing and installing gap cover for dash panel insert
  27
• 1.10 Removing and installing upper steering column trim
  28
• 1.11 Removing and installing lower steering column trim
  29
• 1.12 Removing and installing steering column trim in footwell
  30
• 1.13 Removing and installing footwell cover
  31
• 1.14 Removing and installing glove compartment opener
  33
• 1.15 Removing and installing glove compartment
  34
• 1.16 Removing and installing dash panel compartment
  35
• 1.17 Removing and installing headliner storage compartment
  37
• 1.18 Removing and installing airbag warning lamp trim
  38
• 1.19 Removing and installing handbrake lever trim
  39
• 2 Equipment
  41
• 2.1 Assembly overview - partition, panel van
  41
• 2.2 Assembly overview – sun visors
  44
• 2.3 Assembly overview - grab handles on pillar trims
  45
• 2.4 Assembly overview – ashtray/cup holder, rear
  46
• 2.5 Assembly overview - sun blind
  48
• 2.6 Removing and installing net partition bracket
  50
• 2.7 Removing and installing sun visor
  50
• 2.8 Removing and installing sun visor centre mount
  52
• 2.9 Removing and installing roof grab handle
  53
• 2.10 Removing and installing grab handles on pillar trims
  54
• 2.11 Removing and installing partition, panel van
  56
• 2.12 Removing and installing loading hatch cover
  58
• 2.13 Removing and installing rear ashtray/cup holder
  59
• 2.14 Removing and installing sun blind
  63
• 3 Centre console
  65
• 3.1 Assembly overview – centre console
  65
• 3.2 Removing and installing gearstick cover
  67
• 3.3 Removing and installing centre console front storage compartment
  69
• 3.4 Removing and installing centre console
  70
• 3.5 Removing and installing centre console decorative strip
  72
• 4 Centre armrest
  74
• 4.1 Assembly overview – front centre armrest
  74
• 4.2 Removing and installing centre armrest
  74
• 5 On inside
  77
• 5.1 Assembly overview – interior mirror
  77
• 5.2 Removing and installing interior mirror
  79
• 6 Table module
  89
• 6.1 Assembly overview – table modules
  89
• 6.2 Removing and installing table module
  92
• 6.3 Repairing table module
  95
• Passenger protection
  103
• 1 Seat belts
  103
• 1.1 Overview of fitting locations – seat belts and anchorage points
  103
• 1.2 Assembly overview – front three-point seat belt
  108
• 1.3 Assembly overview – rear outer three-point seat belt
  109
• 1.4 Assembly overview – rear centre three-point seat belt
  111
• 1.5 Assembly overview – front belt buckle
  112
• 1.6 Removing and installing front three-point seat belt
  113
• 1.7 Removing and installing rear three-point seat belt
  119
• 1.8 Removing and installing outer front belt end fitting
  126
• 1.9 Removing and installing rear outer belt end fitting
  126
• 1.10 Removing and installing belt height adjuster
  129
• 1.11 Removing and installing front belt buckle
  132
• 1.12 Removing and installing rear belt buckle
  136
• 2 Child seat anchors
  142
• 2.1 Assembly overview – front child seat anchors, Multivan
  142
• 2.2 Assembly overview – rear child seat anchors
  143
• 3 Airbag system
  144
• 3.1 Overview of fitting locations – airbag system
  144
• 4 Airbag control unit
  146
• 4.1 Assembly overview – airbag control unit
  146
• 4.2 Removing and installing airbag control unit J234
  147
• 5 Battery isolator igniter
  149
• 5.1 Removing and installing battery isolator igniter
  149
• 6 Front airbag, driver side
  150
• 6.1 Assembly overview – front airbag, driver side
  150
• 6.2 Removing and installing airbag unit with igniter
  151
• 6.3 Removing and installing return spring with slip ring (coil connector)
  155
• 6.4 Renewing connector on airbag
  155
• 7 Front passenger airbag
  158
• 7.1 Assembly overview – front passenger airbag
  158
• 7.2 Removing and installing front passenger airbag unit with igniter
  160
• 8 Side airbags
  164
• 8.1 Assembly overview – front side airbag
  164
• 8.2 Removing and installing front side airbag with igniter
  165
• 9 Curtain airbags
  171
• 9.1 Assembly overview – curtain airbag
  171
• 9.2 Removing and installing curtain airbag with igniter
  172
• 10 Airbag crash sensors
  178
• 10.1 Overview of fitting locations – airbag crash sensors
  178
• 10.2 Removing and installing front side airbag crash sensor G179/G180
  180
• 10.3 Removing and installing rear side airbag crash sensors on driver side G256/G257
  182
• 11 Seat occupied recognition
  185
• 11.1 Removing and installing seat occupied recognition
  185
• Trim, insulation
  186
• 1 Front door trims
  186
• 1.1 Assembly overview – front door trim
  186
• 1.2 Removing and installing trim
  187
• 1.3 Removing and installing front door trim
  187
• 1.4 Removing and installing button trim
  189
• 2 Rear door trims
  190
• 2.1 Assembly overview – rear door trim
  190
• 2.2 Removing and installing trim
  194
• 2.3 Removing and installing rear door puller, double cab
  195
• 2.4 Removing and installing interior door handle
  196
• 2.5 Removing and installing rear ashtray
  198
• 2.6 Removing and installing rear door trim
  199
• 3 Dash panel
  204
• 3.1 Overview of fitting locations - dash panel attachments
  204
• 3.2 Assembly overview - dash panel
  206
• 3.3 Removing and installing dash panel end cover
  206
• 3.4 Removing and installing side defroster vent
  207
• 3.5 Removing and installing outer dash panel vents
  209
• 3.6 Removing and installing dash panel insert trim
  210
• 3.7 Removing and installing auxiliary console trim
  211
• 3.8 Removing and installing tachograph console
  212
• 3.9 Removing and installing button plate holder
  213
• 3.10 Removing and installing tachograph holder
  215
• 3.11 Installing “No Airbag” sign
  216
• 3.12 Removing and installing dash panel trim
  217
• 3.13 Removing and installing radio/navigation system mounting frame
  219
• 3.14 Removing and installing dash panel
  219
• 3.15 Removing and installing front centre defroster vent
  223
• 4 Central tube for dash panel
  225
• 4.1 Assembly overview – central tube for dash panel
  225
• 4.2 Removing and installing central tube for dash panel
  227
• 5 Interior trims
  230
• 5.1 Assembly overview - A-pillar trim
  230
• 5.2 Assembly overview – B-pillar trim
  231
• 5.3 Assembly overview - C-pillar trim
  233
• 5.4 Assembly overview - D-pillar trim
  234
• 5.5 Assembly overview - side trim
  235
• 5.6 Removing and installing step moulding
  236
• 5.7 Removing and installing A-pillar trim
  239
• 5.8 Removing and installing B-pillar trim
  241
• 5.9 Removing and installing C-pillar trim
  243
• 5.10 Removing and installing D-pillar trim
  245
• 5.11 Removing and installing side trim
  247
• 5.12 Removing and installing floor covering
  249
• 6 Luggage compartment trims
  254
• 6.1 Assembly overview - lower rear lid trim
  254
• 6.2 Assembly overview – upper rear lid trim
  256
• 6.3 Removing and installing lower rear lid trim
  257
• 6.4 Removing and installing upper rear lid trim
  260
• 6.5 Removing and installing trim panel on side trim
  262
• 6.6 Removing and installing luggage compartment side trim
  263
• 6.7 Removing and installing lock carrier trim
  268
• 6.8 Removing and installing fastening rings
  271
• 7 Roof trims
  275
• 7.1 Assembly overview – moulded headliner
  275
• 7.2 Assembly overview - roof trim
  276
• 7.3 Assembly overview - roof end strip
  277
• 7.4 Removing and installing moulded headliner
  278
• 7.5 Removing and installing roof trim
  282
• 7.6 Removing and installing roof end strip
  283
• 7.7 Removing and installing roof trim cover strips
  284
• Seat frames
  286
• 1 Overview of seat variants
  286
• 1.1 Overview of fitting locations – seat variants
  286
• 2 Front seats
  288
• 2.1 Overview of fitting locations – electrical and electronic components
  288
• 2.2 Assembly overview – front seat
  290
• 2.3 Assembly overview – front backrest
  296
• 2.4 Assembly overview – head restraint
  300
• 2.5 Assembly overview – seat pan
  300
• 2.6 Removing and installing front seat
  307
• 2.7 Removing and installing front trims
  312
• 2.8 Seat frame adapter
  313
• 2.9 Connecting and disconnecting airbag adapter
  316
• 2.10 Removing and installing seat height adjustment handle
  318
• 2.11 Removing and installing seat height adjuster
  318
• 2.12 Removing and installing seat trim, front seat
  319
• 2.13 Removing and installing lumbar support adjuster
  331
• 2.14 Removing and installing lumbar support adjustment motor V125/V126/V129/V130
  334
• 2.15 Removing and installing seat heating control unit
  336
• 2.16 Removing and installing backrest adjuster
  336
• 2.17 Removing and installing backrest adjustment handle
  336
• 2.18 Removing and installing front backrest
  337
• 2.19 Removing and installing head restraint
  344
• 2.20 Removing and installing head restraint guide
  344
• 2.21 Dismantling and assembling seat pan, swivel seat
  345
• 2.24 Removing and installing bench seat locking element
  348
• 3 Rear seats
  351
• 3.1 Assembly overview – bench seat/individual seats
  351
• 3.2 Assembly overview - head restraint, Multivan
  366
• 3.3 Assembly overview - seat rail systems
  366
• 3.4 Removing and installing bench seat/individual seats
  370
• 3.5 Removing and installing rear seat backrest
  379
• 3.6 Removing and installing centre armrest
  388
• 3.7 Trims of individual seat in 2nd row, Multivan
  391
• 3.8 Removing and installing seat pan
  398
• 3.9 Removing and installing seat rails
  400
• Seat - padding, covers
  408
• 1 Front seat covers and padding
  408
• 1.1 Assembly overview – seat heating element
  408
• 1.2 Assembly overview – backrest heating element
  410
• 1.3 Removing and installing cover and padding in area of seat pan
  413
• 1.4 Removing and installing backrest cover and backrest padding
  420
• 1.5 Separating cover and padding in area of seat pan
  425
• 1.6 Separating cover and padding on backrest
  426
• 1.7 Removing and installing seat heating element Z6/Z8
  427
• 1.8 Removing and installing backrest heating element Z7/Z9
  431
• 2 Rear seat covers and padding
  435
• 2.1 Removing and installing covers and padding
  435
• 2.2 Separating cover and padding
  448