Volkswagen Amarok 2011-2022 Repair Manual – PDF DOWNLOAD

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Volkswagen Amarok 2011-2022 Repair Manual – PDF DOWNLOAD

FILE DETAILS:

Volkswagen Amarok 2011-2022 Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 6453
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Volkswagen Amarok 2011-2022 Repair Manual – PDF DOWNLOAD 

00053422020 Trailer towing guide 1
00 – Technical data 5
1 Foreword 5
1 1 Parts certificates 5
1 2 Legal requirements outside Germany 5
2 Technical prerequisites 6
2 1 Factory fitted towing attachment 6
2 2 Retrofitted towing attachment 6
2 3 Ball head 6
2 4 Trailer socket 6
2 4 1 7-pin trailer socket 6
2 4 2 13-pin trailer socket 7
2 5 Trailer detector control unit -J345- 7
2 5 1 Retrofitting trailer detector control unit -J345- 8
2 5 2 Coding trailer detector control unit -J345- 8
2 6 Map-controlled engine cooling 8
2 7 Exterior mirror 9
2 8 Uprated shock absorbers and coil springs 9
3 Notes on operation and driving 10
4 General information 11
4 1 Towing attachment type plate 11
4 2 Weight of vehicle and trailer combination 11
4 3 Tachograph 11
5 Drawbar load details 12
6 Increase in trailer and drawbar loads 13
6 1 General information 13
6 2 Increase in trailer load for LT built from 1996 13
6 2 1 Increase in trailer load with maximum speed of 25 km/h 13
6 2 2 Increase in trailer load by heavy duty towing attachment 14
7 Legal requirements 15
7 1 General information 15
7 2 Legal requirements for Germany 15
8 Trailer loads for Amarok from model year 2011 16
9 Trailer loads for Amarok from model year 2017 19
9 1 Vehicles with manual gearbox 19
9 2 Vehicles with automatic gearbox 21
10 Trailer loads for Caddy, model year 1996 to model year 2002 30
11 Trailer loads for Caddy Pickup, model year 1997 to model year 2002 31
12 Trailer loads for Caddy, model years 2004 to 2010 32
12 1 Caddy Kombi, sales type 2KB 32
12 2 Caddy panel van, sales type 2KA 37
12 3 Caddy Kombi Maxi, sales type 2KJ 46
12 4 Caddy panel van Maxi, sales type 2KH 47
13 Trailer loads for Caddy from model year 2011 50
13 1 Caddy Kombi, sales type 2CB 50
13 2 Caddy panel van, sales type 2CA 69
13 3 Caddy Kombi Maxi, sales type 2CJ 80
13 4 Caddy panel van Maxi, sales type 2CH 84
14 Trailer loads for Caddy from model year 2016 89
14 1 Caddy Kombi, sales type SAB 89
14 1 1 Vehicles with manual gearbox, 5-seater 89
14 1 2 Vehicles with manual gearbox, 7-seater 94
14 1 3 Vehicles with dual clutch gearbox, 5-seater 96
14 1 4 Vehicles with dual clutch gearbox, 7-seater 98
14 2 Caddy Kombi Maxi, sales type SAJ 100
14 2 1 Vehicles with manual gearbox, 5-seater 101
14 2 2 Vehicles with manual gearbox, 7-seater 103
14 2 3 Vehicles with dual clutch gearbox, 5-seater 105
14 2 4 Vehicles with dual clutch gearbox, 7-seater 107
14 3 Caddy panel van, sales type SAA 109
14 3 1 Vehicles with manual gearbox, petrol engine 110
14 3 2 Vehicles with manual gearbox, diesel engine 113
14 3 3 Vehicles with dual clutch gearbox, petrol engine 129
14 3 4 Vehicles with dual clutch gearbox, diesel engine 131
14 4 Caddy panel van Maxi, sales type SAH 137
14 4 1 Vehicles with manual gearbox, petrol engine 137
14 4 2 Vehicles with manual gearbox, diesel engine 138
14 4 3 Vehicles with dual clutch gearbox, petrol engine 145
14 4 4 Vehicles with dual clutch gearbox, diesel engine 146
15 Trailer loads for Caddy from model year 2021 150
15 1 Caddy Kombi, sales type SBB 150
15 1 1 Vehicles with manual gearbox, 5-seater 150
15 1 2 Vehicles with manual gearbox, 7-seater 151
15 1 3 Vehicles with dual clutch gearbox, 5-seater 153
15 1 4 Vehicles with dual clutch gearbox, 7-seater 154
15 2 Caddy Kombi Maxi, sales type SBJ 154
15 2 1 Vehicles with manual gearbox, 5-seater 155
15 2 2 Vehicles with manual gearbox, 7-seater 156
15 2 3 Vehicles with dual clutch gearbox, 5-seater 157
15 2 4 Vehicles with dual clutch gearbox, 7-seater 157
15 3 Caddy Cargo, sales type SBA 158
15 3 1 Vehicles with manual gearbox, petrol engine 158
15 3 2 Vehicles with manual gearbox, diesel engine 158
15 3 3 Vehicles with dual clutch gearbox, petrol engine 160
15 3 4 Vehicles with dual clutch gearbox, diesel engine 160
15 4 Caddy Cargo Maxi, sales type SBH 161
15 4 1 Vehicles with manual gearbox, petrol engine 161
15 4 2 Vehicles with manual gearbox, diesel engine 162
15 4 3 Vehicles with dual clutch gearbox, petrol engine 162
15 4 4 Vehicles with dual clutch gearbox, diesel engine 163
16 Trailer loads for Transporter, model year 1991 to model year 2003 164
16 1 Increase in trailer load 166
17 Trailer loads for Transporter, from model year 2004 to model year 2009 167
17 1 Trailer load increase on 62 and 63 kW diesel engine 168
17 2 Trailer load increase on 75 and 77 kW diesel engine 168
18 Trailer loads for Transporter from model year 2010 169
19 Trailer loads for Transporter from model year 2016 171
19 1 Transporter, type approval model code: 7HC 171
19 1 1 Vehicles with manual gearbox 171
19 1 2 Vehicles with dual clutch gearbox 175
19 2 Transporter, type approval model code: 7HMA 179
19 2 1 Vehicles with manual gearbox 179
19 2 2 Vehicles with dual clutch gearbox 182
19 3 Transporter, type approval model code: 7J0 185
19 3 1 Vehicles with manual gearbox 185
19 3 2 Vehicles with dual clutch gearbox 188
20 Trailer loads for Transporter from model year 2020 191
20 1 Transporter 191
20 1 1 Vehicles with manual gearbox 191
20 1 2 Vehicles with automatic gearbox 194
20 2 Kombi, Multivan 198
20 2 1 Vehicles with manual gearbox 198
20 2 2 Vehicles with automatic gearbox 201
20 3 California 204
20 3 1 Vehicles with manual gearbox 204
20 3 2 Vehicles with automatic gearbox 206
21 Trailer loads for Multivan as of model year 2022 209
21 1 Multivan 209
21 1 1 Vehicles with automatic gearbox 209
22 Trailer loads for ID BUZZ, as of model year 2023 210
22 1 Trailer loads for ID BUZZ, as of model year 2023 210
22 1 1 Vehicles with automatic gearbox 210
22 2 Trailer loads for ID BUZZ “CARGO”, as of model year 2023 210
22 2 1 Vehicles with automatic gearbox 210
23 Trailer loads for LT, model year 1997 to model year 2006 211
23 1 LT 28, type 2DM 211
23 2 LT 28, type 2DX0FE 212
23 3 LT 28, type 2DX0AE 214
23 4 LT 35, type 2DM 216
23 5 LT 35, type 2DX0AE 218
23 6 LT 35, type 2DX0FE 220
23 7 LT 46, type 2DX0FZ 222
23 8 LT 46, type 2DX0AZ 224
24 Trailer loads for Crafter, from model year 2006 228
24 1 Crafter 30, sales types 2EB, 2EE 228
24 2 Crafter 30, sales types 2EA, 2ED 230
24 3 Crafter 30, sales type 2FF 232
24 4 Crafter 35, sales types 2EB, 2EE, 2EK 235
24 5 Crafter 35, sales types 2EA, 2ED, 2EH, 2EX 238
24 5 1 Crafter 35, goods vehicle up to 3,500 kg (N1), sales types 2EA, 2ED, 2EH, 2EX 239
24 5 2 Crafter 35, goods vehicle above 3,500 kg (N2), sales types 2EA, 2ED, 2EH, 2EX 243
24 5 3 Crafter 35, passenger vehicles (M2), sales types 2EA, 2ED, 2EH, 2EX 247
24 6 Crafter 35, sales types 2FC, 2FF, 2FG, 2FL, 2FM, 2FZ 250
24 6 1 Crafter 35, goods vehicle up to 3,500 kg (N1), sales types 2FC, 2FF, 2FG, 2FL, 2FM, 2FZ 250
24 6 2 Crafter 35, goods vehicle above 3,500 kg (N2), sales types 2FC, 2FF, 2FG, 2FL, 2FM, 2FZ 255
24 7 Crafter 50, sales types 2ED, 2EH, 2EX 258
24 7 1 Crafter 50, goods vehicle up to 3,500 kg (N1), sales types 2ED, 2EH, 2EX 259
24 7 2 Crafter 50, goods vehicle above 3,500 kg (N2), sales types 2ED, 2EH, 2EX 264
24 7 3 Crafter 50, passenger vehicles (M2), sales types 2ED, 2EH, 2EX 277
24 8 Crafter 50, sales types 2FF, 2FG, 2FL, 2FM 290
24 8 1 Crafter 50, goods vehicle up to 3,500 kg (N1), sales types 2FF, 2FG, 2FL, 2FM 290
24 8 2 Crafter 50, goods vehicle above 3,500 kg (N2), sales types 2FF, 2FG, 2FL, 2FM 296
25 Trailer loads for Crafter/TGE, from model year 2017 310
25 1 Crafter/TGE, type approval model code SYN1E 310
25 1 1 Vehicles with manual gearbox 310
25 1 2 Vehicles with automatic gearbox 320
25 2 Crafter/TGE, type approval model code SYN1Z 325
25 2 1 Vehicles with manual gearbox 325
25 2 2 Vehicles with automatic gearbox 327
25 3 Crafter/TGE, type approval model code SYN2E 328
25 3 1 Vehicles with manual gearbox 328
25 3 2 Vehicles with automatic gearbox 333
25 4 Crafter/TGE, type approval model code SYN2Z 336
25 4 1 Vehicles with manual gearbox 336
25 4 2 Vehicles with automatic gearbox 341
25 5 Crafter/TGE, type approval model code SYM1E 344
25 5 1 Vehicles with manual gearbox 344
25 5 2 Vehicles with automatic gearbox 345
25 6 Crafter/TGE, type approval model code SYM2E 345
25 6 1 Vehicles with manual gearbox 345
25 7 Crafter California, type approval model code SYMVE 346
25 7 1 Vehicles with automatic gearbox 346
25 8 Crafter California, type approval model code SYMWE 347
25 8 1 Vehicles with automatic gearbox 347
25 9 Crafter/TGE, type approval model code SYM2Z 348
25 9 1 Vehicles with manual gearbox 348
25 9 2 Vehicles with automatic gearbox 351
25 10 Crafter/TGE, type approval model code SZN1E 353
25 10 1 Vehicles with manual gearbox 353
25 10 2 Vehicles with automatic gearbox 362
25 11 Crafter/TGE, type approval model code SZN1Z 366
25 11 1 Vehicles with manual gearbox 366
25 11 2 Vehicles with automatic gearbox 368
25 12 Crafter/TGE, type approval model code SZN2E 369
25 12 1 Vehicles with manual gearbox 369
25 12 2 Vehicles with automatic gearbox 371
25 13 Crafter/TGE, type approval model code SZN2Z 374
25 13 1 Vehicles with manual gearbox 374
25 13 2 Vehicles with automatic gearbox 378
D3E802AA8CD Heating air conditioner 381
00 – Technical data 387
1 Safety information 387
1 1 Safety precautions when working on air conditioning systems 387
1 2 Safety measures when working on vehicles with a start/stop system 387
1 3 Safety precautions when using testers and measuring instruments during a road test 388
1 4 Safety precautions when working on the cooling system 388
1 5 Safety precautions when handling refrigerants 388
1 6 Safety precautions for working on vehicles with auxiliary/supplementary heater 389
1 7 Safety precautions when working on the SCR system 390
2 General information 392
2 1 Type plates 392
3 Repair instructions 393
3 1 Rules for cleanliness 393
3 2 General information 393
3 3 General repair instructions 393
3 4 Contact corrosion 394
3 5 Nuts and bolts 394
3 6 Routing and attachment of lines 394
3 7 Fitting radiators and condensers 394
3 8 Checking cooling output 395
3 9 Working on refrigerant circuit 397
3 10 Refrigerant circuit seals 397
4 Technical data 399
4 1 Refrigerant capacity 399
4 2 Refrigerant oil capacities 399
4 3 Oil distribution 399
80 – Heating 400
1 Heater 400
1 1 Assembly overview – heater unit 400
1 2 Removing and installing fresh air blower -V2- 401
1 3 Removing and installing fresh air blower series resistor with overheating fuse -N24- 401
1 4 Removing and installing dust and pollen filter 401
1 5 Removing and installing heat exchanger 401
1 6 Removing and installing heater unit 401
1 7 Dismantling and assembling heater unit 406
2 Control motors 407
2 1 Overview of fitting locations – front control motors, heating system 407
2 2 Removing and installing fresh air and air recirculation flap control motor -V154- 407
3 Air duct 409
3 1 Removing and installing driver side footwell vents 409
3 2 Checking forced ventilation for passenger compartment 409
3 3 Removing and installing fresh air intake 409
4 Operating and display unit 410
4 1 Removing and installing operating and display unit 410
4 1 1 Removing and installing operating and display unit 410
4 1 2 Cables on operating and display unit 410
87 – Air conditioning system 412
1 Overview of fitting locations – air conditioning system 412
1 1 Overview of fitting locations – components not located in passenger compartment 412
1 2 Overview of fitting locations – components located in front section of passenger compartment 414
1 2 1 Overview of fitting locations – components located in front section of passenger compartment, manually regulated air conditioning system 414
1 2 2 Overview of fitting locations – components inside of front passenger compartment, Climatronic 416
2 Refrigerant circuit 419
2 1 System overview – refrigerant circuit 419
2 1 1 System overview – refrigerant circuit, 4-cylinder engine, left-hand drive vehicle 419
2 1 2 System overview – refrigerant circuit, 4-cylinder engine, right-hand drive vehicle 420
2 1 3 System overview – refrigerant circuit, 6-cylinder engine, left-hand drive vehicle 421
2 1 4 System overview – refrigerant circuit, 6-cylinder engine, right-hand drive vehicle 422
2 2 Removing and installing high-pressure sender -G65- 423
2 3 Removing and installing expansion valve 425
2 4 Removing and installing condenser 428
2 5 Removing and installing desiccant bag or cartridge 431
2 6 Removing and installing evacuating and charging valves on low and high-pressure side 433
2 7 Commissioning air conditioning system after filling refrigerant circuit 435
2 8 When is it necessary to purge the refrigerant circuit with refrigerant 436
3 Air conditioner compressor 438
3 1 Assembly overview – drive unit of air conditioner compressor 438
3 2 Removing and installing air conditioner compressor 439
3 2 1 Removing and installing air conditioning compressor – vehicles with 4-cylinder engine 439
3 2 2 Removing and installing air conditioning compressor – vehicles with 6-cylinder engine 442
3 3 Checking high-pressure safety valve on air conditioner compressor 446
4 Control motors 447
4 1 Overview of fitting locations – control motors at front 447
4 1 1 Overview of fitting locations – front control motors, air conditioning system with electric/manual controls/Climatic 447
4 1 2 Overview of fitting locations – front control motors, Climatronic 448
4 2 Removing and installing temperature flap control motor -V68- 450
4 2 1 Removing and installing temperature flap control motor -V68- 450
4 2 2 Removing and installing retaining plate for temperature flap control motor -V68- 451
4 3 Removing and installing defroster flap control motor -V107- 452
4 3 1 Removing and installing defroster flap control motor -V107- 452
4 3 2 Removing and installing retaining plate for defroster flap control motor -V107- 453
4 4 Removing and installing air recirculation flap control motor -V113- 453
4 5 Removing and installing left temperature flap control motor -V158- 454
4 5 1 Removing and installing left temperature flap control motor -V158- 454
4 5 2 Removing and installing retaining plate for left temperature flap control motor -V158- 455
4 6 Removing and installing right temperature flap control motor -V159- 456
4 7 Footwell flap control motor -V261- 458
4 7 1 Removing and installing footwell flap control motor -V261- 458
4 7 2 Removing and installing retaining plate for footwell flap control motor -V261- 459
4 8 Removing and installing fresh air/air recirculation, air flow flap control motor -V425- 460
4 9 Removing and installing air distribution flap control motor -V428- 461
4 9 1 Removing and installing air distribution flap control motor -V428- 461
4 9 2 Removing and installing retaining plate for air distribution flap control motor -V428- 462
5 Front heater and air conditioning unit 464
5 1 Assembly overview – heater and air conditioning unit 464
5 1 1 Assembly overview – heater and air conditioning unit, manually controlled air conditioning system 464
5 1 2 Assembly overview – heater and air conditioning unit, Climatronic 465
5 2 Removing and installing evaporator 467
5 3 Removing and installing heater and air conditioning unit 468
5 4 Dismantling and assembling heater and air conditioning unit 472
5 5 Removing and installing dust and pollen filter 473
5 6 Removing and installing fresh air blower -V2- 474
5 7 Removing and installing fresh air blower control unit -J126- 476
5 8 Removing and installing heat exchanger 477
5 9 Removing and installing evaporator temperature sensor -G308- 482
5 10 Removing and installing condensation drain 483
5 11 Checking condensation drain 484
5 12 Removing and installing fresh air blower series resistor with overheating fuse -N24- 484
6 Air duct 486
6 1 Assembly overview – air duct and air distribution in passenger compartment 486
6 2 Removing and installing driver side footwell vents 487
6 3 Removing and installing rear footwell vent 487
6 4 Removing and installing air ducts 488
6 4 1 Removing and installing left air duct of dash panel 488
6 4 2 Removing and installing right air duct of dash panel 489
6 5 Checking forced ventilation for passenger compartment 489
6 6 Removing and installing fresh air intake 490
7 Operating and display unit 492
7 1 Overview of operating and display unit 492
7 1 1 Overview of operating and display unit, vehicles with air conditioning system 492
7 1 2 Overview of operating and display unit, vehicles with Climatronic 493
7 1 3 Overview of control and display unit, vehicles with Climatronic from model year 2017 495
7 2 Removing and installing operating and display unit 497
8 Other controlling and regulating components 499
8 1 Removing and installing sunlight penetration photosensor -G107- 499
8 2 Working principles of air quality sensor -G238- 500
8 3 Removing and installing air quality sensor -G238- 501
8 4 Removing and installing ambient temperature sensor -G17- 502
8 5 Removing and installing humidity sender for air conditioning system -G260- 503
8 6 Removing and installing left vent temperature sender -G150- 503
8 7 Removing and installing right vent temperature sender -G151- 503
8 8 Removing and installing footwell vent temperature sender -G192- 504
8 9 Removing and installing left footwell vent temperature sender -G261- 504
8 10 Removing and installing right footwell vent temperature sender -G262- 505
D3E8027D416 Body Repairs 506
00 – Technical data 512
1 Key vehicle data 512
1 1 Vehicle identification number 512
1 2 Type plate 513
1 3 Vehicle data sticker 514
2 Safety information 515
2 1 Safety precautions when working with moulded foam inserts 515
3 Moulded foam inserts 516
4 Tools 518
5 Gaps/shut lines 519
5 1 Body, front 519
5 2 Body – centre, vehicles with double cab 520
5 3 Body – centre, vehicles with single cab 520
5 4 Body – rear, vehicles with double cab 521
5 5 Body – rear, vehicles with single cab 522
5 6 Body add-on parts 523
6 Body dimensions 526
6 1 Double cab chassis dimensions 526
6 1 1 Front chassis dimensions 526
6 1 2 Centre chassis dimensions 527
6 1 3 Rear chassis dimensions 529
6 2 Single cab chassis dimensions 531
6 2 1 Front chassis dimensions 531
6 2 2 Centre chassis dimensions 533
6 2 3 Rear chassis dimensions 535
6 3 Double cab box dimensions 537
6 3 1 Front box dimensions 537
6 3 2 Centre box dimensions 540
6 3 3 Rear box dimensions 541
6 4 Single cab box dimensions 542
6 4 1 Front box dimensions 542
6 4 2 Centre box dimensions 545
6 4 3 Rear box dimensions 547
6 5 Double cab load surface dimensions 548
6 5 1 Upper load surface dimensions 548
6 5 2 Lower load surface dimensions 550
6 5 3 Rear load surface dimensions 551
6 6 Single cab load surface dimensions 552
6 6 1 Upper load surface dimensions 552
6 6 2 Lower load surface dimensions 554
6 6 3 Rear load surface dimensions 555
7 Alignment jig 557
7 1 Tools 557
7 2 Alignment bracket fixture overview of complete vehicle 557
7 3 Alignment bracket fixture overview of vehicle chassis 558
7 4 Alignment bracket fixture overview of vehicle cab 558
7 5 Alignment bracket fixture overview of vehicle cab 559
50 – Body – front 562
1 Renewing cross member 562
1 1 Removing 562
1 2 Installing 564
1 2 1 Preparing new part 564
1 2 2 Welding in 565
2 Renewing deformation element 567
2 1 Removing 567
2 2 Installing 568
2 2 1 Preparing new part 568
2 2 2 Welding in 568
3 Renewing engine mounting cross member 571
3 1 Removing 571
3 2 Installing 572
3 2 1 Preparing new part 572
3 2 2 Welding in 573
4 Renewing differential cross member 576
4 1 Removing 576
4 2 Installing 578
4 2 1 Preparing new part 578
4 2 2 Welding in 579
5 Renewing propshaft cross member 581
5 1 Removing 581
5 2 Installing 582
5 2 1 Preparing new part 582
5 2 2 Welding in 584
6 Renewing cross member for shock absorber mounting 587
6 1 Removing 587
6 2 Installing 589
6 2 1 Preparing new part 589
6 2 2 Welding in 591
7 Renewing suspension turret 595
7 1 Removing 596
7 2 Installing 597
7 2 1 Preparing new part 597
7 2 2 Welding in 598
8 Renewing anti-roll bar mountings 600
8 1 Removing 600
8 2 Installing 601
8 2 1 Preparing new part 601
8 2 2 Welding in 602
9 Renewing wing connecting plate 604
9 1 Removing 604
9 2 Installing 606
9 2 1 Preparing new part 606
9 2 2 Welding in 607
10 Renewing connection piece 609
10 1 Removing 609
10 2 Installing 610
10 2 1 Preparing new part 610
10 2 2 Preparing new part, vehicles with third wing panel brace 611
10 2 3 Welding in 612
11 Renewing headlight mounting 614
11 1 Removing 614
11 2 Installing 616
11 2 1 Preparing new part 616
11 2 2 Welding in 618
12 Renewing upper wheel housing longitudinal member 621
12 1 Removing 621
12 2 Installing 622
12 2 1 Preparing new part 622
12 2 2 Welding in 623
13 Renewing front wheel housing 625
13 1 Removing 625
13 2 Installing 626
13 2 1 Preparing new part 626
13 2 2 Welding in 626
14 Renewing front part of longitudinal member – part section 1- 628
14 1 Removing 628
14 2 Installing 629
14 2 1 Preparing new part 629
14 2 2 Welding in 630
15 Renewing longitudinal member – part section 2- 632
15 1 Removing 632
15 2 Installing 633
15 2 1 Preparing new part 633
15 2 2 Producing longitudinal member reinforcement 635
15 2 3 Welding in 636
16 Renewing longitudinal member complete 639
16 1 Removing 641
16 2 Installing 647
16 2 1 Preparing new part 647
16 2 2 Welding in 651
51 – Body – centre 661
1 Renewing roof (double cab) 661
1 1 Tools 662
1 2 Removing 662
1 3 Installing 664
1 3 1 Preparing new part 664
1 3 2 Welding in 666
2 Renewing roof, single cab 668
2 1 Removing 668
2 2 Installing 670
2 2 1 Preparing new part 670
2 2 2 Welding in 671
3 Renewing roof side member, double cab 674
3 1 Removing 675
3 2 Installing 678
3 2 1 Other approved separating cuts on outer roof side member 678
3 2 2 Preparing new part 679
3 2 3 Welding in 681
4 Renewing roof side member, single cab 684
4 1 Removing 684
4 2 Installing 686
4 2 1 Preparing new part 686
4 2 2 Welding in 687
5 Renewing front cross member for roof 690
5 1 Removing 690
5 2 Installing 691
5 2 1 Preparing new part 691
5 2 2 Welding in 692
6 Renewing roof reinforcement 694
6 1 Removing 694
6 2 Installing 695
6 2 1 Preparing new part 695
6 2 2 Welding in 696
7 Renewing rear roof cross member 698
7 1 Removing 698
7 2 Installing 699
7 2 1 Preparing new part 699
7 2 2 Welding in 700
8 Renewing rear window frame 702
8 1 Removing 702
8 2 Installing 704
8 2 1 Preparing new part 704
8 2 2 Welding in 705
9 Renewing cross member 708
9 1 Removing 708
9 2 Installing 709
9 2 1 Preparing new part 709
9 2 2 Welding in 710
10 Renewing outer side panel completely, double cab 712
10 1 Removing 713
10 2 Installing 716
10 2 1 Other approved separating cuts on outer roof side member 716
10 2 2 Preparing new part 717
10 2 3 Moulded foam inserts 720
10 2 4 Welding in 720
11 Renewing outer side panel completely, single cab 724
11 1 Removing 725
11 2 Installing 728
11 2 1 Other approved separating cuts on outer roof side member 728
11 2 2 Preparing new part 729
11 2 3 Moulded foam inserts 731
11 2 4 Welding in 731
12 Renewing complete side panel, cargo box 736
12 1 Removing 736
12 2 Installing 738
12 2 1 Preparing new part 738
12 2 2 Welding in 739
13 Renewing hinge pillar (A-pillar) 742
13 1 Removing 744
13 2 Installing 746
13 2 1 Preparing new part, vehicles with double cab 746
13 2 2 Preparing new part, vehicles with single cab 747
13 2 3 Welding in 748
13 2 4 Renewing wing bracket 749
14 Renewing hinge pillar (A-pillar) reinforcement 752
14 1 Removing 752
14 2 Installing 754
14 2 1 Preparing new part 754
14 2 2 Welding in 756
15 Renewing inner A-pillar 758
15 1 Removing 758
15 2 Installing 760
15 2 1 Preparing new part 760
15 2 2 Bonding in and welding in new part 761
16 Renewing centre pillar (B-pillar) 763
16 1 Removing 764
16 2 Installing 766
16 2 1 Preparing new part 766
16 2 2 Welding in 767
17 Renewing centre pillar (B-pillar) reinforcement 769
17 1 Removing 770
17 2 Installing 771
17 2 1 Preparing new part 771
17 2 2 Welding in 772
18 Renewing lock column, C-pillar, double cab 774
18 1 Removing 775
18 2 Installing 778
18 2 1 Preparing new part 778
18 2 2 Welding in 779
19 Renewing lock column, B-pillar, single cab 782
19 1 Removing 782
19 2 Installing 784
19 2 1 Preparing new part 784
19 2 2 Welding in 786
20 Renewing outer side member, double cab 788
20 1 Removing 788
20 2 Installing 790
20 2 1 Other approved separating cuts on outer side member (sill) 790
20 2 2 Preparing new part 791
20 2 3 Welding in 792
21 Renewing outer side member, single cab 794
21 1 Removing 794
21 2 Installing 797
21 2 1 Preparing new part 797
21 2 2 Welding in 798
22 Renewing rear inner side member 801
22 1 Removing 802
22 2 Installing 803
22 2 1 Preparing new part 803
22 2 2 Bonding in and welding in new part 804
23 Renewing C-pillar reinforcement, double cab 807
23 1 Removing 808
23 2 Installing 809
23 2 1 Preparing new part 809
23 2 2 Welding in 810
24 Renewing inner C-pillar 812
24 1 Removing 812
24 2 Installing 814
24 2 1 Preparing new part 814
24 2 2 Bonding in and welding in new part 815
25 Renewing mounting bracket for front seat 818
25 1 Removing 818
25 2 Installing 819
25 2 1 Preparing new part 819
25 2 2 Welding in 820
26 Renewing mounting bracket for driver cab 822
26 1 Removing 822
26 2 Installing 823
26 2 1 Preparing new part 823
26 2 2 Welding in 824
27 Renewing mounting plate 826
27 1 Removing 826
27 2 Installing 827
27 2 1 Preparing new part 827
27 2 2 Welding in 828
53 – Body – rear 830
1 Renewing rear apron 830
1 1 Removing 830
1 2 Installing 832
1 2 1 Preparing new part 832
1 2 2 Welding in 833
2 Renewing rear cross member, rear 836
2 1 Removing 836
2 2 Installing 837
2 2 1 Preparing new part 837
2 2 2 Welding in 838
3 Renewing D-pillar 840
3 1 Removing 840
3 2 Installing 841
3 2 1 Preparing new part 841
3 2 2 Welding in 842
4 Renewing front leaf spring mounting bracket 844
4 1 Removing 844
4 2 Installing 845
4 2 1 Preparing new part 845
4 2 2 Welding in 846
5 Renewing rear leaf spring mounting bracket 847
5 1 Removing 847
5 2 Installing 848
5 2 1 Preparing new part 848
5 2 2 Welding in 849
6 Renewing cargo box shock absorber mounting 851
6 1 Removing 851
6 2 Installing 852
6 2 1 Preparing new part 852
6 2 2 Welding in 853
7 Renewing rear longitudinal member – part section 1 855
7 1 Removing 856
7 2 Installing 858
7 2 1 Preparing new part 858
7 2 2 Producing longitudinal member reinforcement 859
7 2 3 Welding in 860
8 Renewing rear longitudinal member – part section 2 864
8 1 Removing 864
8 2 Installing 865
8 2 1 Preparing new part 865
8 2 2 Welding in 866
9 Renewing rear side panel 869
9 1 Removing 869
9 2 Installing 873
9 2 1 Preparing new part 873
9 2 2 Welding in 874
10 Renewing upper load surface cross member 878
10 1 Removing 879
10 2 Installing 880
10 2 1 Preparing new part 880
10 2 2 Welding in 881
11 Renewing lower load surface cross member 883
11 1 Removing 883
11 2 Installing 884
11 2 1 Preparing new part 884
11 2 2 Welding in 885
12 Renewing load surface floor panel, part section 887
12 1 Removing 888
12 2 Installing 889
12 2 1 Preparing new part 889
12 2 2 Welding in 890
13 Renewing load surface bulkhead 892
13 1 Removing 892
13 2 Installing 893
13 2 1 Preparing new part 893
13 2 2 Welding in 894
D3E8033AEE6 Auxiliary heater 896
00 – Technical data 900
1 Safety information 900
1 1 Safety precautions during work on fuel system 900
1 2 Safety measures when working on vehicles with a start/stop system 900
1 3 Safety precautions when using testers and measuring instruments during a road test 901
1 4 Safety precautions when working on the cooling system 901
1 5 Safety precautions for working on vehicles with auxiliary/supplementary heater 901
2 General information 903
2 1 Starting conditions for auxiliary/supplementary heater 903
2 1 1 Starting conditions for auxiliary/supplementary heater, auxiliary/supplementary heater mode 903
2 1 2 Starting conditions for auxiliary/supplementary heater, supplementary heater mode 903
2 2 Notes for vehicles with a start/stop system 903
2 3 Type plates 904
2 3 1 Type plates to model year 2017 904
2 3 2 Type plates from model year 2017 905
3 Repair notes 906
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 906
3 2 Rules for cleanliness when working on fuel supply system 906
3 3 Notes on general repairs on vehicles with auxiliary/supplementary heater 906
82 – Supplementary heating 908
1 Overview of fitting locations – auxiliary/supplementary heater 908
1 1 Overview of fitting locations – components located outside of passenger compartment 908
1 1 1 Overview of fitting locations – components located outside of passenger compartment, up to model year 2017 908
1 1 2 Overview of fitting locations – components located outside of passenger compartment, from model year 2017 onwards 909
2 Auxiliary/supplementary heater 911
2 1 Overview of fitting locations – auxiliary/supplementary heater 911
2 1 1 Overview of fitting locations – auxiliary/supplementary heater, up to model year 2017 911
2 1 2 Overview of fitting locations – auxiliary/supplementary heater, from model year 2017 onwards 912
2 2 Assembly overview – auxiliary/supplementary heater, interior 913
2 2 1 Assembly overview – interior auxiliary/supplementary heater, up to model year 2017 913
2 2 2 Assembly overview – interior auxiliary/supplementary heater, from model year 2017 onwards 915
2 3 Removing and installing auxiliary/supplementary heater 918
2 3 1 Removing and installing auxiliary/supplementary heater, up to model year 2017 918
2 3 2 Removing and installing auxiliary/supplementary heater, from model year 2017 onwards 921
2 4 Dismantling and assembling auxiliary/supplementary heater 924
2 4 1 Dismantling and assembling auxiliary/supplementary heater, up to model year 2017 924
2 4 2 Dismantling and assembling auxiliary/supplementary heater, from model year 2017 onwards 926
2 5 Removing and installing air intake silencer 927
2 5 1 Removing and installing air intake silencer, to model year 2017 927
2 5 2 Removing and installing air intake silencer, from model year 2017 928
2 6 Removing and installing recirculation pump -V55- 929
2 6 1 Removing and installing circulation pump -V55-, to model year 2017 929
2 6 2 Removing and installing circulation pump -V55-, from model year 2017 930
2 7 Removing and installing silencer with bracket 933
2 8 Removing and installing heater coolant shut-off valve -N279- 934
2 8 1 Removing and installing heater coolant shut-off valve -N279-, up to model year 2017 934
2 8 2 Removing and installing heater coolant shut-off valve -N279-, vehicles with 4-cylinder engine, from model year 2017 onwards 935
2 8 3 Removing and installing heater coolant shut-off valve -N279-, vehicles with 6-cylinder engine, from model year 2017 onwards 937
2 9 Coolant temperature sender for heater -G241- 938
2 10 Removing and installing glow plug with flame monitor -Q8-, from model year 2017 939
2 11 Removing and installing temperature sensor -G18- and overheating sensor -G189-, from model year 2017 939
2 12 Pin assignment of auxiliary/supplementary heater 940
2 12 1 Pin assignment of auxiliary/supplementary heater, up to model year 2017 940
2 12 2 Pin assignment of auxiliary/supplementary heater, from model year 2017 onwards 941
2 13 Removing and installing auxiliary heater control unit -J364- with combustion air blower -V6-, from model year 2017 942
2 14 Dismantling and assembling burner unit, from model year 2017 943
3 Coolant circuit with auxiliary/supplementary heater 945
3 1 Coolant hose connection diagram 945
3 1 1 Coolant hose connection diagram for vehicles with supplementary heater, to model year 2017, engine code: CDCA and CDBA 945
3 1 2 Coolant hose connection diagram for vehicles with auxiliary heater, to model year 2017, engine code: CSHA and CNEA (EU 4 and EU 5 emissions standards) 946
3 1 3 Coolant hose connection diagram for vehicles with auxiliary heater, to model year 2017, engine code: CDBA and CNFA (EU 3, EU 4 and EU 5 emissions standards) 947
3 1 4 Coolant hose connection diagram for vehicles with supplementary heater, from model year 2017, engine code: CSHA (EU 3 and EU 4) 948
3 1 5 Coolant hose connection diagram for vehicles with supplementary heater, from model year 2017, engine code: CSHA (EU 5 Plus and PL 6 BR emission standards) 949
3 1 6 Coolant hose connection diagram for vehicles with auxiliary heater, from model year 2017, engine code: CSHA (EU 3 and EU 4) 950
3 1 7 Coolant hose connection diagram for vehicles with auxiliary heater, from model year 2017, engine code: CSHA (EU 5 Plus and PL 6 BR emission standards) 951
3 1 8 Coolant hose connection diagram for vehicles with supplementary heater, from model year 2017, engine code: DDXB and DDXC (EU 5 Plus, EU 6 Plus and PL 6 BR emission standards) 952
3 1 9 Coolant hose connection diagram for vehicles with auxiliary heater, from model year 2017, engine code: DDXB and DDXC (EU 5 Plus, EU 6 Plus and PL 6 BR emission standards) 953
4 Fuel supply system 955
4 1 Overview of fitting locations – fuel supply system 955
4 1 1 Overview of fitting locations – fuel supply system, to model year 2017 955
4 1 2 Overview of fitting locations – fuel supply system, vehicles with 4-cylinder engine, from model year 2017 955
4 1 3 Overview of fitting locations – fuel supply system, vehicles with 6-cylinder engine, from model year 2017 956
4 2 Checking fuel delivery rate 957
4 3 Removing and installing metering pump -V54- 960
4 3 1 Removing and installing metering pump -V54-, to model year 2017 960
4 3 2 Removing and installing metering pump -V54-, vehicles with 4-cylinder engine, from model year 2017 961
4 3 3 Removing and installing metering pump -V54-, vehicles with 6-cylinder engine, from model year 2017 962
5 Regulation of auxiliary/supplementary heater 964
5 1 Functional description 964
5 2 Supplementary heater mode 964
6 Other controlling and regulating components 965
6 1 Removing and installing roof display unit -J702- 965
6 2 Removing and installing remote control receiver for auxiliary coolant heater -R149- 966
6 3 Removing and installing ambient temperature sensor -G17- 968
6 4 Functional description of remote control for auxiliary/supplementary heater 968
D3E8037FAC2 4 cylinder injection engine (2 0 l direct injection engine turbocharger) 971
00 – Technical data 977
1 Safety information 977
1 1 Safety regulations for working on fuel supply 977
1 2 Safety measures when working on vehicles with a start/stop system 977
1 3 Safety precautions when using testers and measuring instruments during a road test 978
1 4 Safety precautions when working on the cooling system 978
1 5 Safety precautions when working on ignition system 978
1 6 Safety precautions when working on exhaust system 979
2 Identification 980
2 1 Engine number/engine data 980
3 Repair instructions 982
3 1 Rules for cleanliness 982
3 2 General notes 982
3 3 General repair notes 983
3 4 Foreign objects in engine 983
3 5 Contact corrosion 983
3 6 Routing and attachment of lines 984
3 7 Fitting radiator and condensers 984
3 8 Checking vacuum system 984
10 – Removing and installing engine 985
1 Removing and installing engine 985
1 1 Removing engine 985
1 2 Securing engine on engine and gearbox support 997
1 3 Installing engine 999
2 Assembly mountings 1003
2 1 Removing and installing engine and gearbox mounting 1003
13 – Crankshaft group 1006
1 Cylinder block (pulley end) 1006
1 1 Assembly overview – poly V-belt drive 1006
1 2 Removing and installing tensioner for poly V-belt 1009
1 3 Removing and installing poly-V belt 1010
1 4 Removing and installing bracket for ancillaries 1012
1 5 Removing and installing vibration damper 1015
1 6 Renewing crankshaft oil seal – belt pulley end 1022
2 Cylinder block, gearbox end 1025
2 1 Assembly overview – cylinder block, gearbox end 1025
2 2 Removing and installing drive plate 1026
2 3 Renewing needle bearing in drive plate 1028
2 4 Removing and installing sealing flange on gearbox side 1030
3 Pistons and conrods 1035
3 1 Assembly overview – pistons and conrods 1035
3 2 Checking pistons and cylinder bores 1037
3 3 Separating new conrod 1039
4 Crankshaft 1041
4 1 Assembly overview – crankshaft 1041
4 2 Allocation of main bearing shells 1043
4 3 Crankshaft dimensions 1045
4 4 Measuring axial clearance of crankshaft 1045
4 5 Measuring radial clearance of crankshaft 1046
4 6 Renewing needle bearing in crankshaft 1047
15 – Cylinder head, valve gear 1050
1 Cylinder head 1050
1 1 Assembly overview – cylinder head 1050
1 2 Removing and installing cylinder head 1053
1 3 Checking compression 1069
1 4 Removing and installing vacuum pump 1071
2 Cover for timing chain 1073
2 1 Assembly overview – cover for timing chain 1073
2 2 Removing and installing timing chain cover 1076
2 2 1 Removing and installing upper timing chain cover 1076
2 2 2 Removing and installing timing chain cover (bottom) 1077
3 Chain drive 1082
3 1 Assembly overview – camshaft timing chains 1082
3 2 Assembly overview – balancer shaft timing chain 1084
3 3 Removing and installing camshaft timing chain 1087
3 4 Removing and installing balance shaft timing chain 1092
3 5 Renewing balancer shaft for inlet camshaft 1095
3 6 Renewing balancer shaft for exhaust camshaft 1099
3 7 Checking valve timing 1102
4 Valve gear 1105
4 1 Assembly overview – valve gear 1105
4 2 Removing and installing camshaft 1107
4 3 Removing and installing valve stem seals 1120
4 3 1 Renewing valve stem seals with cylinder head installed 1120
4 3 2 Renewing valve stem seals with cylinder head removed 1125
4 4 Measuring axial play of camshaft 1131
4 5 Removing and installing camshaft control valve 1 -N205- 1132
5 Inlet and exhaust valves 1133
5 1 Checking valve guides 1133
5 2 Valve dimensions 1134
17 – Lubrication 1135
1 Sump, oil pump 1135
1 1 Assembly overview – sump/oil pump 1135
1 2 Removing and installing lower part of sump 1138
1 3 Removing and installing upper part of sump 1140
1 4 Removing and installing oil pump 1145
1 5 Engine oil: 1147
2 Crankcase ventilation 1148
2 1 Removing and installing coarse oil separator 1148
3 Oil filter, oil pressure switch 1150
3 1 Assembly overview – oil filter housing, oil pressure switch 1150
3 2 Removing and installing oil pressure switch -F22- 1152
3 3 Checking oil pressure 1152
4 Engine oil cooler 1154
4 1 Removing and installing engine oil cooler 1154
19 – Cooling 1156
1 Cooling system/coolant 1156
1 1 Draining and adding coolant 1156
1 1 1 Draining and adding coolant 1156
1 1 2 Charging the cooling system in the case of emergency 1162
1 2 Checking cooling system for leaks 1164
1 3 Connection diagram – coolant hoses 1167
1 3 1 Connection diagram – coolant hoses 1167
1 3 2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger 1167
2 Coolant pump, regulation of cooling system 1169
2 1 Assembly overview – coolant hoses 1169
2 2 Assembly overview – coolant pump, thermostat 1171
2 3 Removing and installing continued coolant circulation pump -V51- 1173
2 4 Removing and installing coolant temperature sender -G62- 1174
2 5 Removing and installing toothed belt for coolant pump 1176
2 6 Renewing oil seal for coolant pump drive 1178
2 7 Removing and installing coolant pump 1180
2 8 Removing and installing thermostat 1182
3 Radiator, radiator fan 1184
3 1 Assembly overview – radiator/radiator fan -V7- 1184
3 2 Assembly overview – radiator cowl and radiator fan -V7- 1186
3 3 Removing and installing radiator cowl with radiator fan -V7- 1186
3 4 Removing and installing radiator 1188
21 – Turbocharging/supercharging 1193
1 Charge air system 1193
1 1 Assembly overview – charge air cooling 1193
1 2 Removing and installing pressure pipe 1195
1 3 Removing and installing charge pressure sender -G31- 1196
1 4 Removing and installing charge air cooler 1196
1 5 Checking charge air system for leaks 1200
2 Turbocharger 1203
2 1 Assembly overview – turbocharger 1203
2 2 Removing and installing turbocharger 1209
2 3 Checking vacuum unit for turbocharger 1213
24 – Mixture preparation – injection 1216
1 Injection system 1216
1 1 Overview of fitting locations – injection system 1216
2 Injectors 1219
2 1 Assembly overview – fuel rail with injectors 1219
2 2 Removing and installing injectors 1221
2 3 Renewing seals on injectors 1224
2 4 Cleaning injectors 1227
3 Air filter 1229
3 1 Assembly overview – air filter housing 1229
3 2 Removing and installing air filter housing 1232
4 Senders and sensors 1234
4 1 Removing and installing air mass meter -G70- 1234
4 2 Removing and installing fuel pressure sender -G247- 1235
4 3 Checking fuel pressure sender -G247- 1237
4 4 Checking double non-return valve 1240
5 Intake manifold 1243
5 1 Assembly overview – intake manifold 1243
5 2 Removing and installing intake manifold 1245
5 3 Removing and installing throttle valve module -J338- 1249
5 4 Cleaning throttle valve module -J338- 1250
5 5 Checking intake manifold change-over 1251
6 High-pressure pump 1254
6 1 Assembly overview – high-pressure pump 1254
6 2 Removing and installing high-pressure pump 1256
6 3 Check fuel holding pressure upstream of high-pressure pump 1257
7 Engine control unit 1261
7 1 Removing and installing engine control unit 1261
26 – Exhaust system 1263
1 Exhaust pipes and silencers 1263
1 1 Assembly overview – silencers 1263
1 2 Removing and installing centre silencer 1265
1 3 Removing and installing rear silencer 1267
1 4 Checking exhaust system for leaks 1268
1 5 Aligning exhaust system free of stress 1268
1 6 Installation position of clamp 1269
2 Emission control 1272
2 1 Removing and installing catalytic converter 1272
28 – Ignition system 1274
1 Ignition system 1274
1 1 Assembly overview – ignition system 1274
1 2 Removing and installing ignition coils with output stage 1275
1 3 Removing and installing spark plugs 1278
1 4 Removing and installing knock sensor 1 -G61- 1280
1 5 Removing and installing engine speed sender -G28- 1280
1 6 Test data, spark plugs 1282
D3E80480C6A 8 speed automatic gearbox 0CM 1283
00 – Technical data 1287
1 Safety information 1287
1 1 Rules for safety when working on the gearbox 1287
1 2 Safety precautions when working on vehicles with a start/stop system 1288
1 3 Safety precautions when using testers and measuring instruments during a road test 1289
1 4 Safety precautions when tow-starting or towing 1289
2 Repair notes 1290
2 1 Rules for cleanliness 1290
2 2 General repair instructions 1290
2 3 Contact corrosion 1291
2 4 Gaskets and seals 1291
2 5 Nuts and bolts 1292
3 Technical data 1293
3 1 Capacities 1293
3 2 Allocation gearbox – engine 1293
3 2 1 Allocation gearbox – engine, rear-wheel drive 1293
3 2 2 Allocation gearbox – engine, all-wheel drive 1294
4 Identification 1296
4 1 Gearbox identification 1296
4 2 Identification of torque converter 1296
32 – Torque converter 1297
1 Torque converter 1297
1 1 Assembly overview – torque converter 1297
1 2 Removing and installing torque converter 1297
1 3 Draining torque converter 1299
1 4 Removing and installing torque converter oil seal 1300
37 – Controls, housing 1302
1 ATF circuit 1302
1 1 Assembly overview – ATF circuit 1302
1 2 Removing and installing ATF cooler 1303
1 3 Removing and installing ATF filter 1307
1 4 Removing and installing ATF lines 1309
1 4 1 Removing and installing ATF lines, ATF cooler/thermostat 1309
1 4 2 Removing and installing ATF lines, thermostat/gearbox 1312
2 ATF 1315
2 1 Checking ATF level 1315
2 2 Draining and filling ATF 1318
2 3 Purging ATF circuit 1323
3 Removing and installing gearbox 1325
3 1 Specified torques for gearbox 1325
3 2 Removing gearbox 1325
3 2 1 Removing gearbox, 4×2 vehicles with rear-wheel drive 1325
3 2 2 Removing gearbox, 4×4 vehicles with all-wheel drive 1335
3 3 Installing gearbox 1344
4 Assembly mountings 1346
4 1 Assembly overview – assembly mountings 1346
4 1 1 Assembly overview – assembly mountings, version A 1346
4 1 2 Assembly overview – assembly mountings, version B 1348
5 Transporting gearbox 1351
5 1 Transporting gearbox 1351
6 Selector mechanism 1352
6 1 Assembly overview – selector mechanism 1352
6 2 Assembly overview – selector lever handle 1353
6 3 Checking selector mechanism 1354
6 4 Manual release from position P 1355
6 5 Removing and installing selector mechanism 1356
6 6 Removing and installing selector lever handle 1359
6 7 Removing and installing gear selector cable 1361
6 8 Dismantling and assembling selector mechanism 1362
6 8 1 Removing and installing cable support bracket for selector lever cable 1362
6 8 2 Removing and installing gearbox selector lever 1365
6 9 Checking and adjusting selector lever cable 1366
38 – Gears, control 1368
1 ATF system 1368
1 1 Assembly overview – sump/oil strainer 1368
1 2 Removing and installing sump 1370
1 3 Removing and installing hydraulic impulse oil storage with accumulator solenoid -N485- 1373
2 Oil seals in gearbox 1375
2 1 Renewing oil seal in gearbox 1375
2 1 1 Renewing output flange oil seal, 4×2 vehicles with rear-wheel drive 1375
2 1 2 Renewing output flange oil seal, 4×4 vehicles with all-wheel drive 1381
3 Mechatronic unit 1385
3 1 Removing and installing mechatronic unit 1385
D3E802838CF Electrical system 1391
00 – Technical data 1397
1 Safety information 1397
1 1 Safety precautions when working on air conditioning systems 1397
1 2 Safety precautions when working on vehicles with a start/stop system 1397
1 3 Safety precautions when using testers and measuring instruments during a road test 1398
1 4 Safety precautions when working on the cooling system 1398
1 5 Safety precautions for working on vehicles with auxiliary heater 1398
2 Repair instructions 1400
2 1 Contact corrosion 1400
2 2 Routing and attachment of lines 1400
3 Battery 1401
3 1 Types of battery 1401
3 2 Battery – general notes 1401
27 – Starter, current supply, CCS 1402
1 Battery 1402
1 1 Assembly overview – battery 1402
1 1 1 Assembly overview – vehicles without battery monitor control unit -J367- 1402
1 1 2 Assembly overview – vehicles with battery monitor control unit -J367- 1403
1 2 Removing and installing battery 1404
1 2 1 Removing and installing battery -A- 1404
1 2 2 Parametrising battery after replacement, vehicles with start/stop system 1406
1 3 Disconnecting and connecting battery 1407
1 3 1 Disconnecting and connecting battery, earth wire on negative battery terminal 1407
1 3 2 Disconnecting and connecting battery 1408
1 4 Checking battery 1409
1 5 Charging battery 1409
1 6 Removing and installing earth wire with battery monitor control unit -J367- 1409
1 7 Adapting battery monitor control unit -J367- 1411
2 Alternator 1412
2 1 Assembly overview – alternator 1412
2 1 1 Assembly overview – alternator, diesel engines 1412
2 1 2 Assembly overview – alternator, petrol engines 1412
2 2 Removing and installing alternator 1413
2 2 1 Removing and installing alternator -C-, 4-cylinder petrol engines 1413
2 2 2 Removing and installing alternator -C-, 4-cylinder diesel engines 1416
2 2 3 Removing and installing alternator -C-, 6-cylinder diesel engines 1421
2 3 Checking alternator 1422
2 4 Repairing alternator 1423
2 4 1 Removing and installing voltage regulator -C1-, Bosch 1423
2 4 2 Removing and installing voltage regulator -C1-, Valeo 1424
2 4 3 Checking alternator carbon brushes 1426
2 4 4 Removing and installing poly V-belt pulley on alternator 1426
2 5 Checking poly V-belt 1428
3 Starter 1430
3 1 Assembly overview – starter 1430
3 2 Removing and installing starter 1431
3 2 1 Removing and installing starter, 4-cylinder diesel engine with manual gearbox 1431
3 2 2 Removing and installing starter, 4-cylinder petrol engine with manual gearbox 1434
3 2 3 Removing and installing starter, 4-cylinder diesel engine with automatic gearbox 1438
3 2 4 Removing and installing starter, 6-cylinder diesel engine 1441
3 3 Checking starter 1443
4 Start/stop system 1444
4 1 General description – start/stop system 1444
4 2 Overview of fitting locations – start/stop system 1445
4 3 Removing and installing start-stop operation button 1447
4 3 1 Removing and installing start-stop operation button up to model year 2017 1447
4 3 2 Removing and installing start-stop operation button as of model year 2017 1448
4 4 Removing and installing voltage stabiliser 1448
4 4 1 General description – voltage stabiliser 1448
4 4 2 Removing and installing voltage stabiliser -J532- 1449
90 – Gauges, instruments 1451
1 Dash panel insert 1451
1 1 Removing and installing dash panel insert -KX2- 1451
1 1 1 General description – dash panel insert -KX2- 1451
1 1 2 Removing and installing dash panel insert -KX2- up to model year 2017 1452
1 1 3 Removing and installing dash panel insert -KX2- from model year 2017 1454
1 1 4 Renewing dash panel insert -KX2- 1457
1 1 5 Coding dash panel insert -KX2- 1457
2 Horn 1458
2 1 Removing and installing treble horn and bass horn 1458
2 1 1 Checking treble horn and bass horn 1458
2 1 2 Removing and installing treble horn and bass horn, vehicles up to 06 2012 1458
2 1 3 Removing and installing treble horn and bass horn, vehicles as of 07 2012 1459
92 – Windscreen wash/wipe system 1460
1 Windscreen wiper system 1460
1 1 Moving wipers to service position 1460
1 2 Removing and installing wiper arms 1460
1 3 Removing and installing window wiper mounting with wiper motor 1463
1 4 Removing and installing wiper motor 1465
1 5 Removing and installing wiper blades 1468
1 5 1 Removing and installing wiper blades, vehicles without joint-free windscreen wipers 1468
1 5 2 Removing and installing wiper blades, vehicles with joint-free windscreen wipers 1469
1 6 Adjusting wiper arms 1470
1 6 1 Checking and adjusting angle of incidence of wiper blades, vehicles without joint-free windscreen wipers 1470
1 6 2 Adjusting wiper blade park position 1471
1 7 Removing and installing rain and light sensor -G397- 1472
1 7 1 Removing and installing rain and light sensor -G397-, up to model year 2017 1472
1 7 2 Removing and installing rain and light sensor -G397-, as of model year 2017 1475
1 7 3 Repairing rain and light sensor -G397- (made by TRW) 1477
2 Windscreen washer system 1480
2 1 Assembly overview – windscreen washer system 1480
2 2 Removing and installing filler pipe for washer fluid reservoir 1481
2 3 Removing and installing washer fluid reservoir 1482
2 4 Removing and installing windscreen washer fluid level sender 1483
2 5 Removing and installing windscreen wash pump 1485
2 6 Removing and installing windscreen washer system spray jets 1486
2 7 Adjusting spray jets for windscreen washer system 1488
3 Washer fluid lines 1489
3 1 Repairing washer fluid lines 1489
3 1 1 Washer fluid line hose couplings 1489
3 1 2 Hose repair 1489
94 – Lights, bulbs, switches – exterior 1490
1 Headlights 1490
1 1 Operation and safety notes for gas discharge lamps 1490
1 2 Assembly overview – headlight 1492
1 2 1 Assembly overview – Arteb headlights with H1 bulb 1492
1 2 2 Assembly overview – Valeo headlights with H1 bulb 1494
1 2 3 Assembly overview – Arteb headlights with H15 bulb 1496
1 2 4 Assembly overview – Valeo headlights with H15 bulb 1498
1 2 5 Assembly overview – gas discharge headlight 1500
1 3 Removing and installing headlight 1502
1 3 1 Removing and installing headlights, Arteb headlights with H1 bulb 1502
1 3 2 Removing and installing headlights, Valeo headlights with H1 bulb 1506
1 3 3 Removing and installing headlights, Arteb headlights with H15 bulb 1506
1 3 4 Removing and installing headlights, Valeo headlights with H15 bulb 1506
1 3 5 Removing and installing headlights, gas discharge headlights 1506
1 4 Adjusting headlights 1507
1 5 Removing and installing front turn signal bulb 1508
1 5 1 Removing and installing front turn signal bulb, Arteb headlights with H1 bulb 1508
1 5 2 Removing and installing front turn signal bulb, Valeo headlights with H1 bulb 1510
1 5 3 Removing and installing front turn signal bulb, Arteb headlights with H15 bulb 1510
1 5 4 Removing and installing front turn signal bulb, Valeo headlights with H15 bulb 1510
1 5 5 Removing and installing front turn signal bulb, gas discharge headlights 1511
1 6 Removing and installing side light bulb 1513
1 6 1 Removing and installing side light bulb, Arteb headlights with H1 bulb 1513
1 6 2 Removing and installing side light bulb, Valeo headlights with H1 bulb 1515
1 6 3 Removing and installing side light bulb, Arteb headlights with H15 bulb 1515
1 6 4 Removing and installing side light bulb, Valeo headlights with H15 bulb 1516
1 6 5 Removing and installing side light bulb, gas discharge headlights 1518
1 7 Removing and installing dipped beam bulb 1518
1 7 1 Removing and installing dipped beam bulb, Arteb headlights with H1 bulb 1518
1 7 2 Removing and installing dipped beam bulb, Valeo headlights with H1 bulb 1520
1 7 3 Removing and installing dipped beam bulb, Arteb headlights with H15 bulb 1520
1 7 4 Removing and installing dipped beam bulb, Valeo headlights with H15 bulb 1521
1 8 Removing and installing main beam bulb 1523
1 8 1 Removing and installing main beam bulb, Arteb headlights with H1 bulb 1523
1 8 2 Removing and installing main beam bulb, Valeo headlights with H1 bulb 1526
1 9 Removing and installing daytime running light and main beam bulb 1529
1 9 1 Removing and installing daytime running light and main beam bulb, Arteb headlights with H15 bulb 1529
1 9 2 Removing and installing daytime running light and main beam bulb, Valeo headlights with H15 bulb 1531
1 10 Removing and installing gas discharge bulb -L13-/-L14- 1533
1 11 Removing and installing LED module for daytime running light and side light -L176-/-L177- 1535
1 12 Removing and installing control unit for daytime running light and side light -J860-/-J861- 1535
1 13 Removing and installing gas discharge bulb control unit -J343-/-J344- 1537
1 14 Headlight conversion for left-hand/right-hand traffic 1538
1 15 Removing and installing headlight range control motor 1544
1 15 1 Removing and installing headlight range control motor, Arteb headlights with H15 bulb 1544
1 15 2 Removing and installing headlight range control motor, Valeo headlights with H15 bulb 1544
1 15 3 Removing and installing headlight range control motor -V48-/-V49-, gas discharge headlights 1544
2 Main beam headlights on roof 1547
2 1 Removing and installing main beam headlights on roof 1547
2 1 1 Removing and installing main beam headlights on roof, halogen headlights 1547
2 1 2 Removing and installing main beam headlights on roof, LED headlights 1549
2 1 3 Removing and installing bulb for main beam headlights on roof, Halogen headlights 1550
2 1 4 Removing and installing headlight main beam bulb on roof, LED headlights 1551
2 1 5 Adjusting main beam headlights on roof, halogen headlights 1551
2 1 6 Adjusting main beam headlights on roof, LED headlights 1553
3 Fog lights 1555
3 1 Assembly overview – fog lights 1555
3 2 Removing and installing fog light 1556
3 2 1 Removing and installing fog lights up to model year 2017 1556
3 2 2 Removing and installing fog lights as of model year 2017 1557
3 3 Removing and installing fog light bulb 1558
3 4 Adjusting fog lights 1558
4 Side turn signals 1559
4 1 Removing and installing turn signal repeater 1559
4 2 Removing turn signal repeater bulb 1560
5 Tail lights 1562
5 1 Assembly overview – tail light 1562
5 2 Removing and installing tail light cluster 1563
5 3 Removing and installing tail light bulb 1564
5 4 Removing and installing brake light bulb 1565
5 5 Removing and installing rear fog light bulb 1566
5 6 Removing and installing reversing light bulb 1567
5 7 Removing and installing turn signal bulb 1568
6 High-level brake light 1570
6 1 Removing and installing high-level brake light 1570
6 1 1 Removing and installing high-level brake light to model year 2017 1570
6 1 2 Removing and installing high-level brake light from model year 2017 1571
6 1 3 Removing and installing high-level brake light “CANYON” 1571
6 2 Removing and installing high-level brake light 1573
7 Number plate light 1574
7 1 Removing and installing number plate light 1574
7 2 Removing and installing bulb for number plate light 1575
8 Load area light 1576
8 1 Removing and installing load area light 1576
8 1 1 Removing and installing load area light 1576
8 1 2 Removing and installing load area light “CANYON” 1577
8 2 Removing and installing bulb for load area light 1578
9 Steering column switch module 1579
9 1 Removing and installing steering column switch module 1579
9 2 Removing and installing ignition/starter switch 1582
9 3 Removing and installing lock cylinder 1584
9 4 Removing and installing steering lock housing 1586
10 Parking aid 1589
10 1 Assembly overview – parking aid 1589
10 2 Removing and installing parking aid control unit 1592
10 2 1 Removing and installing parking aid control unit 1592
10 2 2 Adapting rear parking aid control unit 1593
10 3 Removing and installing rear parking aid warning buzzer 1593
10 4 Removing and installing front parking aid warning buzzer 1594
10 5 Removing and installing rear parking aid senders 1596
10 6 Removing and installing front parking aid senders 1598
11 Towing bracket 1601
11 1 Removing and installing trailer detector control unit 1601
11 2 Connector pin assignment for trailer socket 1602
96 – Lights, bulbs, switches – interior 1603
1 Lights and controls in the dash panel 1603
1 1 Overview of fitting locations – switches in centre of dash panel 1603
1 2 Removing and installing light switch 1605
1 3 Removing and installing headlight range control regulator with switches and instruments illumination regulator 1606
1 4 Removing and installing buttons in dash panel 1608
1 4 1 Removing and installing buttons in centre of dash panel up to model year 2017 1608
1 4 2 Removing and installing buttons in centre of dash panel as of model year 2017 1610
2 Lights and controls in front doors 1612
2 1 Removing and installing window regulator switches in driver door 1612
2 2 Removing and installing window regulator switches in front passenger door 1613
2 3 Removing and installing mirror adjuster switch 1613
2 4 Removing and installing driver side interior locking button for central locking system 1614
3 Lights and controls in rear doors 1616
3 1 Removing and installing window regulator switch in rear doors 1616
4 Lights and controls in the centre console 1618
4 1 Removing and installing buttons in centre console 1618
5 Lights and controls in the roof trim 1620
5 1 Removing and installing front interior light 1620
5 2 Removing and installing bulb of front interior light 1621
5 3 Removing and installing centre interior light 1622
5 4 Removing and installing bulb of centre interior light 1623
6 Cigarette lighter and 12 V socket 1625
6 1 Removing and installing cigarette lighter -U1- 1625
6 2 Removing and installing 12 V socket 1625
6 2 1 Removing and installing upper 12 V socket in centre dash panel, up to model year 2017 1625
6 2 2 Removing and installing upper 12 V socket in centre dash panel, as of model year 2017 1627
6 2 3 Removing and installing lower 12 V socket in centre dash panel 1628
6 2 4 Removing and installing 12 V socket on load area 1630
6 2 5 Removing and installing lower 12 V socket in rear centre console 1631
7 Immobiliser 1633
7 1 Removing and installing immobiliser control unit 1633
7 2 Removing and installing immobiliser reader coil 1633
8 Anti-theft alarm system 1634
8 1 Assembly overview – anti-theft alarm system 1634
8 2 Removing and installing interior monitoring switch 1636
8 3 Removing and installing alarm horn -H12- 1637
8 3 1 Removing and installing alarm horn -H12-, intelligent siren design 1637
8 3 2 Removing and installing alarm horn -H12-, simple signal horn design 1638
8 4 Removing and installing anti-theft alarm sensor -G578- 1640
8 5 Adapting the anti-theft alarm system 1641
8 5 1 Adapting sensitivity of interior monitoring system 1642
8 5 2 Adapting sensitivity of inclination sensor 1642
8 5 3 Adapting alarm delay on opening driver door 1642
8 5 4 Adapting country setting for intelligent alarm horn 1643
97 – Wiring 1644
1 Relay carriers, fuse holders, electronics boxes 1644
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 1644
1 1 1 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes; up to model year 2016 1644
1 1 2 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes; as of model year 2017 1645
1 2 Removing and installing relay carrier 1645
1 2 1 Removing and installing relay carrier up to model year 2017 1645
1 2 2 Removing and installing relay carrier 1 as of model year 2017 1646
1 2 3 Removing and installing relay carrier 2 as of model year 2017 1647
1 3 Removing and installing fuse holder 1648
1 3 1 Removing and installing fuse holder A -SA- 1648
1 3 2 Removing and installing fuse holder C -SC- 1650
1 3 3 Removing and installing fuse holder F -SF- 1651
2 Control units 1652
2 1 Removing and installing onboard supply control unit 1652
2 2 Flashing, commissioning and coding onboard supply control unit 1653
2 3 Removing and installing data bus diagnostic interface -J533- 1654
3 Connectors 1657
3 1 Repairing electrical wiring harnesses and plug-in connections 1657
3 1 1 Wiring harness and connector repairs 1657
3 1 2 Contact surface cleaning set VAS 6410 1657
4 Vehicle diagnosis, testing and information systems 1658
D3E8028924F Transfer box and final drive 1659
00 – Technical data 1663
1 Identification 1663
1 1 Identification of transfer box 1663
1 1 1 Distinguishing features of transfer boxes 1663
1 1 2 Identification of transfer box 1664
1 2 Identification of final drive 1665
2 Technical data 1666
2 1 Allocation gearbox – engine 1666
2 1 1 Allocation of rear final drive – engine/capacities 1666
2 1 2 Allocation of front final drive – engine/capacities 1666
2 1 3 Allocation of transfer box – engine/capacities 1666
2 1 4 Allocation of rear axle – engine/capacities, to model year 2017 1667
2 1 5 Allocation of rear axle – engine/capacities, from model year 2017 1668
2 2 Calculation of gear ratios 1671
3 Overview – power transmission 1672
3 1 Overview – power transmission – all-wheel drive 1672
4 Repair notes 1673
4 1 General repair instructions 1673
4 1 1 Gearbox 1673
4 1 2 Rear axle 1673
4 1 3 Gaskets and seals 1673
4 1 4 Locking devices 1674
4 1 5 Nuts and bolts 1674
4 1 6 Mountings 1674
4 1 7 Shims 1674
39 – Final drive – rear differential 1675
1 Final drive 1675
1 1 Assembly overview – final drive 1675
1 2 Assembly overview – differential 1678
1 3 Removing and installing drive pinion and differential 1679
1 4 Dismantling and assembling differential 1692
1 5 Removing and installing crown wheel 1695
1 6 Checking backlash and contact pattern 1696
1 7 Pulling tapered roller bearing for drive pinion off and pressing it on 1699
1 8 Pulling tapered roller bearing for differential off and pressing it on 1701
1 9 Overview of shims 1703
1 10 Adjustment overview 1705
1 11 Determining shims for crown wheel 1706
1 12 Determining shims for drive pinion 1709
1 13 Repairing propshaft flange 1714
2 Differential lock 1718
2 1 Function 1718
2 2 Rear differential lock components and their locations 1718
2 2 1 Rear differential lock components and their locations 1718
2 2 2 Removing and installing axle differential lock Hall sender 1 -G460- 1719
3 Propshaft 1723
3 1 Assembly overview – propshaft 1723
3 1 1 Assembly overview – flexible coupling for propshaft 1723
3 1 2 Assembly overview – “Tirsan” propshaft 1724
3 1 3 Assembly overview – “Dana” propshaft 1726
3 2 Removing and installing propshaft 1728
3 2 1 Removing and installing front propshaft 1728
3 2 2 Removing and installing rear propshaft 1731
3 3 Dismantling and assembling propshaft 1733
3 3 1 Dismantling and assembling centre propshaft bearing, “Dana” propshaft 1733
3 3 2 Dismantling and assembling centre propshaft bearing, “Tirsan” propshaft 1737
3 3 3 Dismantling and assembling front propshaft 1741
3 3 4 Removing and installing universal joint bearing bushes, rear propshaft 1744
4 Gear oil for rear final drive 1746
4 1 Checking gear oil level 1746
5 Seals for rear final drive 1747
5 1 Renewing propshaft flange seal 1747
39 – Final drive – front differential 1755
1 Front final drive 1755
1 1 Assembly overview – final drive 1755
1 2 Removing and installing front final drive 1755
1 3 Renewing bonded rubber bush on rear of final drive 1761
1 4 Renewing bonded rubber bush on front of final drive 1764
1 5 Renewing bonded rubber on left of final drive 1767
1 6 Preparing foot pump 1770
2 Gear oil for front final drive 1773
2 1 Checking level of gear oil 1773
3 Oil seals for front final drive 1775
3 1 Renewing flange shaft seal 1775
3 1 1 Renewing left flange shaft oil seal 1775
3 1 2 Renewing oil seal for right flange shaft 1777
3 1 3 Renewing input shaft seal 1781
3 2 Renewing dust cap for flange shaft 1784
3 2 1 Renewing dust cap for left flange shaft 1784
3 2 2 Renewing dust cap for right flange shaft 1785
3 3 Renewing needle bearing for left flange shaft 1787
39 – Final drive – differential 1790
1 Transfer box 1790
1 1 Assembly overview – transfer box 1790
1 1 1 Assembly overview – transfer box, “selectable all-wheel drive”, “0C7” 1790
1 1 2 Assembly overview – transfer box, “self-locking”, “0BU” 1793
1 1 3 Components and their locations 1795
1 2 Checking gear oil level 1797
1 2 1 Checking gear oil level, transfer box with “selectable all-wheel drive” 1797
1 2 2 Checking gear oil level, “self-locking” transfer box 1798
1 3 Removing and installing transfer box 1800
1 4 Dismantling and assembling transfer box 1803
1 4 1 Assembly overview – transfer box 0C7 1803
1 4 2 Dismantling and assembling transfer box, transfer box 0C7 1807
1 4 3 Removing and installing transfer box, transfer box 0C7 1810
1 4 4 Assembly overview – selector fork, “4 x 4 LOW”, “0C7” 1812
1 4 5 Removing and installing selector fork, “4 x 4 LOW”, “0C7” 1813
1 4 6 Dismantling and assembling selector fork, “4 x 4 LOW”, “0C7” 1814
1 4 7 Removing and installing selector fork, “4 x 4 HIGH/LOW”, “0C7” 1815
1 4 8 Removing and installing oil pump, transfer box 0C7 1817
1 4 9 Removing and installing main shaft bearing – rear-wheel drive, transfer box 0C7 1818
1 4 10 Removing and installing selector shaft bearing, transfer box 0C7 1819
1 4 11 Removing and installing main shaft bearing – main gearbox, transfer box 0C7 1820
1 4 12 Removing and installing output shaft bearing – front final drive, transfer box 0C7 1822
1 4 13 Removing and installing output shaft bearing – front final drive, gearbox side, transfer box 0C7 1823
1 4 14 Removing and installing drive worm gear bearing, transfer box 0C7 1824
1 4 15 Removing and installing drive worm gear, transfer box 0C7 1825
1 4 16 Removing and installing bearing in sun gear, transfer box 0C7 1826
1 4 17 Removing and installing O-ring of sun gear, transfer box 0C7 1827
1 4 18 Removing and installing transfer box control unit -J646-, transfer box 0C7 1828
1 4 19 Removing and installing Hall sender for transfer box -G759-, transfer box 0C7 1828
1 4 20 Removing and installing transfer box control motor -V455-, transfer box 0C7 1830
1 4 21 Removing and installing reduction stage, transfer box 0C7 1832
1 4 22 Assembly overview – main shaft, transfer box 0C7 1832
1 4 23 Removing and installing main shaft, transfer box 0C7 1833
1 4 24 Dismantling and assembling main shaft, transfer box 0C7 1834
1 5 Renewing oil seals 1836
1 5 1 Renewing oil seals for input shaft, “selectable all-wheel drive”, “0C7” 1836
1 5 2 Renewing oil seals for output shaft, “selectable all-wheel drive”, “0C7” 1838
1 5 3 Renewing oil seals for propshaft flange, “selectable all-wheel drive”, “0C7” 1840
1 5 4 Renewing oil seals for input shaft, “self-locking”, “0BU” 1845
1 5 5 Renewing oil seals for output shaft, “self-locking”, “0BU” 1846
1 5 6 Renewing oil seals for propshaft flange, “self-locking”, “0BU” 1848
D4B806DC758 6 speed manual gearbox 0F6 1853
00 – Technical data 1857
1 Safety information 1857
1 1 Safety measures when working on vehicles with a start/stop system 1857
1 2 Safety precautions when using testers and measuring instruments during a road test 1857
2 Repair notes 1858
2 1 General repair instructions 1858
3 Technical data 1861
3 1 Capacities 1861
3 2 Allocation gearbox – motor 1861
3 2 1 Allocation gearbox – engine, rear-wheel drive 1861
3 2 2 Allocation gearbox – engine, all-wheel drive 1861
30 – Clutch 1863
1 Clutch mechanism 1863
1 1 Assembly overview – clutch mechanism 1863
1 2 Assembly overview – clutch release mechanism 1865
1 3 Removing and installing over-centre spring 1866
1 4 Removing and installing mounting bracket 1866
1 5 Removing and installing clutch master cylinder 1867
1 6 Removing and installing clutch slave cylinder together with release bearing 1869
1 7 Bleeding clutch mechanism 1871
1 8 Removing and installing clutch pedal switch 1873
1 8 1 Removing and installing clutch pedal switch -F36- 1873
1 8 2 Removing and installing clutch pedal switch for stop/start system -F71- 1874
2 Clutch 1876
2 1 Assembly overview – clutch 1876
2 2 Removing and installing clutch 1876
34 – Controls, housing 1881
1 Selector mechanism 1881
1 1 Installation position – selector mechanism 1881
1 2 Assembly overview – gear knob and cover 1882
1 3 Assembly overview – Gear lever and selector housing 1883
1 4 Removing and installing selector mechanism 1884
1 5 Adjusting selector mechanism 1887
1 5 1 Adjusting selector mechanism, vehicles with white coloured selector housing top part 1887
1 5 2 Adjusting selector mechanism, vehicles with black coloured selector housing top part 1889
1 6 Checking selector mechanism 1892
1 7 Removing and installing selector lever handle 1892
1 8 Dismantling and assembling selector mechanism 1894
1 8 1 Dismantling and assembling selector mechanism, relay lever 1894
1 8 2 Dismantling and assembling selector mechanism, gearbox selector lever 1895
1 9 Renewing selector shaft seal 1897
1 10 Removing and installing reversing light switch -F4- 1898
1 11 Removing and installing gearbox neutral position sender -G701- 1899
2 Removing and installing gearbox 1901
2 1 Specified torques for gearbox 1901
2 2 Removing gearbox 1901
2 3 Installing gearbox 1910
3 Assembly mountings 1912
3 1 Assembly overview – assembly mountings 1912
4 Gear oil 1915
4 1 Checking gear oil level 1915
4 2 Draining and filling gear oil 1916
5 Gearbox housing, clutch housing 1918
5 1 Assembly overview – clutch housing 1918
5 2 Fitting and detaching clutch housing 1918
35 – Gears, shafts 1926
1 Input and output shafts 1926
1 1 Assembly overview – output shaft 1926
1 2 Renewing input shaft seal 1926
1 3 Renewing output shaft seal 1928
1 4 Removing and installing output flange 1930
D4B807DC77D Chemicals Manual 1933
00 – Technical data 1939
1 — Change history — 1939
2 Introduction 1941
3 List of Suppliers 1942
3 1 3M do Brasil 1942
3 2 Brascola Ltda 1942
3 3 Castrol Brasil Ltda 1942
3 4 Cia Brasileira de Petróleo Ipiranga 1942
3 5 Chemours 1942
3 6 Chevron Brasil S/A 1942
3 7 Cremer S A Prod Têxteis e Cirúrgicos 1942
3 8 Dow Corning do Brasil Ltda 1942
3 9 Elf Lubrificantes do Brasil 1942
3 10 ExxonMobil 1942
3 11 Henkel do Brasil Ltda 1942
3 12 Klüber Lubrification Lubrificantes Especiais Ltda 1942
3 13 Loctite Brasil Ltda 1942
3 14 Lumobrás Imp Com Ind Ltda 1942
3 15 Motul Synthetic Lubricants 1942
3 16 Ocean Indústria Química 1942
3 17 Pentosin do Brasil Ltda 1943
3 18 Petrobras Distr S/A 1943
3 19 Shell Brasil S/A 1943
3 20 Sika S/A 1943
3 21 Solplás – Ind de Plásticos Ltda 1943
3 22 Solvay Química 1943
3 23 Three Bond do Brasil Ind e Com Ltda 1943
3 24 Total Lubrificantes Brasil Ltda 1943
3 25 Tutela Lubrificantes S/A 1943
3 26 Valvoline Lubrificantes Internacionais Ltda 1943
4 Work Instructions for Handling Chemicals 1944
4 1 Handling of Solvents 1944
4 2 Work instruction – Flammable material handling 1946
4 3 Handling used engine oil 1947
4 4 General guidelines on the storage of chemicals 1948
5 List of authorized products 1949
5 1 Polyurethane-based sealing adhesive 1949
5 2 High-resistance locking adhesive 1949
5 3 Low viscosity lock adhesive 1949
5 4 Sealing adhesive 1949
5 5 Self-adhesive PVC tape 1949
5 6 Double-sided adhesive tape 1949
5 7 Refrigerant gas – R134a 1950
5 8 Underbody coating 1950
5 9 Lubricating engine oil as per VW 502 00 and VW 505 00 standards 1950
5 10 Lubricating engine oil as per VW 507 00 standard 1950
5 11 Lubricating engine oil as per VW 508 88 and VW 509 99 standards 1951
5 12 Lubricating oil for manual gearbox and steering rack – SAE 90, MIL-L-2105B, API – GL5 1951
5 13 Lubricating oil for manual gearbox – SAE 80, MIL-L-2105, API – GL4 1951
5 14 Tire assembly paste 1951
5 15 Biodegradable degreasing product 1951
5 16 Grease remover spray 1952
6 List of fractionated products 1953
6 1 -000 096 319 D- Polishing material (chromium and aluminium) 1953
6 2 -032 198 561- Additional seal 1953
6 3 -AMV 188 001 02- Adhesive silicone 1954
6 4 -AMV 188 200 03- Sealing paste 1954
6 5 -AMV 189 300- Activating agent 1955
6 6 -AMV 189 400- Sealing compound 1955
6 7 Liquid sealant -D 000 600 A2- 1955
6 8 -D 001 210 M2- Universal adhesive 1956
6 9 -D 002 000 A2-Adhesive remover 1956
6 10 -D 004 660 M2- Adhesive set 1956
6 11 -D 007 000 A2- Spray silicone 1957
6 12 -D 009 200 02- Glass primer 1957
6 13 -D 009 401 04- Cleaning solution 1958
6 14 -D 009 500 25- Applicator 1958
6 15 Liquid sealant -D 154 000 A1- 1959
6 16 Liquid sealant -D 154 100 A1- 1959
6 17 -D 154 102 A1- Sealing compound 1959
6 18 -D 154 103 A1- Adhesive silicone 1960
6 19 -D 169 300 M1- Window adhesive 1960
6 20 -D 169 300 M2- Window adhesive 1960
6 21 -D 172 090 A2- Adhesive 1961
6 22 -D 174 003 M2- Silicone sealant 1961
6 23 -D 176 404 A3- Adhesive silicone 1962
6 24 -D 176 204 R2- Adhesive silicone 1962
6 25 -D 176 404 M2- Adhesive silicone 1962
6 26 -D 176 501 A1- Adhesive silicone 1962
6 27 -D 180 KU1 A1- 2-component adhesive for plastic 1963
6 28 -D 180 KU2 A1- 2-component adhesive for plastic 1963
6 29 -D 181 220 A1- Activating agent 1964
6 30 -D 181 655 A1- Activating agent 1964
6 31 -D 181 802 M1- Glass primer 1964
6 32 Liquid sealant -D 185 400 A2- 1965
6 33 Liquid sealant -D 185 400 A3- 1965
6 34 Liquid sealant -D 185 410 A2- 1965
6 35 -D 185 520 A2- Sealing compound 1965
6 36 -D 190 MKD A3- Assembly adhesive 1966
6 37 Liquid sealant -D 192 100 A2- 1966
6 38 -D 195 850 A1- Cleaning solution 1966
6 39 -D 316 D38 A2- Protective wax 1967
6 40 -D 322 000 A2- Wachs-spray 1967
6 41 -D 322 100 M2- Wachs-spray 1967
6 42 -D 330 KD2 A1- Cavity spray 1968
6 43 -D 366 PR1 A1- Plastic primer 1968
6 44 -D 454 300 A2- Sealing compound 1968
6 45 -D 469 101 A3- Gluing and sealing compound 1969
6 46 -D 822 150 A1- Plastic surfacer 1969
6 47 -G 000 100- Coupling teeth lubricant compound 1969
6 48 -G 000 115 A2- Spray lubricant 1970
6 49 -G 000 150- Consistent lubricating paste 1970
6 50 -G 000 405 A2- Silicone paste 1970
6 51 -G 000 450 02- Lubrication paste 1971
6 52 -G 000 650- Consistent lubricating paste 1972
6 53 -G 052 109 A2- Assembly paste 1972
6 54 -G 052 112 A3- High temperature paste 1972
6 55 -G 052 128 A1- Thrust ring sealing grease 1973
6 56 -G 052 133 A2- Lubricating paste for high temperatures 1973
6 57 -G 052 135 A1- Lubricating oil 1973
6 58 -G 052 142 A2- Polyurethane lubricating compound 1974
6 59 -G 052 150 A2- Lithium lubricating paste 1974
6 60 -G 052 168 A1- Steering box lubricant 1975
6 61 -G 052 172 A1- Special lubricant 1975
6 62 -G 052 172 M2- Special lubricant 1975
6 63 -G 052 181 A4- Lubricating paste for constant velocity joints 1976
6 64 -G 052 528 A2- Lubricating paste for constant velocity joints 1976
6 65 -G 052 565 A1- Silicone paste 1976
6 66 -G 052 723 A2- Moly paste 1977
6 67 -G 052 735 A2- Multi-purpose grease 1977
6 68 -G 052 738 A2- Lubricating paste for constant velocity joints 1977
6 69 -G 052 738 A3- Thrust ring sealing grease 1978
6 70 -G 052 745 A3- Lubricating paste for low temperature 1978
6 71 -G 052 751 A1- Molybdenum pasta 1978
6 72 -G 052 778 A2- Spray lubricant 1979
6 73 -G 052 817 A1- Contact grease 1979
6 74 -G 055 128 A1- Thrust ring sealing grease 1979
6 75 -G 060 567 A2- Special lubricant 1980
6 76 -G 060 735 A2- Multi-purpose grease 1980
6 77 -G 060 751 A2- Consistent lubricating paste 1980
6 78 -G 065 567 A2- Cleaning solution 1981
6 79 -G 070 528 R2- Lubricating paste for constant velocity joints 1981
6 80 -G 294 421 A1- Lubricating oil for assembly 1981
D4B807E3B5B Body Repairs General Body Repairs 1982
1 Safety instructions 1986
1 1 Part removal 1986
1 2 Battery and welding operation 1986
1 3 Electronic control unit 1986
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 1986
1 4 Paint, glass, soft pad and trim 1987
1 5 Fuel tank or fuel delivery pipeline 1987
1 6 Air conditioner 1987
1 6 1 Remedial measures: 1987
1 7 Airbag System 1988
1 8 Check the seat belts 1988
1 8 1 Belt body 1989
1 8 2 Automatic retractor (locking function) 1989
1 8 3 Visual inspection of the seat belt buckle 1990
1 8 4 Seat belt buckle function 1990
1 8 5 Seat belt guide member and tongue 1991
1 8 6 Fixing piece and fixing point 1991
1 9 Safety specifications for the seat belt tensioner 1991
1 10 Body repair on a vehicle equipped with the seat belt tensioners 1992
1 10 1 The following vehicles have been equipped with: 1992
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 1993
1 12 Remove the front seats with a side airbag 1993
2 Basic instruction 1994
2 1 Diagnosis of the accident vehicle 1994
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 1994
2 3 Correction 1994
2 4 Cutting 1994
2 5 Body-cut part and part section 1994
2 6 Original connection 1995
2 7 Galvanized body parts 1995
2 8 Remove the rest part 1995
2 9 New parts 1995
2 10 Parts 1995
2 11 Molded foam plastic pads 1996
3 Symbolic interpretation 1997
3 1 Symbolic interpretation for welding 1997
3 2 Symbolic interpretation for the operation method 1997
3 2 1 Grinding 1998
3 2 2 Thinning 1998
3 2 3 Punching 1998
3 2 4 Drilling 1999
3 2 5 Polishing 1999
3 2 6 Cavity corrosion protection 1999
3 2 7 Bonding 2000
3 2 8 Precise sealing 2000
4 Body repair tools 2001
4 1 Flaring tool -V A G 1317- 2001
4 2 Punching pliers -V A G 1329- 2001
4 3 Basic equipment -V A G 1366/3- 2001
4 4 Bottom protection layer spray gun -V A G 1379- 2002
4 5 Electric blower -V A G 1416- 2002
4 6 Door tensioner -V A G 1438- 2002
4 7 Body equipment component -V A G 1439- 2003
4 8 Pneumatic cutting knife -V A G 1523 A- 2003
4 9 Air chisel -V A G 1577- 2003
4 10 Edge closing iron block -V A G 1585- 2004
4 11 Welding fume ventilator -V A G 1586- 2004
4 12 Welding spot releasing device -V A G 1731- 2004
4 13 Pneumatic spray gun -V A G 1761/1- 2005
4 14 Pneumatic punching and thinning pliers -VAS 1996- 2005
4 15 Pneumatic adhesive spray gun -V A G 2005- 2005
4 16 Door hinge correction tool 2006
4 17 Hose kit 5023 for the inert gas protection welding 2006
4 18 Angle grinder -VAS 5174- 2006
4 19 Angle grinder -VAS 5175- 2007
4 20 Wire brush -VAS 5182- 2007
5 Body bonding 2008
5 1 Transporter 1991 → 2008
5 1 1 Separation process: 2008
5 1 2 Bonding process: 2008
5 2 Bonding types 2008
5 2 1 Bonding-strong 2008
5 2 2 Bonding-spot welding 2009
5 3 Repair method for replacing the parts 2009
5 3 1 Spot welding and bonding 2009
5 3 2 Plug welding and bonding (if spot welding is impossible) 2009
5 3 3 Welding fume ventilator 2010
5 3 4 Preparations 2010
5 3 5 Trimming 2010
6 Corrosion protection measures 2011
6 1 Corrosion protection 2011
7 Waste disposal instructions 2012
7 1 Waste disposal 2012
7 2 Air pressure tappet exhaust 2012
7 3 Airbag 2013
7 3 1 Waste disposal 2013
8 Contact corrosion protection 2014
8 1 Connection of aluminum alloy/magnesium alloy with steel 2014
9 Steel plate repair 2015
9 1 High-strength body plate 2015
9 2 Galvanized body parts 2015
9 2 1 Preparations 2015
9 2 2 Part cutting 2016
9 2 3 Connection process 2016
9 3 Welding on the galvanized body steel plate 2016
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 2016
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 2017
9 3 3 Welding transformer 2017
9 3 4 Welding clamp 2017
9 4 Tearing test 2017
10 Aluminum repair 2018
10 1 Painting 2018
10 2 Surface treatment 2018
10 3 Leveling 2019
10 4 Temperature control for heating 2019
11 Plastic repair method 2020
11 1 Material 2020
11 2 Repairing the pit 2021
11 3 Repairing the scratch 2022
11 4 Repair the crack 2024
11 5 Repairing the small hole (the diameter is more than 30 mm) 2025
11 6 Plastic repair (glass fibre material) 2026
11 7 Repair process 2027
11 7 1 Repairing the breakage position 2027
11 7 2 Repairing the surface damage 2029
12 Glass repair 2030
12 1 Repairing the windshield 2030
12 1 1 Premises 2030
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 2031
12 1 3 Repair description 2032
D4B8026D002 6 speed manual gearbox 0C6 2036
00 – Technical data 2040
1 Safety information 2040
1 1 Safety measures when working on vehicles with a start/stop system 2040
1 2 Safety precautions when using testers and measuring instruments during a road test 2040
2 Identification 2041
2 1 Gearbox identification 2041
3 Repair notes 2042
3 1 General repair instructions 2042
3 2 Gaskets and seals 2043
3 3 Nuts and bolts 2044
4 Technical data 2045
4 1 Capacities 2045
4 2 Allocation gearbox – motor 2045
4 2 1 Allocation gearbox – engine, rear-wheel drive 2045
4 2 2 Allocation gearbox – engine, all-wheel drive 2046
30 – Clutch 2048
1 Clutch mechanism 2048
1 1 Assembly overview – clutch mechanism 2048
1 2 Assembly overview – clutch release mechanism 2050
1 3 Removing and installing over-centre spring 2051
1 4 Removing and installing mounting bracket 2051
1 5 Removing and installing clutch master cylinder 2053
1 6 Bleeding clutch mechanism 2055
1 7 Removing and installing clutch pedal switch 2056
1 7 1 Removing and installing clutch pedal switch -F36- 2056
1 7 2 Removing and installing clutch pedal switch for stop/start system -F71- 2058
2 Clutch 2060
2 1 Assembly overview – clutch 2060
2 2 Removing and installing clutch 2063
34 – Controls, housing 2066
1 Selector mechanism 2066
1 1 Installation position – selector mechanism 2066
1 2 Assembly overview – gear knob and cover 2067
1 3 Assembly overview – Gear lever and selector housing 2067
1 4 Removing and installing selector mechanism 2068
1 5 Adjusting selector mechanism 2071
1 6 Checking selector mechanism 2075
1 7 Removing and installing selector lever handle 2075
1 8 Dismantling and assembling selector mechanism 2076
2 Removing and installing gearbox 2080
2 1 Specified torques for gearbox 2080
2 2 Removing gearbox 2080
2 3 Installing gearbox 2088
3 Assembly mountings 2090
3 1 Assembly overview – assembly mountings 2090
3 1 1 Assembly overview – assembly mountings, version A 2090
3 1 2 Assembly overview – assembly mountings, version B 2092
3 2 Removing and installing gearbox mounting 2094
4 Transporting gearbox 2097
4 1 Gearbox transport 2097
5 Dismantling and assembling gearbox 2098
5 1 Schematic overview – gearbox 2098
5 2 Assembly overview – clutch housing and input shaft 2098
5 3 Assembly overview – gearbox housing, layshaft, output shaft and selector unit 2099
5 4 Assembly overview – selector unit 2101
5 5 Assembly overview – selector forks 2104
5 6 Removing and installing propshaft flange 2104
5 7 Removing and installing adapter shaft 2106
5 8 Dismantling and assembling gearbox 2109
6 Gearbox housing, clutch housing 2127
6 1 Assembly overview – gearbox housing 2127
6 1 1 Assembly overview – gearbox housing, gearboxes manufactured up to 06 2012 2127
6 1 2 Assembly overview – gearbox housing, gearboxes manufactured as of 06 2012 2129
6 2 Assembly overview – clutch housing 2130
6 3 Repairing gearbox housing 2131
6 4 Repairing clutch housing 2135
7 Gear oil 2140
7 1 Checking gear oil level 2140
7 2 Draining and filling gear oil 2141
35 – Gears, shafts 2142
1 Input and output shafts 2142
1 1 Assembly overview – input shaft and output shaft 2142
1 2 Dismantling and assembling output shaft 2145
1 3 Renewing input shaft seal 2160
1 4 Renewing output shaft seal 2162
2 Layshaft 2166
2 1 Assembly overview – layshaft 2166
2 2 Dismantling and assembling layshaft 2168
3 Reverse shaft 2178
3 1 Assembly overview – reverse shaft 2178
3 2 Removing and installing reverse shaft 2179
D4B8026F790 General body repairs exterior 2180
50 – Body – front 2188
1 Lock carrier 2188
1 1 Assembly overview – lock carrier 2188
1 1 1 Assembly overview – lock carrier, to week 49/2014 2188
1 1 2 Assembly overview – lock carrier, vehicles as of week 50/2014 2189
1 2 Removing and installing lock carrier 2191
1 2 1 Removing and installing lock carrier 2191
1 2 2 Removing and installing lock carrier support 2192
1 2 3 Removing and installing air duct system, to week 26/2014 2193
1 2 4 Removing and installing air duct system, as of week 27/2014 2194
2 Wing 2196
2 1 Assembly overview – wing 2196
2 2 Removing and installing wing 2197
2 2 1 Removing and installing wing PR number “0FX” 2197
2 2 2 Removing and installing wing PR number “0FA” 2199
3 Bulkhead 2202
3 1 Assembly overview – plenum chamber cover 2202
3 2 Removing and installing plenum chamber cover 2202
51 – Body – centre 2205
1 Removing and installing ladder frame 2205
1 1 General notes; Body repairs, General body repairs 2205
1 2 Assembly overview – ladder frame 2205
1 3 Installing holder for ABS hydraulic unit -N55- with ABS control unit -J104- 2207
1 4 Removing and installing rear cross member 2209
1 5 Installing spare wheel bracket 2210
1 6 Installing brake lines 2211
1 7 Installing fuel lines 2212
55 – Bonnet, rear lid 2215
1 Bonnet 2215
1 1 Assembly overview – bonnet 2215
1 2 Assembly overview – Bowden cable 2216
1 3 Removing and installing bonnet 2217
1 4 Adjusting bonnet 2219
1 5 Removing and installing bonnet lock 2222
1 5 1 Removing and installing bonnet lock, to model year 2016 2222
1 5 2 Removing and installing bonnet lock, from model year 2017 2223
1 6 Removing and installing bonnet lock release lever 2224
1 7 Removing and installing striker pin 2224
1 8 Removing and installing hinges 2225
1 9 Removing and installing insulation 2227
1 10 Removing and installing Bowden cable 2228
1 11 Removing and installing bonnet stay 2230
2 Rear lid 2231
2 1 Assembly overview – rear lid 2231
2 1 1 Assembly overview – rear lid, attachments 2231
2 1 2 Assembly overview – tailgate retaining bracket 2232
2 1 3 Assembly overview – tailgate with torsion bar 2233
2 1 4 Assembly overview – tailgate hinge 2234
2 1 5 Assembly overview – tailgate lock 2235
2 1 6 Assembly overview – tailgate handle 2236
2 1 7 Assembly overview – tailgate handle with lock cylinder 2237
2 1 8 Assembly overview – tailgate arrester cable up to 2010 2238
2 1 9 Assembly overview – tailgate arrester cable as of 2011 2239
2 1 10 Assembly overview – tailgate spacer 2240
2 1 11 Assembly overview – tailgate seals 2241
2 2 Removing and installing rear lid 2242
2 3 Adjusting rear lid 2242
2 4 Removing and installing hinge 2243
2 5 Removing and installing tailgate lock 2245
2 6 Removing and installing tailgate handle 2246
2 6 1 Removing and installing tailgate handle 2246
2 6 2 Removing and installing tailgate handle with lock cylinder 2247
2 6 3 Dismantling exterior handle 2249
2 7 Removing and installing striker plate 2250
2 7 1 Removing and installing striker plate, to model year 2010 2250
2 7 2 Removing and installing striker plate from model year 2011 2250
2 7 3 Removing and installing anchor 2251
2 8 Removing and installing torsion bar 2253
3 Load bed 2254
3 1 Assembly overview – load area 2254
3 1 1 Assembly overview of load area 2254
3 1 2 Assembly overview – load area, add-on parts 2255
3 1 3 Assembly overview – load area, double cab fastening rings 2255
3 1 4 Assembly overview – load area, single cab fastening rings 2256
3 2 Removing and installing load bed 2257
3 2 1 Removing and installing load bed 2257
3 2 2 Removing and installing load bed, stop – cross member 2259
4 Cab 2260
4 1 Assembly overview – cab 2260
4 1 1 Assembly overview – cab (Double Cab) 2260
4 1 2 Assembly overview – cab (Single Cab) 2261
4 2 Assembly overview – front mountings, cab 2261
4 3 Assembly overview – centre mountings, cab 2262
4 4 Assembly overview – rear mountings, cab 2263
4 4 1 Assembly overview – rear mountings, cab (Double Cab) 2263
4 4 2 Assembly overview – rear mountings, cab (Single Cab) 2264
4 5 Assembly overview – retaining strap, cab 2265
4 6 Removing and installing cab 2266
4 7 Removing and installing tether cab 2268
4 8 Removing and installing pressure hoses and hose connections with screw-type clamps 2269
4 8 1 Hose connections with push-on couplings 2269
4 8 2 Pressure hose with corrugated pipe connection and hose clip 2271
4 8 3 Notes on hose connections with screw-type clips 2272
5 Tank flap unit 2274
5 1 Assembly overview – tank flap unit 2274
5 2 Removing and installing fuel tank flap 2274
5 3 Removing and installing tank flap unit 2275
5 3 1 Removing and installing tank flap unit 2275
5 3 2 Removing and installing tank flap unit with SCR neck 2277
5 3 3 Removing and installing actuator 2277
57 – Front doors, door components, central locking 2279
1 Door 2279
1 1 Assembly overview – door 2279
1 1 1 Assembly overview – door hinge on A-pillar 2279
1 1 2 Assembly overview – door hinge on door 2280
1 2 Removing and installing inner door seal 2281
1 3 Removing and installing outer door seal 2283
1 3 1 Removing and installing top primary seal 2283
1 3 2 Removing and installing bottom primary seal 2284
1 4 Removing and installing door 2285
1 4 1 Removing and installing door 2285
1 4 2 Renewing front door 2287
1 5 Adjusting striker pin 2288
1 6 Removing and installing door hinge 2289
1 6 1 Removing and installing door hinge on A-pillar 2289
1 6 2 Removing and installing door hinge on door 2291
1 7 Removing and installing door arrester 2291
2 Door components 2294
2 1 Assembly overview – door components 2294
2 1 1 Assembly overview – door components 2294
2 1 2 Assembly overview – door components, Bowden cable 2296
2 1 3 Assembly overview – door components, door lock cover 2296
2 1 4 Assembly overview – door components, cap 2297
2 2 Assembly overview – window regulator 2298
2 2 1 Assembly overview – window regulator 2298
2 2 2 Assembly overview – window regulator, motor 2299
2 3 Removing and installing window regulator motor 2300
2 4 Removing and installing window regulator 2302
2 5 Removing and installing window crank 2303
2 6 Removing and installing door handle 2304
2 7 Removing and installing door lock 2304
2 8 Removing and installing window channel 2307
2 9 Removing and installing lock cylinder 2308
2 10 Removing and installing housing (without lock cylinder) 2309
2 11 Removing and installing interior door handle 2311
2 12 Removing and installing mounting bracket 2313
2 13 Removing and installing striker pin 2314
2 14 Removing and installing outer window slot seal 2314
2 15 Removing and installing window slot inner seal 2316
2 16 Assembly overview – front door impact bar 2319
3 Central locking 2320
3 1 Assembly overview – ignition key 2320
3 2 Removing and installing ignition key battery 2320
58 – Rear doors, door components 2323
1 Door 2323
1 1 Assembly overview – door 2323
1 1 1 Assembly overview – door hinges on B-pillar 2323
1 1 2 Assembly overview – door hinge on door 2324
1 2 Removing and installing door 2325
1 3 Adjusting striker pin 2327
1 4 Removing and installing door hinge 2328
1 4 1 Removing and installing door hinge on B-pillar 2328
1 4 2 Removing and installing door hinge on door 2329
1 5 Removing and installing door arrester 2330
1 6 Removing and installing inner door seal 2331
1 7 Removing and installing outer door seal 2332
2 Door components 2334
2 1 Assembly overview – door components 2334
2 1 1 Assembly overview – door components 2334
2 1 2 Assembly overview – door components, Bowden cable 2335
2 1 3 Assembly overview – door components, door lock cover 2336
2 1 4 Assembly overview – door components, cap 2337
2 2 Assembly overview – window regulator 2338
2 2 1 Assembly overview – window regulator 2338
2 2 2 Assembly overview – window regulator, window regulator motor 2339
2 3 Removing and installing window regulator motor 2340
2 4 Removing and installing window regulator 2342
2 5 Removing and installing window crank 2343
2 6 Removing and installing door handle 2344
2 7 Removing and installing door lock 2344
2 8 Removing and installing housing (without lock cylinder) 2346
2 9 Removing and installing interior door handle 2348
2 10 Removing and installing mounting bracket 2350
2 11 Removing and installing striker pin 2351
2 12 Removing and installing window channel 2351
2 13 Removing and installing window slot inner seal 2353
60 – Sunroof 2355
1 Sliding/tilting sunroof 2355
61 – Convertible roof, hardtop, canopy 2356
1 Hardtop 2356
1 1 Assembly overview – hardtop 2356
1 1 1 Assembly overview – hardtop, aluminium rail 2356
1 1 2 Assembly overview – hardtop, seals 2357
1 1 3 Assembly overview – hardtop, protective film 2358
1 2 Removing and installing hardtop 2359
1 2 1 Removing and installing hardtop 2359
1 2 2 Preassembly of aluminium rail 2367
2 Lid for hardtop 2369
2 1 Assembly overview – hardtop lid 2369
2 2 Assembly overview – hinge 2370
2 3 Assembly overview – rotary latch lock 2371
2 4 Assembly overview – handle with lock cylinder 2372
2 5 Assembly overview – gas strut bracket 2373
2 6 Assembly overview – striker for lid 2374
2 7 Removing and installing hardtop lid 2375
2 8 Removing and installing hardtop lid hinge 2377
2 9 Removing and installing rotary latch lock 2378
2 10 Removing and installing handle with lock cylinder 2378
2 11 Removing and installing gas strut bracket 2380
2 12 Removing and installing hardtop lid striker 2381
2 13 Removing gas strut 2382
2 14 Releasing gas from gas strut 2383
2 15 Removing and installing lock cover 2383
2 16 Removing and installing high-level brake light 2384
2 17 Removing and installing hardtop lid seal 2386
3 Glazing 2388
3 1 Assembly overview – glazing 2388
3 2 Assembly overview – rear window 2388
3 3 Removing and installing rear window 2389
3 4 Removing and installing sliding window 2395
3 5 Removing and installing front sliding window 2396
4 Trims, foam components 2399
4 1 Removing and installing top panel 2399
4 2 Removing and installing right D-pillar trim 2400
4 3 Removing and installing left D-pillar trim 2402
4 4 Removing and installing hardtop middle trim 2405
4 5 Removing and installing front trim 2410
4 6 Removing and installing edge protector 2412
4 7 Removing and installing rear seal 2412
63 – Bumpers 2414
1 Bumper, front 2414
1 1 Assembly overview – bumper cover 2414
1 1 1 Assembly overview – bumper cover to model year 2016 2414
1 1 2 Assembly overview – bumper cover from model year 2017 2415
1 2 Assembly overview – bumper carrier 2416
1 3 Assembly overview – attachments 2417
1 3 1 Assembly overview – add-on parts PR number “0FA” to model year 2016 2417
1 3 2 Assembly overview – add-on parts PR number “0FX” to model year 2016 2419
1 3 3 Assembly overview – add-on parts from model year 2017 2420
1 3 4 Assembly overview – wheel arch trim, bumper cover 2420
1 3 5 Assembly overview – parking aid retainer 2421
1 4 Removing and installing bumper cover 2422
1 4 1 Removing and installing bumper cover, to model year 2016 2422
1 4 2 Removing and installing bumper cover from model year 2017 2425
1 5 Removing and installing bumper carrier 2426
1 5 1 Removing and installing locking element, to week 49/2014 2426
1 5 2 Removing and installing locking element, as of week 50/2014 2426
1 5 3 Removing and installing foam reinforcement 2427
1 6 Removing and installing attachments 2428
1 6 1 Removing and installing wheel arch trim on bumper cover 2428
1 6 2 Removing and installing bumper cover support, to week 46/2017 2430
1 6 3 Removing and installing bumper cover support, as of week 47/2017 2430
1 7 Repairing bumper cover 2432
1 7 1 Repairing bumper cover 2432
1 7 2 Installing brackets for parking aid system 2432
2 Bumper, rear 2436
2 1 Assembly overview – bumper cover 2436
2 2 Removing and installing bumper carrier 2438
2 3 Removing and installing bumper cover 2439
2 4 Removing and installing closure plate 2440
2 5 Removing and installing step 2441
2 5 1 Removing and installing lower step 2441
2 5 2 Removing and installing upper step 2441
2 6 Repairing bumper cover 2443
64 – Glazing 2444
1 Repair instructions 2444
1 1 Minimum drying times for bonded windows 2444
1 2 Window repair 2444
1 3 Installation instructions for bonded windows 2445
1 3 1 Installation instructions for bonded windows 2445
1 3 2 Materials 2446
1 4 Preparing old undamaged windows for installing 2447
1 5 Preparing new windows for installing 2447
1 6 Preparing body flange for installing 2448
1 7 Cleaning off excess adhesive 2450
2 Windscreen 2451
2 1 Assembly overview – windscreen 2451
2 2 Removing and installing windscreen 2451
3 Rear windscreen 2457
3 1 Assembly overview – rear window 2457
3 2 Removing and installing rear window 2457
4 Door windows 2464
4 1 Assembly overview – front door window 2464
4 2 Assembly overview – rear door window 2464
4 3 Removing and installing front door window 2465
4 4 Removing and installing guide rail 2467
4 5 Removing and installing rear door window 2468
4 6 Removing and installing fixed door-window 2470
66 – Exterior equipment 2475
1 Radiator grille and front trim 2475
1 1 Assembly overview – radiator grille 2475
1 2 Removing and installing radiator grille 2476
2 Mouldings, trims, extensions 2479
2 1 Assembly overview – heat shield 2479
2 2 Removing and installing underbody heat shield 2480
2 2 1 Removing and installing underbody heat shield to model year 2016 2480
2 2 2 Removing and installing underbody heat shield from model year 2017 2482
3 Noise insulation 2484
3 1 Assembly overview – power unit skid plate 2484
3 1 1 Assembly overview – power unit skid plate PR number “0FA” 2484
3 1 2 Assembly overview – power unit skid plate PR number “0FX” 2484
3 2 Removing and installing power unit skid plate 2485
3 2 1 Removing and installing power unit skid plate PR number “0FA” 2485
3 2 2 Removing and installing power unit skid plate PR number “0FX” 2487
4 Trim film and protective film 2489
4 1 Renewing protective films 2489
4 1 1 Fitting instructions 2489
4 1 2 Overview of fitting locations – decorative film 2490
4 1 3 Assembly overview – anti-abrasion film, tailgate and load bed D-pillar 2490
4 1 4 Renewing decorative film for door window frame 2491
4 1 5 Renewing decorative film for doors 2493
4 1 6 Renewing decorative film for wheel arches 2494
4 1 7 Renewing door inner film for front door 2495
4 1 8 Renewing door inner film for rear door 2496
4 1 9 Renewing scuff-protection film 2498
4 1 10 Renewing B-pillar protective film 2499
4 1 11 Renewing adjusting buffer film 2500
5 Roof moulding and roof railing 2501
5 1 Renewing roof strip 2501
6 Exterior mirror 2503
6 1 Assembly overview – exterior mirror 2503
6 2 Removing and installing mirror glass 2504
6 3 Removing and installing mirror frame 2506
6 4 Removing and installing mirror cover 2507
6 5 Removing and installing exterior mirror 2509
6 5 1 Removing and installing exterior mirror 2509
6 5 2 Renewing exterior mirror 2510
7 Wheel housing liner 2512
7 1 Assembly overview – front wheel housing liner 2512
7 2 Assembly overview – rear wheel housing liner 2513
7 2 1 Assembly overview – rear wheel housing liner 2513
7 2 2 Assembly overview – fasteners for rear wheel housing liner 2514
7 3 Removing and installing front wheel housing liner 2515
7 4 Removing and installing rear wheel housing liner 2516
8 Lettering and badges 2518
8 1 Assembly overview – lettering and badges 2518
8 2 Removing and installing lettering 2518
8 3 Dimensions – lettering and badges on rear 2520
8 3 1 Rear lid lettering 2520
8 3 2 Tailgate lettering, 4 MOTION 2521
8 3 3 Rear lid lettering “AUTOMATIC” 2521
8 3 4 Rear lid lettering “CANYON” 2522
8 3 5 Rear lid lettering “V6 TDI” 2523
8 4 Dimensions – lettering and badges on sides 2524
8 4 1 Renewing design badge on sports bar 2524
8 4 2 Renewing 4 Motion lettering on cargo box 2524
8 5 Removing and installing lettering and badges for radiator grille 2525
8 5 1 Removing and installing badge for radiator grille to model year 2016 2525
8 5 2 Removing and installing badge for radiator grille from model year 2017 2526
8 5 3 Removing and installing “V6” lettering 2527
8 6 Renewing lettering and badges at rear 2527
9 Special add-on parts 2529
9 1 Assembly overview – special add-on parts 2529
9 1 1 Assembly overview – special add-on parts, “CANYON” 2529
9 1 2 Assembly overview – special add-on parts, “sportsbar” 2530
9 1 3 Assembly overview – special attachments “sportsbar with luggage compartment cover” 2531
9 2 Assembly overview – side bar 2533
9 3 Assembly overview – design double roll bar 2534
9 3 1 Assembly overview – design double roll bar without luggage compartment cover 2534
9 3 2 Assembly overview – design double roll bar with luggage compartment cover 2535
9 4 Assembly overview – carrier for additional driving lights 2536
9 5 Assembly overview – rear step 2537
9 6 Removing and installing carrier for additional main beam headlights 2538
9 7 Roller cover for luggage compartment 2540
9 7 1 Fitting instructions 2540
9 7 2 Assembly overview – roller cover for luggage compartment 2541
9 7 3 Assembly overview – luggage compartment cover attachments 2542
9 7 4 Assembly overview – water drain hoses at front and rear, version 1 2544
9 7 5 Assembly overview – water drain hoses at front and rear, version 2 2545
9 7 6 Assembly overview – luggage compartment cover protective films 2546
9 7 7 Assembly overview – roller cover bracket for luggage compartment 2547
9 7 8 Removing and installing luggage compartment roller cover 2548
9 7 9 Removing and installing guide rail for luggage compartment roller cover 2557
9 7 10 Removing and installing louvre of luggage compartment cover 2559
9 7 11 Removing and installing seal of guide rail for luggage compartment roller cover 2560
9 7 12 Removing and installing seals of end louvre for luggage compartment cover 2562
9 8 Removing and installing sports bar 2565
9 8 1 Removing and installing sports bar 2565
9 8 2 Removing and installing sportsbar with luggage compartment cover 2566
9 9 Removing and installing design double roll bar for luggage compartment cover 2570
10 Wheel arch cover 2574
10 1 Repair instructions 2574
10 1 1 Safety requirements 2574
10 1 2 Installation instructions for wheel arch trims 2574
10 1 3 Preparing new add-on part for bonding 2575
10 1 4 Preparing body component for bonding 2575
10 1 5 Installation instructions for wheel arch trims 2576
10 1 6 Minimum curing period 2577
10 1 7 Touching up paint damage 2577
10 1 8 Removing soiling caused by adhesive sealant 2577
10 1 9 Cleaning guidelines 2578
10 2 Removing and installing front wheel arch trim 2578
10 2 1 Removing and installing wheel arch trim – wing, PR number “0FA” 2578
10 2 2 Removing and installing wheel arch trim – wing, PR number “0FX” 2582
10 3 Removing and installing rear wheel cover 2586
10 3 1 Removing and installing wheel arch cover – left load bed, PR number “0FA” 2586
10 3 2 Removing and installing wheel arch cover – left load bed, PR number “0FX” 2590
10 3 3 Removing and installing wheel arch cover – right load bed, PR number “0FA” 2594
10 3 4 Removing and installing wheel arch cover – right load bed, PR number “0FX” 2598
11 Buffer – cross panel 2601
11 1 Assembly overview – buffer – rear cross panel 2601
12 Towing bracket 2602
12 1 Assembly overview – towing bracket 2602
12 2 Removing and installing towing bracket 2603
13 Spare wheel bracket 2605
13 1 Removing and installing spare wheel tether 2605
13 2 Assembly overview – spare wheel bracket 2607
13 2 1 Assembly overview – spare wheel winch to model year 2016 2607
13 2 2 Assembly overview – spare wheel winch from model year 2017 2608
14 Mudflap 2610
14 1 Assembly overview – mudflap 2610
14 1 1 Assembly overview – front mudflap, without wheel arch trim 2610
14 1 2 Assembly overview – front mudflap, with wheel arch trim 2611
14 1 3 Assembly overview – rear mudflap, without wheel arch trim 2612
14 1 4 Assembly overview – rear mudflap, with wheel arch trim 2613
14 1 5 Assembly overview – rear mudflap bracket 2614
14 2 Removing and installing mudflap 2615
14 2 1 Removing and installing front mud flaps, without wheel arch trim 2615
14 2 2 Removing and installing front mud flaps, with wheel arch trim 2616
14 2 3 Removing and installing rear mud flaps, without wheel arch trim 2617
14 2 4 Removing and installing rear mud flaps, with wheel arch trim 2619
D4B8038DA8A Wheels and Tyres Guide 2621
44 – Wheels, tyres, vehicle geometry 2625
1 General notes on using the “Wheels and Tyres Guide” 2625
1 1 General information 2625
1 2 Wheel housing extension 2626
1 3 General information 2626
1 4 Definition of tyre package 2626
1 5 Procedure for determining the required tyre package 2627
1 5 1 Determining the required tyre package via PR number 2627
1 5 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 2627
2 Notes on the vehicle registration certificate 2629
2 1 Vehicle registration certificate part 1 2629
2 2 Version key (D2) 2630
2 2 1 Version key (D2) type approval no : e1*2007/46*0356*13 2630
2 2 2 Version key (D2) type approval no : e1*2007/46*0356*14 2630
2 2 3 Version key (D2) type approval No : e1*2007/46*0356*15 to e1*2007/46*0356*17 2631
2 2 4 Version key (D2) type approval number: e1*2007/46*0356*18 and e1*2007/46*0356*19 2631
3 Wheel and tyre combinations without tyre package 2633
3 1 Vehicles without wheel house extension 2633
3 2 Vehicles with wheel housing extension 2636
4 Wheel and tyre combinations depending on tyre packages 2644
4 1 Type approval number (K): e1*2007/46*0356*13 2644
4 2 Type approval number (K): e1*2007/46*0356*14 2645
4 3 Type approval number (K): e1*2007/46*0356*15 2646
4 4 Type approval number (K): e1*2007/46*0356*16 2648
4 5 Type approval number (K): e1*2007/46*0356*17 2649
5 Wheel and tyre combinations according to WLTP 2652
5 1 Type approval number (K): e1*2007/46*0356*18 and e1*2007/46*0356*19 2652
6 Wheel allocation 2653
6 1 Wheel allocation for vehicles without wheel housing extension 2653
6 1 1 61/2 J x 16 offset 52 2653
6 1 2 61/2 J x 16 offset 62 2654
6 2 Wheel allocation for vehicles with wheel housing extension 2655
6 2 1 61/2 J x 16 2655
6 2 2 8 J x 17 2656
6 2 3 71/2 J x 18 2659
6 2 4 8 J x 19 2660
6 2 5 8 J x 20 2662
7 Recommended summer tyres 2664
8 Recommended winter tyres 2665
9 Recommended temporary spare tyres and wheels 2666
D4B8067A9CA 6 cylinder diesel engine (3 0 l engine common rail) 2667
00 – Technical data 2675
1 Safety information 2675
1 1 Safety regulations for working on fuel supply 2675
1 2 Safety measures when working on vehicles with start/stop system 2675
1 3 Safety precautions when using testers and measuring instruments during a road test 2676
1 4 Safety precautions when working on the cooling system 2676
1 5 Safety precautions when working on ignition system 2676
1 6 Safety precautions when working on exhaust system 2677
2 Identification 2678
2 1 Engine number/engine data 2678
3 Repair notes 2679
3 1 Rules for cleanliness 2679
3 2 General information 2679
3 3 General repair instructions 2680
3 4 Foreign bodies in engine 2680
3 5 Contact corrosion 2680
3 6 Nuts and bolts 2681
3 7 Routing and attachment of lines 2681
3 8 Fitting radiators and condensers 2681
3 9 Checking vacuum system 2681
10 – Removing and installing engine 2683
1 Removing and installing engine 2683
1 1 Removing engine 2683
1 2 Securing engine on engine and gearbox support 2694
1 3 Installing engine 2697
2 Assembly mountings 2702
2 1 Assembly overview – assembly mountings 2702
2 2 Removing and installing engine mounting 2704
2 2 1 Removing and installing right engine mounting 2704
2 2 2 Removing and installing left engine mounting 2707
2 3 Removing and installing gearbox mounting 2711
2 4 Supporting engine in installation position 2713
2 4 1 Supporting engine in installation position, vehicles without pedestrian protection 2713
2 4 2 Supporting engine in installation position, vehicles with pedestrian protection 2714
3 Engine cover panel 2717
3 1 Removing and installing engine cover 2717
13 – Crankshaft group 2718
1 Cylinder block (pulley end) 2718
1 1 Assembly overview – cylinder block (pulley end) 2718
1 2 Assembly overview – sealing flange, belt pulley end 2721
1 3 Removing and installing poly-V belt 2723
1 4 Removing and installing tensioner for poly V-belt 2725
1 5 Removing and installing vibration damper 2726
1 6 Removing and installing bracket for ancillaries 2728
1 6 1 Removing and installing air conditioner compressor bracket 2728
1 6 2 Removing and installing bracket for alternator 2730
1 7 Removing and installing engine support 2731
1 7 1 Removing and installing right engine support 2731
1 7 2 Removing and installing left engine support 2731
1 7 3 Removing and installing adapter for left engine support 2731
1 8 Renewing crankshaft oil seal for pulley end 2732
1 9 Removing and installing sealing flange on pulley end 2733
2 Cylinder block, gearbox end 2738
2 1 Assembly overview – drive plate 2738
2 2 Assembly overview – flywheel 2738
2 3 Removing and installing drive plate 2739
2 4 Removing and installing flywheel 2741
2 5 Renewing crankshaft oil seal (gearbox end) 2743
3 Crankshaft 2747
3 1 Assembly overview – crankshaft 2747
3 2 Crankshaft dimensions 2749
3 3 Allocation of main bearing shells 2749
3 4 Measuring axial clearance of crankshaft 2751
3 5 Measuring radial clearance of crankshaft 2752
3 6 Removing and installing sender wheel 2752
3 6 1 Removing and installing sender wheel 2752
3 6 2 Checking sender wheel 2753
4 Balancer shaft 2755
4 1 Assembly overview – balance shaft 2755
4 2 Removing and installing balance shaft 2755
5 Pistons and conrods 2763
5 1 Assembly overview – pistons and conrods 2763
5 2 Removing and installing pistons 2766
5 3 Measuring piston projection at TDC 2767
5 4 Checking pistons and cylinder bores 2769
5 5 Checking radial clearance of conrods 2771
15 – Cylinder head, valve gear 2772
1 Cylinder head 2772
1 1 Assembly overview – cylinder head 2772
1 2 Assembly overview – cylinder head cover 2775
1 3 Removing and installing cylinder head 2778
1 3 1 Removing cylinder head, bank 1 (right side) 2778
1 3 2 Removing cylinder head, bank 2 (left side) 2783
1 4 Removing and installing cylinder head cover 2788
1 4 1 Removing and installing cylinder head cover, bank 1 (right side) 2788
1 4 2 Removing and installing cylinder head cover, bank 2 (left side) 2791
1 5 Removing and installing injector seals 2794
1 6 Checking compression 2795
2 Cover for timing chain 2797
2 1 Assembly overview – cover for timing chain 2797
2 2 Removing and installing timing chain cover 2801
2 2 1 Removing and installing timing chain cover (left) 2801
2 2 2 Removing and installing timing chain cover (right) 2804
2 2 3 Removing and installing timing chain cover (bottom) 2808
3 Chain drive 2812
3 1 Assembly overview – camshaft timing chains 2812
3 2 Assembly overview – drive chain for high pressure pump 2814
3 3 Assembly overview – drive chain for oil pump 2815
3 4 Assembly overview – intermediate drive 2816
3 5 Removing camshaft timing chain from camshafts 2817
3 6 Removing and installing camshaft timing chain 2829
3 7 Removing and installing drive chain for high-pressure pump 2840
3 8 Installing intermediate drive 2842
3 8 1 Installing right intermediate drive, cylinder bank 1 and adjusting the backlash 2842
3 8 2 Installing left intermediate drive, cylinder bank 2 and adjusting the backlash 2845
4 Valve gear 2849
4 1 Assembly overview – valve gear 2849
4 2 Measuring axial play of camshaft 2855
4 3 Measuring radial play of camshaft 2857
4 4 Removing and installing camshaft 2858
4 4 1 Removing and installing camshaft 2858
4 4 2 Renewing camshaft 2865
4 5 Checking hydraulic compensation elements 2868
4 6 Removing and installing valve stem oil seals 2870
4 6 1 Removing and installing valve stem seals (cylinder head installed) 2870
4 6 2 Removing and installing valve stem seals (cylinder head removed) 2875
5 Inlet and exhaust valves 2880
5 1 Reworking valve seats 2880
5 2 Checking valve guides 2880
5 3 Checking valves 2881
5 4 Valve dimensions 2882
17 – Lubrication 2883
1 Sump, oil pump 2883
1 1 Assembly overview – sump/oil pump 2883
1 2 Engine oil: 2887
1 3 Removing and installing oil level and oil temperature sender -G266- 2887
1 4 Removing and installing lower part of sump 2888
1 5 Removing and installing upper part of sump 2893
1 6 Removing and installing oil pump 2897
1 7 Removing and installing dipstick tube 2900
2 Engine oil cooler 2902
2 1 Assembly overview – engine oil cooler 2902
2 2 Assembly overview – engine oil cooler temperature regulator 2903
2 3 Removing and installing engine oil cooler 2904
2 4 Removing and installing temperature regulator for engine oil cooler 2905
3 Oil filter, oil pressure switch 2907
3 1 Assembly overview – oil filter housing, oil pressure switch 2907
3 2 Removing and installing oil pressure sender -G10- 2909
3 3 Checking oil pressure 2910
3 4 Removing and installing oil filter housing 2910
3 5 Removing and installing oil pressure regulating valve -N428- 2912
3 6 Removing and installing oil temperature sender 2 -G664- 2913
19 – Cooling 2915
1 Cooling system/coolant 2915
1 1 Connection diagram – coolant hoses 2915
1 1 1 Coolant hose schematic diagram, left-hand drive vehicle 2915
1 1 2 Coolant hose schematic diagram, right-hand drive vehicle 2917
1 1 3 Connection diagram – coolant hoses, vehicles with supplementary heater, left-hand drive vehicle 2919
1 1 4 Connection diagram – coolant hoses, vehicles with supplementary heater, right-hand drive vehicle 2921
1 1 5 Connection diagram – coolant hoses, vehicles with auxiliary coolant heater, left-hand drive vehicle 2923
1 1 6 Connection diagram – coolant hoses, vehicles with auxiliary coolant heater, right-hand drive vehicle 2925
1 2 Checking cooling system for leaks 2927
1 3 Draining and adding coolant 2930
1 3 1 Draining and adding coolant 2930
1 3 2 Charging the cooling system in the case of emergency 2937
2 Coolant pump, regulation of cooling system 2940
2 1 Assembly overview – coolant pump 2940
2 2 Assembly overview – thermostat 2941
2 3 Assembly overview – coolant temperature sender 2942
2 4 Assembly overview – coolant valve 2943
2 5 Removing and installing coolant pump 2944
2 6 Removing and installing map-controlled engine cooling thermostat -F265- 2946
2 6 1 Removing and installing map-controlled engine cooling thermostat -F265- 2946
2 6 2 Removing and installing thermostat housing for map-controlled engine cooling thermostat -F265- 2947
2 7 Removing and installing coolant temperature sender -G62- 2948
2 8 Removing and installing coolant temperature sender 2 -G802- 2950
2 9 Removing and installing coolant temperature sender 3 -G812- 2951
2 10 Removing and installing coolant valve 2953
3 Coolant pipes 2955
3 1 Assembly overview – coolant pipes 2955
3 2 Removing and installing coolant pipes 2956
3 2 1 Removing and installing upper coolant pipe 2956
3 2 2 Removing and installing front coolant pipe 2957
3 2 3 Removing and installing upper coolant pipe for turbocharger 2958
3 2 4 Removing and installing rear coolant pipe for turbocharger 2960
3 2 5 Removing and installing right coolant pipe 2962
3 2 6 Removing and installing front coolant pipe on radiator cowl 2965
4 Radiator, radiator fan 2967
4 1 Assembly overview – radiator / radiator fan 2967
4 2 Assembly overview – radiator cowl and radiator fan 2969
4 3 Removing and installing radiator 2969
4 4 Removing and installing radiator cowl with radiator fan 2973
4 5 Removing and installing radiator fan -V7- 2975
21 – Turbocharging/supercharging 2977
1 Turbocharger 2977
1 1 Assembly overview – turbocharger 2977
1 2 Removing and installing turbocharger 2981
2 Charge air system 2989
2 1 Assembly overview – charge air system 2989
2 2 Removing and installing charge air cooler 2990
2 3 Removing and installing charge pressure sender -G31- 2992
2 4 Removing and installing intake air temperature sender -G42- 2992
2 5 Checking charge air system for leaks 2993
23 – Mixture preparation – injection 2997
1 Injection system 2997
1 1 Filling/bleeding fuel system 2997
1 2 Checking fuel system for leaks 2997
2 Vacuum system 2999
2 1 Connection diagram – vacuum system 2999
2 2 Checking vacuum system 2999
3 Injectors/high-pressure accumulator (rail) 3001
3 1 Assembly overview – injectors 3001
3 2 Assembly overview – fuel rail 3002
3 3 Adapting correction values for injectors 3006
3 4 Testing injectors 3007
3 5 Checking open injectors 3007
3 6 Checking return flow rate of injectors with engine running 3011
3 7 Checking return flow rate of injectors at starter speed 3015
3 8 Check pressure retention valve in fuel return line 3017
3 9 Removing and installing injectors 3019
3 9 1 Removing and installing right injectors, cylinder bank 1 3019
3 9 2 Removing and installing left injectors, cylinder bank 2 3022
3 10 Removing and installing high-pressure lines 3026
3 10 1 Removing and installing right high-pressure lines, cylinder bank 1 3026
3 10 2 Removing and installing left high-pressure lines, cylinder bank 2 3029
3 10 3 Removing and installing high pressure line between right high pressure reservoir 1 and left high pressure reservoir 2 3033
3 10 4 Removing and installing high pressure line between left high pressure reservoir 2 and high pressure pump 3036
3 11 Removing and installing fuel rail 3039
3 11 1 Removing and installing right high-pressure reservoir (rail element), cylinder bank 1 3039
3 11 2 Removing and installing left high-pressure reservoir (rail element), cylinder bank 2 3041
4 Air filter 3043
4 1 Assembly overview – air filter housing 3043
4 2 Removing and installing air filter housing 3045
5 Intake manifold 3047
5 1 Assembly overview – intake manifold 3047
5 2 Removing and installing intake manifold flap control unit -GX14- 3050
5 3 Removing and installing intake manifold upper part 3052
5 4 Removing and installing lower part of intake manifold 3055
5 5 Removing and installing throttle valve module -GX3- 3056
6 Senders and sensors 3058
6 1 Removing and installing air mass meter -G70- 3058
6 2 Removing and installing fuel pressure sender -G247- 3059
6 3 Removing and installing fuel pressure regulating valve -N276- 3061
6 4 Removing and installing pressure differential sender -G505- 3062
6 5 Removing and installing fuel temperature sender -G81- 3064
6 6 Removing and installing fuel pressure sender for low-pressure -G410- 3065
6 7 Removing and installing intake manifold sender -GX9- 3066
7 Engine/motor control unit 3068
7 1 Removing and installing engine control unit -J623- 3068
8 High-pressure pump 3070
8 1 Assembly overview – high-pressure pump 3070
8 2 Removing and installing high-pressure pump 3072
9 Lambda probe 3078
9 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 3078
9 2 Removing and installing control unit for NOx sender -J583-/NOx sender -G295- 3080
9 3 Removing and installing control unit for NOx sender 2 -J881-/NOx sender 2 -G687- 3082
9 4 Removing and installing control unit for sensor electronics -J849-/particulate sensor -G784- 3083
26 – Exhaust system 3085
1 Exhaust pipes and silencers 3085
1 1 Assembly overview – silencers 3085
1 2 Removing and installing exhaust pipe 3085
1 3 Removing and installing rear silencer 3086
1 4 Aligning exhaust system free of stress 3088
1 5 Checking exhaust system for leaks 3088
1 6 Installation position of clamp 3089
2 Emission control 3090
2 1 Assembly overview – emission control 3090
2 2 Removing and installing catalytic converter 3092
2 3 Removing and installing particulate filter 3095
3 SCR system (selective catalytic reduction) 3099
3 1 Assembly overview – reducing agent tank 3099
3 2 Assembly overview – delivery module for reducing agent 3100
3 3 Removing and installing reducing agent tank -VX85- 3101
3 4 Removing and installing delivery unit for reducing agent metering system -GX19- 3104
3 5 Removing and installing injector for reduction agent -N474- 3107
3 6 Removing and installing control unit for reducing-agent heater -J891- 3110
3 7 Draining reducing agent tank -VX85- 3111
3 8 Removing and installing filler pipe for reducing agent tank -VX85- 3114
4 Exhaust gas temperature regulation 3117
4 1 Assembly overview – exhaust gas temperature regulation 3117
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 3119
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 3120
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 3121
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 3123
5 Exhaust gas recirculation 3125
5 1 Assembly overview – exhaust gas recirculation 3125
5 1 1 Assembly overview – exhaust gas recirculation 3125
5 1 2 Assembly overview – repair kit for exhaust gas recirculation cooler 3127
5 2 Removing and installing exhaust gas recirculation cooler 3130
5 2 1 Removing and installing exhaust gas recirculation cooler 3130
5 2 2 Installing repair kit for exhaust gas recirculation cooler 3132
5 3 Removing and installing exhaust gas recirculation pipes 3135
5 3 1 Removing and installing exhaust gas recirculation pipe between turbocharger and exhaust gas recirculation cooler 3135
5 3 2 Removing and installing exhaust gas recirculation pipe between intake manifold and exhaust gas recirculation cooler 3137
5 4 Removing and installing exhaust gas recirculation temperature sensor -G98- 3138
6 Exhaust manifold 3140
6 1 Assembly overview – exhaust manifold 3140
6 2 Removing and installing exhaust manifold 3141
6 2 1 Removing and installing right exhaust manifold 3141
6 2 2 Removing and installing left exhaust manifold 3143
28 – Glow plug system 3146
1 Glow plug system 3146
1 1 Assembly overview – glow plug system 3146
1 2 Removing and installing glow plug 3148
1 3 Checking glow plug 3150
1 4 Removing and installing automatic glow period control unit -J179- 3150
1 5 Removing and installing Hall sender -G40- 3151
1 6 Removing and installing engine speed sender -G28- 3151
D4B8067AAC8 8 speed automatic gearbox 0DR 3153
00 – Technical data 3157
1 Safety information 3157
1 1 Safety precautions when working on fuel supply system 3157
1 2 Safety measures when working on vehicles with a start/stop system 3157
1 3 Safety precautions when using testers and measuring instruments during a road test 3158
1 4 Safety precautions when working on the cooling system 3158
1 5 Safety precautions when working on ignition system 3158
1 6 Safety precautions when tow-starting or towing 3158
2 Repair instructions 3160
2 1 Rules for cleanliness 3160
2 2 General information 3160
2 3 General repair instructions 3160
2 4 Contact corrosion 3161
2 5 Gaskets and seals 3161
2 6 Nuts and bolts 3162
2 7 Pipe/wire routing and attachment 3162
3 Technical data 3163
3 1 Capacities 3163
3 2 Allocation gearbox – engine 3163
32 – Torque converter 3165
1 Torque converter 3165
1 1 Assembly overview – torque converter 3165
1 2 Removing and installing torque converter 3165
1 3 Draining torque converter 3167
1 4 Removing and installing torque converter oil seal 3168
37 – Controls, housing 3170
1 ATF circuit 3170
1 1 Assembly overview – ATF circuit 3170
1 2 Removing and installing ATF cooler 3171
1 3 Removing and installing ATF filter 3173
1 4 Removing and installing ATF lines 3175
1 4 1 Removing and installing ATF lines, ATF cooler/thermostat 3175
1 4 2 Removing and installing ATF lines, thermostat/gearbox 3178
2 ATF 3182
2 1 Checking ATF level 3182
2 2 Draining and filling ATF 3183
2 3 Purging ATF circuit 3188
3 Removing and installing gearbox 3190
3 1 Specified torques for gearbox 3190
3 2 Removing gearbox 3190
3 3 Installing gearbox 3200
4 Assembly mountings 3206
4 1 Assembly overview – assembly mountings 3206
5 Transporting gearbox 3208
5 1 Transporting gearbox 3208
6 Selector mechanism 3210
6 1 Assembly overview – selector mechanism 3210
6 2 Assembly overview – selector lever handle 3211
6 3 Checking selector mechanism 3212
6 4 Manual release from position P 3213
6 5 Removing and installing selector mechanism 3214
6 6 Dismantling and assembling selector mechanism 3216
6 6 1 Removing and installing cable support bracket for selector lever cable 3216
6 6 2 Removing and installing gearbox selector lever 3220
6 7 Removing and installing selector lever handle 3220
6 8 Removing and installing gear selector cable 3223
6 9 Checking and adjusting selector lever cable 3223
38 – Gears, control 3226
1 ATF system 3226
1 1 Assembly overview – sump/oil strainer 3226
1 2 Removing and installing sump 3228
1 3 Removing and installing hydraulic impulse oil storage with accumulator solenoid -N485- 3231
2 Oil seals in gearbox 3234
2 1 Renewing oil seal in gearbox 3234
3 Mechatronic unit 3236
3 1 Removing and installing mechatronic unit 3236
D4B8071B6D3 Factory installed accessories and conversions 3242
00 – Technical data 3254
1 Tipper body (Henschel) 3254
1 1 Data 3254
1 1 1 Type plate 3254
1 1 2 Operating and maintenance instructions 3254
2 Box body (Junge) 3255
2 1 Data 3255
2 1 1 Type plate 3255
2 1 2 Operating and maintenance instructions 3255
3 Box body (Spier) 3257
3 1 Data 3257
3 1 1 Type plate 3257
3 1 2 Operating and maintenance instructions 3257
4 Box body (Schmitz Cargobull) 3259
4 1 General information 3259
4 2 Data 3259
4 2 1 Type plate 3259
4 2 2 Operating and maintenance instructions 3260
5 Tail lift (Sörensen) 3261
5 1 General information 3261
5 2 Data 3262
5 2 1 Type plate 3262
5 2 2 Safety notes 3263
6 Tail lift (BÄR – Cargolift) 3265
6 1 General information 3265
6 2 Data 3266
6 2 1 Type plate 3266
6 2 2 Safety notes 3267
7 Tail lift (Palfinger) 3268
7 1 General information 3268
7 2 Data 3269
7 2 1 Type plate 3269
7 2 2 Safety notes 3269
8 Design double tube bar 3270
8 1 Safety notes 3270
9 Hazard classification of high-voltage system 3271
27 – Starter, current supply, CCS 3272
1 Preparation for second battery 3272
1 1 System overview – preparation for second battery 3272
1 2 Overview of fitting locations – preparation for second battery 3273
1 3 Removing and installing second battery charging circuit relay -J713- 3275
1 4 Notes on function of second battery charging circuit relay -J713- 3276
53 – Body – rear 3277
1 Storage well liner and load compartment trim for rear lid 3277
1 1 Assembly overview – storage well liner 3277
1 2 Removing and installing storage well liner 3278
1 3 Removing and installing load compartment for rear lid 3279
2 Aluminium load compartment trim 3282
2 1 General notes 3282
2 2 Assembly overview – aluminium load compartment trim 3282
2 3 Removing and installing load compartment trim, aluminium 3284
2 3 1 Removing and installing load compartment trim, aluminium, front 3284
2 3 2 Removing and installing load compartment trim, aluminium, floor 3285
2 3 3 Removing and installing load compartment trim, aluminium, tailgate 3287
2 3 4 Removing and installing load compartment trim, aluminium, side panel trims 3288
3 Bracket and wing for single and twin tyres, tipper body 3291
3 1 Assembly overviews – wing bracket 3291
3 1 1 Assembly overview – wing bracket, single tyres, ►03 2019 3291
3 1 2 Assembly overview – wing bracket, single tyres, 04 2019 ► 3292
3 1 3 Assembly overview – wing bracket, twin tyres, ►03 2019 3292
3 1 4 Assembly overview – wing bracket, twin tyres, 04 2019 ► 3293
3 2 Removing and installing wing 3294
3 3 Removing and installing wing bracket 3295
61 – Convertible roof, hardtop, canopy 3297
1 Hardtop 3297
1 1 Assembly overview – hardtop 3297
1 2 Removing and installing hardtop 3297
1 3 Renewing adhesive film 3301
1 4 Renewing seals 3302
1 5 Removing and installing gas strut 3303
1 6 Removing and installing vent window 3303
66 – Exterior equipment 3306
1 Tipper body (Henschel) 3306
1 1 Load bed 3306
1 1 1 Removing and installing bulkhead attachment 3306
1 1 2 Removing and installing bulkhead 3307
1 1 3 Removing and installing panels (side panels and tailboard) 3308
1 1 4 Removing and installing hinge 3309
1 1 5 Removing and installing rear lid 3310
1 1 6 Removing and installing rear lock for tail lift 3310
1 1 7 Removing and installing wing 3311
1 1 8 Removing and installing tipper bearing 3312
1 1 9 Removing and installing safety support 3313
1 1 10 Removing and installing safety cable 3314
1 2 Hydraulic system 3316
1 2 1 Removing and installing pop-up cylinder 3316
1 2 2 Removing and installing shaft ring 3317
1 2 3 Removing and installing hydraulic hose 3318
1 2 4 Removing and installing hydraulic pump 3320
1 2 5 Renewing hydraulic fluid 3323
1 2 6 Bleeding the hydraulic system 3325
2 Tipper body (Schoon) 3326
2 1 Load bed 3326
2 1 1 Removing and installing bulkhead 3326
2 1 2 Removing and installing panels (side panels and tailboard) 3327
2 1 3 Removing and installing wing (single tyres) 3328
2 2 Hydraulic system 3329
2 2 1 5-stage pop-up cylinder (stroke: 875 mm/1150 mm) 3329
2 2 2 Removing and installing hydraulic hose 3331
2 2 3 Removing and installing hydraulic unit 3333
2 2 4 Renewing hydraulic fluid 3335
2 2 5 Bleeding the hydraulic system 3337
3 Box body (Junge) 3339
3 1 Box body, exterior 3339
3 1 1 Removing and installing roof corner 3339
3 2 Box body, rear 3339
3 2 1 Removing and installing gas strut 3339
3 2 2 Removing and installing tail flap 3340
3 2 3 Removing and installing tail flap seal 3341
3 2 4 Removing and installing box body seals 3342
3 2 5 Removing and installing reversing camera 3343
4 Box body (Spier) 3345
4 1 Box body, exterior 3345
4 1 1 Removing and installing front roof corner 3345
4 1 2 Removing and installing rear roof corner 3346
4 2 Box body, rear 3348
4 2 1 Removing and installing gas strut 3348
4 2 2 Removing and installing tail flap 3350
4 2 3 Removing and installing tail flap seals 3351
4 2 4 Removing and installing rear box body seals 3351
4 2 5 Removing and installing reversing camera 3351
5 Box body (Schmitz Cargobull) 3353
5 1 Box body, exterior 3353
5 1 1 Removing and installing roof corner, front 3353
5 1 2 Removing and installing roof corner, rear 3355
5 1 3 Removing and installing stirrup 3356
5 2 Box body, rear 3358
5 2 1 Removing and installing gas strut 3358
5 2 2 Removing and installing tail flap 3358
5 2 3 Removing and installing side door 3360
5 2 4 Removing and installing wing door 3360
5 2 5 Removing and installing wing door/tail flap seals 3362
5 2 6 Removing and installing rear box body seals 3363
5 2 7 Removing and installing reversing camera 3364
5 2 8 Removing and installing grab handle 3365
5 2 9 Removing and installing lock case 3366
6 Tail lift (Sörensen) 3368
6 1 Platform 3368
6 1 1 ‏Removing and installing platform 3368
6 1 2 Adjusting platform to floor of vehicle 3369
6 1 3 Adjusting platform to body 3370
6 1 4 Adjusting platform angle 3372
6 1 5 Removing and installing warning flag 3372
6 2 Hydraulic system 3373
6 2 1 Removing and installing pop-up cylinder 3373
6 2 2 Removing and installing lock cylinder 3375
6 2 3 Removing and installing hydraulic pump 3377
6 2 4 Changing hydraulic fluid 3377
6 2 5 Bleeding the hydraulic system 3378
6 2 6 Removing and installing tail lift pressure switch -F559- 3378
6 2 7 Removing and installing solenoid valve -N729/N730- 3380
7 Tail lift (BÄR – Cargolift) 3383
7 1 Platform 3383
7 1 1 ‏Removing and installing platform 3383
7 1 2 Adjusting platform to body 3384
7 1 3 Removing and installing warning flag 3386
7 2 Hydraulic system 3387
7 2 1 Removing and installing pop-up cylinder 3387
7 2 2 Removing and installing lock cylinder 3389
7 2 3 Removing and installing tail lift hydraulics motor -V642- 3391
7 2 4 Removing and installing solenoid valve -N729/N730- 3393
7 2 5 Removing and installing tail lift pressure switch -F559- 3395
7 2 6 Renewing hydraulic fluid 3396
7 2 7 Bleeding the hydraulic system 3397
8 Tail lift (Palfinger) 3398
8 1 Platform 3398
8 1 1 ‏Removing and installing platform 3398
8 1 2 Adjusting tilt switch 3400
8 1 3 Adjusting platform to body 3400
8 1 4 Removing and installing warning flag 3402
8 2 Hydraulic system 3403
8 2 1 Removing and installing pop-up cylinder 3403
8 2 2 ‏Removing and installing tilt cylinder 3405
8 2 3 Removing and installing hydraulic pump 3407
8 2 4 Removing and installing solenoid valve 3410
8 2 5 Renewing hydraulic fluid 3412
8 2 6 Bleeding the hydraulic system 3413
9 Repairing box body 3414
9 1 Repairing plywood panel 3414
9 2 Repairing sandwich panel 3418
9 2 1 Repairing GRP cover layer 3418
9 2 2 Repairing one-sided damage 3420
9 2 3 Repairing two-sided damage 3427
9 3 Repairing transparent roof 3434
10 Trim film and protective film 3438
10 1 Assembly overview – protective film 3438
10 1 1 Assembly overview – warning film, bonnet 3438
10 1 2 Assembly overview – warning film, rear wing doors 3438
10 1 3 Assembly overview – warning film, dropside 3439
10 2 Renewing protective films 3440
10 2 1 Renewing protective films 3440
10 2 2 Renewing warning film 3441
10 2 3 Dimensions – warning film, bonnet 3443
10 2 4 Dimensions – warning film, rear wing doors 3444
10 2 5 Dimensions – warning film, dropside 3444
11 Taxi roof sign preparation 3445
11 1 Removing and installing taxi roof sign preparation 3445
12 Taxi roof sign preparation 3447
12 1 Removing and installing taxi roof sign preparation 3447
13 Taxi roof sign preparation 3449
13 1 Removing and installing taxi roof sign preparation 3449
14 Roof spoiler 3450
14 1 Removing and installing roof spoiler 3450
15 Mounting bracket for towing bracket 3452
15 1 Assembly overview – mounting bracket for towing bracket 3452
15 2 Removing and installing mounting bracket for towing bracket 3452
16 Roof basket 3454
16 1 Assembly overview – roof basket 3454
16 2 Removing and installing roof basket 3456
16 2 1 Removing and installing roof basket 3456
16 2 2 Removing and installing foot for roof basket 3456
16 2 3 Removing and installing loading roller and cross member for roof basket 3457
17 Storage box on drop-side 3460
17 1 Assembly overview – storage box on drop-side 3460
17 2 Removing and installing storage box on drop-side 3460
18 Cross strut 3462
18 1 Assembly overview – cross strut 3462
18 2 Removing and installing cross strut 3464
18 2 1 Removing and installing cross strut on drop-side 3464
18 2 2 Removing and installing cross strut on base frame for ladder transport 3466
19 Storage box under drop-side 3468
19 1 Assembly overview – storage box bracket 3468
19 1 1 Assembly overview – storage box bracket, version 1 3468
19 1 2 Assembly overview – storage box bracket, version 2 3470
19 2 Removing and installing bracket for storage box 3472
20 Side underbody guard 3474
20 1 Assembly overview – side underbody guard 3474
20 2 Removing and installing side underbody guard 3474
21 Storage box 3476
21 1 Assembly overview – storage compartment 3476
21 2 Removing and installing storage compartment 3476
22 Ladder carrier 3478
22 1 Assembly overview – ladder carrier 3478
22 1 1 Assembly overview – front ladder carrier 3478
22 1 2 Assembly overview – rear ladder carrier 3479
22 2 Removing and installing ladder carrier 3480
22 2 1 Removing and installing front ladder carrier 3480
22 2 2 Removing and installing rear ladder carrier 3482
23 Roof carrier system with securing device 3483
23 1 Assembly overview – roof carrier system with securing device 3483
23 2 Removing and installing roof carrier system with securing device 3483
24 Easy Entry, right rear wing door 3485
24 1 Assembly overview – Easy Entry, right rear wing door 3485
24 2 Removing and installing Easy Entry, right rear wing door 3485
25 Underbody guard (protection package) 3489
25 1 Assembly overview – underbody guard (protection package) 3489
25 2 Removing and installing underbody guard (protection package) 3491
25 2 1 Removing and installing skid plate, front 3491
25 2 2 Removing and installing bracket for skid plate, front 3492
25 2 3 Removing and installing skid plate, centre 3493
25 2 4 Removing and installing skid plate, rear 3494
26 Roof ventilator 3495
26 1 Assembly overview – roof ventilator 3495
26 2 Removing and installing roof ventilator 3495
26 2 1 Removing and installing electric/mechanical roof ventilator with catch 3495
26 2 2 Removing and installing electric/mechanical roof ventilator without catch 3497
27 Ladder support 3499
27 1 Assembly overview – ladder support 3499
27 2 Removing and installing ladder support 3500
27 2 1 Removing and installing ladder support, front 3500
27 2 2 Removing and installing ladder support, rear 3501
27 2 3 Removing and installing cross bars 3502
28 Design double tube bar 3504
28 1 Assembly overview – design double tube bar 3504
28 2 Removing and installing design double tube bar 3506
28 3 Installation instructions – design double tube bar 3508
29 Load compartment partition 3516
29 1 Assembly overview – load compartment partition 3516
29 2 Removing and installing locking device 3516
29 3 Removing and installing grille 3517
29 4 Removing and installing frame 3518
30 Loading edge protection 3520
30 1 Assembly overview – loading edge protection 3520
30 2 Removing and installing loading edge protection 3521
30 2 1 Removing and installing loading edge protection, left 3521
30 2 2 Removing and installing loading edge protection, right 3523
30 2 3 Removing and installing loading edge protection, rear 3524
31 Loading edge protection 3526
31 1 Removing and installing loading edge protection 3526
32 Load compartment cover, aluminium 3527
32 1 Assembly overview – load compartment cover 3527
32 2 Removing and installing load compartment cover 3527
32 3 Removing and installing gas strut 3529
32 4 Removing and installing hinge for load compartment cover 3530
33 Protective grille for rear window 3532
33 1 Assembly overview – protective grille for rear window 3532
33 2 Removing and installing protective grille for rear window 3532
33 3 Removing and installing retaining bracket 3533
34 Rail system for load bed 3535
34 1 Assembly overview – rail system 3535
34 2 Removing and installing cross bars 3537
34 3 Removing and installing retaining brackets for cross bars 3537
34 4 Removing and installing guide rails 3538
34 4 1 Removing and installing guide rails, load bed 3538
34 4 2 Removing and installing guide rails, side 3540
35 Side bar 3541
35 1 Assembly overview – side bars 3541
35 2 Removing and installing side bar 3543
35 2 1 Removing and installing side bar 3543
35 2 2 Removing and installing bumper cover, with step panel 3544
35 3 Removing and installing bracket for side bar 3545
35 4 Removing and installing step panel 3546
36 Fuel tank skid plate 3548
36 1 Assembly overview – fuel tank skid plate 3548
36 2 Removing and installing underbody guard for fuel tank 3548
37 Bumper trim 3550
37 1 Assembly overview – bumper trim 3550
37 2 Removing and installing bumper trim 3550
38 Towing bracket (for Australia only) 3553
38 1 Assembly overview – towing bracket 3553
38 2 Removing and installing towing bracket 3553
39 Roof load carrier 3556
39 1 Assembly overview – roof rails/cross bars 3556
39 2 Assembly overview – ladder holder 3557
39 3 Assembly overview – loading roller with holder 3558
39 4 Removing and installing roof rails 3559
39 5 Removing and installing cross bars 3560
39 6 Removing and installing ladder holder 3561
39 7 Removing and installing loading roller with holder 3562
40 Underbody protection 3564
40 1 Assembly overview – skid plate 3564
40 2 Removing and installing skid plate 3564
41 Cross bars 3567
41 1 Assembly overview – cross bars 3567
41 2 Removing and installing cross bars 3567
68 – Interior equipment 3569
1 Box body (Junge) 3569
1 1 Removing and installing fastening rail 3569
1 2 Removing and installing securing strap recesses 3570
1 3 Removing and installing pull strap 3571
2 Box body (Spier) 3573
2 1 Removing and installing fastening rail 3573
2 2 Removing and installing securing strap recess 3575
2 3 Pull strap 3576
3 Box body (Schmitz Cargobull) 3577
3 1 Removing and installing roof cross strut 3577
3 2 Removing and installing fastening rail 3579
3 3 Removing and installing pull strap 3581
4 Equipment 3583
4 1 Universal floor 3583
4 1 1 Assembly overview – universal floor, longitudinal rails 3583
4 1 2 Assembly overview – universal floor, transverse rails 3583
4 1 3 Removing and installing universal floor 3585
4 2 Removable floor panel 3587
4 2 1 Removing and installing removable floor panel 3587
4 3 Roof carrier in load compartment 3589
4 3 1 Assembly overview – roof carrier in load compartment 3589
4 3 2 Removing and installing roof carrier in load compartment 3589
4 4 Removing and installing grab handle, A-pillar 3590
4 5 Partition panel (Holland double cab) 3592
4 5 1 Assembly overview – partition 3592
4 5 2 Removing and installing upper partition 3592
4 5 3 Removing and installing lower partition 3595
5 Box body (Plus) 3599
5 1 Assembly overview – box body (Plus) 3599
5 1 1 Assembly overview – upper partition and lower partition 3599
5 1 2 Assembly overview – bench seat trim, complete 3600
5 1 3 Assembly overview – bench seat, complete 3601
5 1 4 Assembly overview – floor, complete 3602
5 1 5 Assembly overview – roof, complete 3603
5 2 Removing and installing seat bench padding 3604
5 3 Removing and installing upper partition 3605
5 4 Removing and installing lower partition 3606
5 5 Removing and installing connection to side panel 3607
5 6 Removing and installing side panel 3608
5 7 Removing and installing sliding door step 3611
5 8 Removing and installing front and rear bench trim 3612
5 9 Removing and installing bench seat 3614
5 10 Removing and installing floor items 3615
5 11 Removing and installing headliner 3616
5 12 Removing and installing roof items 3617
6 Tool cabinet 3619
6 1 Assembly overview – tool cabinet 3619
6 1 1 Assembly overview – tool cabinet, Caddy, short wheelbase 3619
6 1 2 Assembly overview – tool cabinet, Caddy, long wheelbase 3620
6 2 Removing and installing tool cabinet 3621
6 2 1 Removing and installing tool cabinet, Caddy, short wheelbase 3621
6 2 2 Removing and installing tool cabinet, Caddy, long wheelbase 3623
6 2 3 Removing and installing tool cabinet, Caddy, long wheelbase, right-hand side 3624
6 2 4 Removing and installing workbench with vice 3626
7 Fastening rails 3627
7 1 Assembly overview – fastening rails 3627
7 2 Removing and installing fastening rail 3628
7 2 1 Removing and installing fastening rail, Caddy, short wheelbase, left-hand side 3628
7 2 2 Removing and installing fastening rail, Caddy, long wheelbase, left-hand side 3629
7 2 3 Removing and installing fastening rail, Caddy, short wheelbase, right-hand side 3630
7 2 4 Removing and installing fastening rail, Caddy, long wheelbase, right-hand side 3631
8 Load bed covering, wood 3633
8 1 Assembly overview – load bed covering, wood 3633
8 2 Removing and installing load bed covering, wood 3633
8 2 1 Removing and installing load bed covering, wood, Caddy, short wheelbase 3633
8 2 2 Removing and installing load bed covering, wood, Caddy, long wheelbase 3635
9 C-pillar partition 3637
9 1 Assembly overview – C-pillar partition 3637
9 2 Removing and installing C-pillar partition 3638
9 2 1 Removing and installing C-pillar partition, upper part 3638
9 2 2 Removing and installing C-pillar partition, lower part 3640
9 2 3 Removing and installing bracket, upper 3641
9 2 4 Removing and installing bracket, lower 3642
9 2 5 Removing and installing assembly strut 3643
10 Rear window protective grille 3645
10 1 Assembly overview – rear window protective grille 3645
10 2 Removing and installing rear window protective grille 3645
11 Partition grille 3647
11 1 Removing and installing partition grille 3647
11 2 Removing and installing partition grille reinforcement 3648
11 3 Removing and installing bracket for partition grille reinforcement bracket 3650
11 4 Removing and installing partition grille bracket adapter 3652
12 Partition grille 3654
12 1 Assembly overview – partition grille 3654
12 2 Removing and installing partition grille 3654
13 Tool box for load bed 3657
13 1 Assembly overview – tool box 3657
13 2 Removing and installing tool box 3657
14 Wheel housing trim 3659
14 1 Assembly overview – wheel housing trim 3659
14 2 Removing and installing wheel housing trim 3659
15 Stowage cases on wing door 3661
15 1 Assembly overview – stowage cases 3661
15 2 Removing and installing stowage cases 3662
15 3 Removing and installing brackets for stowage cases 3662
16 Floor ventilation, load bed 3664
16 1 Assembly overview – floor ventilation 3664
16 2 Removing and installing floor ventilation 3664
17 High load floor with drawers 3666
17 1 Assembly overview – high load floor with drawers 3666
17 2 Removing and installing load floor, upper part 3668
17 3 Removing and installing load floor, lower part 3669
17 4 Removing and installing frame for drawers 3671
18 Storage compartment on wheel housing 3673
18 1 Assembly overview – storage compartment on wheel housing 3673
18 2 Removing and installing storage compartment 3673
19 Protective grille on wing door 3675
19 1 Assembly overview – protective grille on wing door 3675
19 2 Removing and installing protective grille 3675
20 Interior mirror 3677
20 1 Removing and installing mirror taximeter -G511- 3677
21 Interior mirror 3678
21 1 Removing and installing interior mirror, mirror taximeter -G511- 3678
22 Interior mirror 3679
22 1 Removing and installing interior mirror, mirror taximeter -G511- 3679
69 – Passenger protection 3680
1 Seat belts 3680
1 1 Removing and installing front three-point seat belt, bench seat (Holland double cab) 3680
1 2 Removing and installing belt buckle, bench seat (Holland double cab) 3681
1 2 1 Removing and installing outer belt buckle 3681
1 2 2 Removing and installing centre belt buckle 3682
70 – Trim, insulation 3684
1 Interior trims 3684
1 1 Removing and installing bench seat trim (Holland double cab) 3684
1 2 Removing and installing sliding door trim (Holland double cab) 3684
72 – Seat frames 3687
1 Bench seats 3687
1 1 Removing and installing bench seat (Holland double cab) 3687
74 – Seat – padding, covers 3689
91 – Communication 3690
1 Fitting locations 3690
1 1 Overview of fitting locations of components/control units in front section of the vehicle (taxi) 3690
2 Fitting locations 3691
2 1 Overview of fitting locations of components/control units in front section of the vehicle (taxi) 3691
3 Sound system 3692
3 1 Overview of fitting locations – sound system 3692
3 2 Removing and installing two-way radio loudspeaker -R25- 3693
4 Aerial systems 3694
4 1 Removing and installing roof aerial -R295- 3694
5 Aerial systems 3696
5 1 Removing and installing roof aerial -RX5- 3696
6 Aerial systems 3698
6 1 Removing and installing roof aerial -R295- 3698
7 Aerial systems 3700
7 1 Removing and installing roof aerial -R295- 3700
8 Aerial systems 3702
8 1 Removing and installing roof aerial -R295- 3702
9 Taximeter 3704
9 1 Removing and installing taximeter -G41- 3704
9 2 Removing and installing mounting for taximeter -G41- 3705
9 3 Removing and installing centre console cover with mounting for taximeter -G41- 3706
10 Taximeter 3707
10 1 Removing and installing taximeter -G41- 3707
10 1 1 Removing and installing taximeter console 3707
10 2 Removing and installing mirror taximeter -G511- 3707
11 Taximeter 3711
11 1 Removing and installing taximeter -G41- 3711
11 1 1 Removing and installing taximeter console 3711
11 2 Removing and installing mirror taximeter -G511- 3713
12 Two-way radio 3716
12 1 Assembly overview – two-way radio 3716
12 2 Removing and installing two-way radio -R8- 3717
12 3 Removing and installing two-way radio bracket 3717
12 4 Removing and installing two-way radio unit microphone -R122- 3718
13 Two-way radio 3719
13 1 Removing and installing two-way radio -R8- 3719
13 2 Removing and installing microphone 2 on driver side -R225- 3719
13 3 Removing and installing two-way radio loudspeaker -R25- 3720
14 Two-way radio 3721
14 1 Removing and installing two-way radio -R8- 3721
14 2 Removing and installing 2-way radio unit microphone -R122-, vehicles with panoramic sunroof 3721
14 3 Removing and installing 2-way radio unit microphone -R122-, vehicles without panoramic sunroof 3722
14 4 Removing and installing two-way radio loudspeaker -R25- 3722
94 – Lights, bulbs, switches – exterior 3724
1 Tipper body (Henschel) 3724
1 1 Lights 3724
1 1 1 Removing and installing side marker lights, 3-way tipper 3724
1 2 Electrical system, general 3726
1 2 1 Switching off the hydraulic unit – removing and installing limit switch 3726
1 2 2 Removing and installing start relay 3728
1 2 3 Removing and installing main switch 3730
1 2 4 Switch for 3-way tipper 3731
2 Tipper body (Schoon) 3732
2 1 Electrics 3732
2 1 1 Switching off the hydraulic unit – removing and installing limit switch 3732
2 1 2 Removing and installing start relay for 12 V Bosch Rexroth pumps 3733
2 1 3 Removing and installing main fuse 3735
2 1 4 Switch for 3-way tipper 3737
3 Box body (Junge) 3738
3 1 Removing and installing tail light -MX3-/-MX4- 3738
3 2 Removing and installing rear fog light -L46-/-L47- 3739
3 3 Removing and installing number plate light -X4-/-X5- 3740
3 4 Removing and installing additional brake light -M25- 3741
3 5 Removing and installing upper marker lights 3742
3 6 Removing and installing side marker light -M33-/-M34-/-M37-/-M38-/-M39-/-M40- with bracket 3742
3 7 Removing and installing lower marker light 3743
4 Box body (Spier) 3745
4 1 Removing and installing tail light -MX3-/-MX4- 3745
4 2 Removing and installing number plate light -X4-/-X5- 3746
4 3 Removing and installing high-level brake light 3747
4 4 Removing and installing upper marker lights 3747
4 5 Removing and installing side marker light -M33-/-M34-/-M37-/-M38-/-M39-/-M40- 3748
5 Box body (Schmitz Cargobull) 3751
5 1 Removing and installing tail light cluster 3751
5 2 Removing and installing number plate light 3752
5 3 Removing and installing high-level brake light 3754
5 4 Removing and installing rear upper marker light 3755
5 5 Removing and installing front upper marker light 3756
5 6 Removing and installing side marker light 3756
6 Tail lift (Sörensen) 3759
6 1 Removing and installing hazard warning light -M115/M116- 3759
6 2 Removing and installing foot switch -F558- 3760
6 3 Removing and installing tail lift operating unit -EX56- 3760
6 4 ‏Removing and installing tilt angle sensor 3761
7 Tail lift (BÄR – Cargolift) 3764
7 1 Removing and installing hazard warning light -M115/M116- 3764
7 2 Removing and installing foot switch -F556/F557- 3765
7 3 Removing and installing operating unit -EX56- 3766
7 4 Removing and installing foot switch unit -F558- 3767
8 Tail lift (Palfinger) 3771
8 1 Removing and installing hazard warning light 3771
8 2 Removing and installing foot controls 3772
8 3 Removing and installing tilt switch 3772
8 4 Removing and installing angle sensor 3773
8 5 ‏Removing and installing control box 3774
9 Roof spoiler elevated side light 3777
9 1 Removing and installing roof spoiler elevated side light 3777
10 Cross strut/tarpaulin lighting 3779
10 1 Removing and installing cross strut/tarpaulin lighting 3779
11 Cross strut/tarpaulin wiring harness 3781
11 1 Removing and installing cross strut/tarpaulin wiring harness 3781
12 LED rotating light 3782
12 1 Removing and installing LED rotating light 3782
13 Taxi roof sign 3784
13 1 Assembly overview – taxi roof sign 3784
13 2 Removing and installing taxi roof sign -J1066- 3785
13 3 Removing and installing bracket for taxi roof sign -J1066- 3786
14 Taxi roof sign 3788
14 1 Assembly overview – taxi roof sign 3788
14 2 Removing and installing taxi roof sign -J1066- 3789
14 3 Removing and installing bracket for taxi roof sign -J1066- 3790
15 Taxi roof sign 3792
15 1 Assembly overview – taxi roof sign 3792
15 2 Removing and installing taxi roof sign -J1066- 3793
15 3 Removing and installing bracket for taxi roof sign -J1066- 3794
96 – Lights, bulbs, switches – interior 3795
1 Box body (Junge) 3795
1 1 Removing and installing load area illumination switch -E481- 3795
1 2 Removing and installing interior lighting 3795
2 Box body (Spier) 3797
2 1 Removing and installing load area illumination switch -E481- 3797
2 2 Removing and installing interior lighting 3797
3 Box body (Schmitz Cargobull) 3799
3 1 Removing and installing interior lighting 3799
4 Tail lift (Sörensen) 3801
4 1 Tail lift switch -E629- 3801
5 Tail lift (BÄR – Cargolift) 3802
5 1 Tail lift switch -E629- 3802
6 Tail lift (Palfinger) 3803
6 1 Tail lift switch 3803
7 Controls 3804
7 1 Overview of fitting locations – controls in dash panel, Taxi 3804
7 2 Removing and installing interior light switch (taxi) -E115- 3804
7 3 Removing and installing taxi sign switch -E138- 3805
7 4 Removing and installing alarm system off switch -E217- 3805
7 5 Removing and installing hands-free system button -E487- 3805
8 Controls 3806
8 1 Removing and installing taxi alarm active button -E485- 3806
8 2 Removing and installing passive taxi alarm button -E580- 3806
8 3 Removing and installing switch module 2 in dash panel, next to steering wheel -EX44- 3808
9 Controls 3809
9 1 Removing and installing taxi alarm active button -E485- 3809
9 2 Removing and installing passive taxi alarm button -E580- 3809
9 3 Removing and installing taxi alarm off button -E486- 3810
9 4 Removing and installing switch module for taxi functions -EX62- 3810
10 Controls 3812
10 1 Removing and installing taxi alarm active button -E485- 3812
10 2 Removing and installing taxi alarm off button -E486- 3812
10 3 Removing and installing passive taxi alarm button -E580- 3813
10 4 Removing and installing centre switch module 2 in dash panel -EX35- 3814
11 Anti-theft alarm 3815
11 1 Assembly overview – treble horn -H2- 3815
11 2 Removing and installing treble horn -H2- 3815
11 2 1 Removing and installing treble horn -H2- 3815
11 2 2 Removing and installing bracket for treble horn -H2- 3816
12 LED spot lights 3818
12 1 Assembly overview – LED spot lights 3818
12 1 1 Assembly overview – LED spot lights, cab 3818
12 1 2 Assembly overview – LED spot lights, passenger compartment 3818
12 2 Removing and installing LED spot lights 3819
12 2 1 Removing and installing LED spot lights, cab 3819
12 2 2 Removing and installing LED spot lights, passenger compartment 3820
13 Cigarette lighter, socket 3822
13 1 Assembly overview – DC/AC converter/socket 3822
13 2 Removing and installing DC/AC converter with socket, 12 V-230 V -U13- 3823
13 3 Overview of fitting locations – 230 V components 3826
13 4 Assembly overview – exterior socket, 230 V, 110 V -U8- 3827
13 5 Assembly overview – interior socket, 230 V, 110 V -U11- 3828
13 6 Assembly overview – 220 V automatic personnel protection circuit breaker -S59- 3829
13 7 Removing and installing interior socket, 230 V, 110 V -U11- 3830
13 7 1 Removing and installing interior socket, 230 V, 110 V -U11-, rear left 3830
13 7 2 Removing and installing interior socket, 230 V, 110 V -U11-, on seat frame of driver seat 3833
13 8 Removing and installing 220 V automatic personnel protection circuit breaker -S59- 3835
13 9 Removing and installing exterior socket, 230 V, 110 V -U8- 3837
13 10 Removing and installing battery charger, 230 V or 110 V/12 V -A10- 3839
13 10 1 Removing and installing battery charger, 230 V or 110 V/12 V -A10-, under driver seat 3839
13 10 2 Removing and installing battery charger, 230 V or 110 V/12 V -A10-, under bench seat on front passenger side 3841
13 10 3 Removing and installing bracket from battery charger, 230 V or 110 V/12 V -A10-, under bench seat on front passenger side 3842
13 10 4 Removing and installing fuse on battery charger, 230 V or 110 V/12 V -A10- 3843
13 11 Removing and installing DC/AC converter with socket, 12 V-230 V -U13- 3843
97 – Wiring 3846
1 Control units 3846
1 1 Removing and installing special vehicle control unit -J608- 3846
1 1 1 Removing and installing special vehicle control unit -J608- 3846
1 1 2 Removing and installing bracket for special vehicle control unit -J608- 3848
2 Control units 3849
2 1 Removing and installing special vehicle control unit -J608- 3849
2 1 1 Removing and installing special vehicle control unit -J608-, vehicles with single seat on front passenger side 3849
2 1 2 Removing and installing special vehicle control unit -J608-, vehicles with bench seat on front passenger side 3850
2 1 3 Removing and installing bracket of special vehicle control unit -J608-, vehicles with single seat on front passenger side 3850
2 1 4 Removing and installing bracket of special vehicle control unit -J608-, vehicles with bench seat on front passenger side 3851
D4B80275F7F Running gear axles steering 3852
00 – Technical data 3858
1 Safety information 3858
1 1 Safety precautions when working on subframe 3858
2 Assessing accident-damaged vehicles 3859
2 1 Check list for evaluating running gear on accident vehicles 3859
3 General information 3861
3 1 Tyre types 3861
3 2 Vehicle data sticker 3861
3 3 General notes on tyre pressure indicator 3861
4 Repair instructions 3863
4 1 Leaks at shock absorbers 3863
4 2 Noises from shock absorbers 3863
4 3 Checking shock absorbers when removed 3864
4 4 Steering rack 3864
4 5 Gaskets and seals 3865
4 6 Nuts and bolts 3865
4 7 Electrical components 3865
4 8 Raising wheel bearing assembly to unladen position 3866
4 8 1 Raising front wheel suspension to unladen position 3866
4 8 2 Raising rear wheel suspension to unladen position 3869
5 Disposal 3872
5 1 Releasing gas and draining front gas-filled shock absorbers 3872
5 2 Releasing gas and draining rear gas-filled shock absorbers 3872
40 – Front suspension 3874
1 Front axle 3874
1 1 Overview – front axle 3874
2 Subframe 3875
2 1 Assembly overview – subframe 3875
2 2 Removing and installing anti-roll bar 3875
2 3 Renewing anti-roll bar bushes 3877
2 4 Removing and installing coupling rod 3878
3 Wheel bearing 3880
3 1 Assembly overview – wheel bearing assembly 3880
3 2 Removing and installing wheel bearing housing 3881
3 3 Removing and installing wheel bearing 3884
4 Suspension strut, upper suspension link 3891
4 1 Assembly overview – suspension strut, upper suspension link 3891
4 2 Assembly overview – suspension strut 3893
4 3 Removing and installing suspension strut 3893
4 4 Removing and installing upper links 3896
4 5 Renewing bushes for upper suspension link 3899
4 6 Repairing front suspension strut 3901
5 Lower suspension link, swivel joint 3906
5 1 Removing and installing lower suspension link 3906
5 2 Renewing bonded rubber bush for lower suspension link 3908
5 2 1 Renewing bonded rubber bush for lower suspension link 3908
5 2 2 Removing and installing suspension strut mounting 3912
5 3 Checking swivel joint 3913
6 Drive shaft 3915
6 1 Assembly overview – drive shaft 3915
6 2 Removing and installing drive shaft 3917
6 3 Dismantling and assembling drive shaft 3921
6 4 Checking outer constant velocity joint 3926
42 – Rear suspension 3928
1 Rear axle 3928
1 1 Overview of fitting locations – rear axle 3928
1 2 Assembly overview – rear axle 3929
1 3 Assembly overview – rear axle shafts 3931
1 4 Removing and installing bump stop for axle beam 3933
1 5 Removing and installing rear axle 3933
1 5 1 Removing and installing rear axle 3933
1 5 2 Removing and installing rear axle shaft 3938
1 6 Removing and installing leaf spring 3941
1 6 1 Removing and installing leaf spring 3941
1 6 2 Removing and installing plastic insert for leaf spring 3944
1 6 3 Aligning leaf spring 3945
1 7 Renewing leaf spring bushes 3946
1 8 Removing and installing shackle 3948
2 Suspension strut, shock absorber, spring 3953
2 1 Removing and installing shock absorber 3953
44 – Wheels, tyres, vehicle geometry 3955
1 Wheels, tyres 3955
1 1 Specified torques for wheel bolts 3955
1 2 Pressing tyre off wheel rim 3955
1 3 Removing tyre from wheel 3956
1 4 Fitting tyres 3957
1 5 Wheel change 3958
1 5 1 Wheel change, protecting wheel centring seat against corrosion 3958
1 5 2 Wheel change, installation requirements 3958
1 5 3 Wheel change, installation instructions for wheel change 3960
1 6 Wheel change, wheel installation 3961
2 Tyre Pressure Monitoring System 3963
2 1 System description – tyre pressure monitoring system with autolocation 3963
2 2 Overview of fitting locations – tyre pressure monitoring system 3963
2 3 Assembly overview – tyre pressure sensor 3964
2 4 Removing and installing tyre pressure monitoring system control unit -J502- 3965
2 5 Removing and installing tyre pressure sensor 3966
3 Wheel alignment 3968
3 1 Notes for wheel alignment 3968
3 2 Necessity of wheel alignment 3968
3 3 Conditions for testing 3969
3 4 Preparations for testing 3970
3 4 1 Preparations for testing 3970
3 4 2 Measuring vehicle longitudinal inclination 3972
3 5 Specifications for wheel alignment 3972
3 6 Wheel alignment procedure 3973
3 7 Adjusting camber and caster at front wheels 3975
3 8 Adjusting front axle toe 3976
3 9 Vehicle data sticker 3977
3 10 Steering angle sender – basic setting 3978
4 Vibration due to wheels/tyres – causes and rectification 3979
4 1 Causes of rough running 3979
4 2 Conducting a road test before balancing wheels 3979
4 3 Balancing wheel 3980
4 4 Vibration control system 3983
4 5 Checking radial and lateral runout of wheels and tyres 3984
4 6 Checking radial and lateral run-out on wheel rim 3986
4 7 Matching wheels and tyres 3986
4 8 Determining flat spots on tyres 3988
48 – Steering 3990
1 Steering wheel 3990
1 1 Assembly overview – steering wheel 3990
1 2 Removing and installing steering wheel 3990
2 Steering column 3993
2 1 Assembly overview – steering column 3993
2 2 Removing and installing steering column 3994
2 2 1 Removing and installing steering column 3994
2 2 2 Removing and installing sealing boot 3999
2 3 Handling and transporting steering column 4000
2 4 Checking steering column for damage 4001
3 Steering rack 4002
3 1 Assembly overview – steering rack 4002
3 2 Removing and installing steering rack 4002
3 3 Repairing steering rack 4006
3 3 1 Repairing steering rack 4006
3 3 2 Checking shock absorber mountings 4007
3 3 3 Removing and installing shock absorber mountings 4008
3 4 Removing and installing track rod 4011
3 5 Removing and installing track rod ball joint 4015
3 6 Removing and installing bellows 4017
4 Hydraulic power steering 4019
4 1 Assembly overview – vane pump 4019
4 2 Assembly overview – hydraulic lines, reservoir 4023
4 3 Checking delivery pressure of vane pump 4023
4 4 Removing and installing vane pump 4026
4 4 1 Removing and installing vane pump, 4-cylinder engines 4026
4 4 2 Removing and installing vane pump, 6-cylinder engine 4030
4 5 Checking hydraulic fluid level of power steering 4034
4 6 Bleeding steering system 4035
4 7 Check steering for leaks 4035
D4B80305DED Brake systems 4037
00 – Technical data 4041
1 Safety information 4041
1 1 Safety measures when working on vehicles with a start/stop system 4041
1 2 Safety precautions when using testers and measuring instruments during a road test 4041
2 Identification 4042
2 1 Allocation of PR number – brakes 4042
2 1 1 Front brake 4042
2 1 2 Rear brake 4042
3 Repair instructions 4043
3 1 Rules for cleanliness 4043
3 2 General repair instructions 4043
3 3 Checking vacuum system 4043
3 4 Repair instructions for repair work on ABS 4044
4 Technical data 4045
4 1 Technical data for brakes 4045
5 Brake test 4048
5 1 General information 4048
5 2 Checking vehicles with rear-wheel drive 4048
5 3 Checking vehicles with all-wheel drive 4048
5 3 1 On a regulated roller dynamometer with counter-rotating rollers for models with all-wheel drive 4048
5 3 2 Without roller dynamometer for models with all-wheel drive 4049
45 – Anti-lock brake system 4050
1 General information 4050
1 1 General notes on ABS 4050
2 Overview of fitting locations 4052
2 1 Overview of fitting locations – (ABS, EDL, TCS, ESP) 4052
3 Control unit and hydraulic unit 4057
3 1 Assembly overview – control unit and hydraulic unit 4057
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 4061
3 2 1 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, 4-cylinder engines up to model year 2017 4061
3 2 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, 4-cylinder engines as of model year 2017 4064
3 2 3 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-, 6-cylinder engine 4067
3 3 Removing and installing ABS control unit -J104- without ABS hydraulic unit -N55- 4071
3 3 1 Removing and installing ABS control unit -J104- without ABS hydraulic unit -N55-, 4-cylinder engines up to model year 2017 4071
3 3 2 Removing and installing ABS control unit -J104- without ABS hydraulic unit -N55-, 6-cylinder engine 4073
3 4 Separating control unit from hydraulic unit 4074
3 5 Fitting control unit to hydraulic unit 4075
3 6 Connecting brake lines to hydraulic unit 4077
3 6 1 Connecting brake lines to hydraulic unit, 4-cylinder engines 4077
3 6 2 Connecting brake lines to hydraulic unit, 6-cylinder engine 4080
4 Sensors 4082
4 1 Assembly overview – front axle speed sensors -G45-/-G47- 4082
4 2 Assembly overview – rear axle speed sensors -G44-/-G46- 4082
4 3 Removing and installing front axle speed sensors -G45-/-G47- 4084
4 4 Removing and installing rear axle speed sensors -G44-/-G46- 4085
4 4 1 Removing and installing speed sensor -G44-/-G46- on rear axle, drum brake 4085
4 4 2 Removing and installing speed sensors -G44-/-G46- on rear axle, disc brake 4087
46 – Brakes – mechanism 4088
1 Front brake 4088
1 1 Assembly overview – front brake 4088
1 2 Removing and installing brake pads 4091
1 3 Removing and installing brake caliper 4094
2 Rear brake 4098
2 1 Assembly overview – rear brakes 4098
2 2 Removing and installing brake pads 4104
2 3 Removing and installing brake caliper 4108
2 4 Removing and installing brake carrier 4112
2 4 1 Removing and installing brake carrier, drum brakes 4112
2 4 2 Removing and installing brake carrier for disc brakes 4114
2 5 Removing and installing brake shoes 4115
2 6 Resetting drum brakes 4120
3 Parking brake 4123
3 1 Assembly overview – parking brake 4123
3 2 Assembly overview – brake cable 4123
3 2 1 Assembly overview – brake cable, drum brake 4123
3 2 2 Assembly overview – brake cable, disc brake 4124
3 3 Removing and installing handbrake lever 4125
3 4 Removing and installing front handbrake cable 4127
3 5 Removing and installing rear handbrake cable 4128
3 5 1 Removing and installing rear handbrake cable, drum brakes 4128
3 5 2 Removing and installing rear handbrake cable, disc brakes 4131
3 6 Adjusting parking brake 4133
3 6 1 Adjusting parking brake – drum brake up to 2016-06 4133
3 6 2 Adjusting parking brake – drum brake as of 2016-06 4134
3 6 3 Adjusting handbrake – disc brake 4135
4 Brake pedal 4137
4 1 Assembly overview – brake pedal 4137
4 2 Removing and installing brake pedal 4137
47 – Brakes – hydraulics 4139
1 Front brake caliper 4139
1 1 Assembly overview – front brake caliper 4139
1 2 Removing and installing brake caliper piston 4140
2 Rear brake caliper 4143
2 1 Assembly overview – rear brake caliper 4143
2 2 Removing and installing brake caliper piston 4143
3 Hydraulic system 4148
3 1 General notes on brake fluid 4148
3 1 1 Changing brake fluid 4149
3 2 Pre-bleeding hydraulic system 4149
3 3 Bleeding hydraulic system following standard procedure 4151
3 4 Subsequent bleeding of hydraulic system 4151
3 5 Leak test 4151
4 Brake servo and brake master cylinder 4153
4 1 Assembly overview – brake servo/brake master cylinder 4153
4 2 Removing and installing brake light switch -F- 4155
4 3 Removing and installing brake servo 4156
4 3 1 Removing and installing brake servo, 4-cylinder engines 4156
4 3 2 Removing and installing brake servo, 6-cylinder engine (LHD vehicles) 4160
4 3 3 Removing and installing brake servo, 6-cylinder engine (RHD vehicles) 4163
4 4 Removing and installing brake master cylinder 4167
4 5 Removing and installing brake fluid reservoir 4170
5 Vacuum system 4173
5 1 Assembly overview – vacuum pump 4173
5 2 Checking non-return valve 4173
5 3 Removing and installing non-return valve 4173
5 4 Checking vacuum system 4174
5 4 1 Connecting brake servo tester -VAS 6721- 4174
5 4 2 Checking vacuum generation 4175
5 4 3 Checking for leaks 4176
5 4 4 Vacuum generation with manual vacuum pump -VAS 6213- 4177
6 Brake lines 4179
6 1 Repairing brake lines 4179
6 1 1 Repairing brake lines 4179
6 1 2 Assembly overview – flanging tool 4181
6 1 3 Required tools 4183
7 Hydraulic system 4185
7 1 Removing and installing wheel brake cylinder 4185
D4B80646B0E General information Paint for commercial vehicles 4187
00 – Technical data 4191
1 Safety information 4191
1 1 Safety precautions when painting vehicles with gas drive 4191
1 2 Safety precautions when painting vehicles with electric drive 4191
2 General information 4192
2 1 Paintwork structure of a factory finish 4192
2 2 Paint structure of service department finish 4195
2 2 1 Paintwork structure, base coat 4195
2 2 2 Paintwork structure, metallic effect 4198
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 4199
2 4 Reduced paint structure in engine compartment and inside of bonnet 4199
2 5 Instructions for work on underbody and stone chip protection 4199
2 6 Work instruction for window flange area 4201
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 4203
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 4206
2 9 Notes on treating corroded fold areas 4207
2 10 Corrosion protection for body components, add-on components and welded components 4209
2 11 Painting parking aid sensor 4210
2 12 ACC – Adaptive Cruise Control 4212
2 13 Painting instructions for D-pillar trim in the area of the lane change assist control unit 4213
2 14 Painting instructions for bi-colour paintwork 4214
3 Genuine products 4216
3 1 Paint products in customer service 4216
3 2 General application instructions for repair and painting systems 4217
3 2 1 Aqua Premium – application instructions for water-based products 4217
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 4220
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 4230
3 2 4 Repair paintwork system for matt-finished vehicles 4232
3 2 5 Paintwork system for plastic components 4237
3 2 6 Aqua Premium system, blending system for 2-stage colours 4244
3 2 7 Aqua Premium system, blending system for 3-stage colours 4253
3 2 8 Aqua Premium system, product preparation for processing 4260
3 2 9 Aqua Premium system for special mother of pearl colour tone Renault NNP – Rouge Flamme 4267
3 2 10 Aquaplus design and multi-colour painting 4274
3 2 11 Processing instructions for paint with limited hiding power 4278
3 3 Filler 4279
3 3 1 2-pack steel filler set 4279
3 3 2 2-pack fine filler 4282
3 3 3 2-pack fine filler, flexible 4286
3 3 4 2-pack spray filler 4289
3 3 5 2-pack IR premium filler 4295
3 3 6 2-pack diamond aluminium filler 4299
3 3 7 2-pack epoxy resin filler 4302
3 4 Priming metal 4306
3 4 1 1-pack anti-corrosion wash primer 4306
3 4 2 1-pack wash primer 4311
3 4 3 2-pack wash primer 4316
3 5 Priming plastic materials 4321
3 5 1 Adhesion promoter (transparent) 4321
3 6 Surfacer 4326
3 6 1 2-pack HS Vario surfacer 4326
3 6 2 2-pack HS premium surfacer 4336
3 6 3 2-pack HS mixture surfacer 4345
3 6 4 2-pack HS Performance surfacer 4361
3 6 5 2-pack primer surfacer for plastics 4370
3 6 6 2-pack HS wet-on-wet surfacer 4376
3 6 7 2-pack base filler, professional 4386
3 7 Top coats 4403
3 7 1 2-pack HS top coat 4403
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 4412
3 7 3 Aquaplus system (pearlescent and heliochrome) 4420
3 7 4 Aquaplus blending system 4428
3 7 5 Aqua Premium system 4434
3 7 6 Aqua Premium blending system 4446
3 7 7 Aqua Premium system (painting rims) 4454
3 8 Clear coats 4462
3 8 1 2-pack HS clear coat 4462
3 8 2 2-pack MS matt clear coat 4469
3 8 3 2-pack HS Vario clear coat 4475
3 8 4 2-pack HS optimum plus clear coat 4482
3 8 5 2-pack HS brilliant plus clear coat 4488
3 8 6 2-pack HS Performance clear coat 4494
3 8 7 Blender 4500
3 9 Hardener 4505
3 9 1 2-pack HS hardener 4505
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 4509
3 9 3 Hardener for 2-pack primer surfacer 4513
3 9 4 Aqua Premium hardener 4513
3 10 Thinners 4514
3 10 1 2-pack thinner 4514
3 10 2 HS spot thinner 4517
3 10 3 Demineralised water 4519
3 11 Anti-corrosion materials 4520
3 11 1 Anti-corrosion wax 4520
3 11 2 Cavity sealant 4521
3 11 3 Anti-corrosion wax (in aerosol can) 4523
3 12 Underseal 4524
3 12 1 Permanent underseal -D 314 D36 M2-, grey 4524
3 12 2 Permanent underseal -D 314 D37 M2-, black 4527
3 12 3 Permanent underseal -D 314 D38 M2-, light 4530
3 12 4 Underseal -D 314 D39 A3-, black 4533
3 13 Stone deflector 4535
3 13 1 Stone chip guard -AKR 311 KD1 05- 4535
3 13 2 Stone chip guard -AKR 311 KD1 10- 4537
3 14 Wax-based underseal 4544
3 14 1 Wax-based underseal -D 316 D38 A2- 4544
3 14 2 Wax-based underseal -D 316 000 A1- 4546
3 14 3 Spray wax -D 322 100 M2- 4547
3 15 Sealing materials 4548
3 15 1 Polyurethane adhesive sealant (bonding compound) 4548
3 15 2 Sprayable sealant 4551
3 15 3 Adhesive sealant 4554
3 16 Cleaning agents 4556
3 16 1 Silicone remover 4556
3 16 2 Cleaner for plastics 4558
3 16 3 Cleaner for plastics, anti-static 4559
3 16 4 Industrial dirt remover 4560
3 17 SprayMax system 4561
3 17 1 1-pack anti-corrosion primer 4561
3 17 2 1-pack test paint 4565
3 17 3 1-pack clear coat 4568
3 17 4 1-pack wash primer 4571
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 4575
3 17 6 1-pack Fill-Clean spray can -LLS MAX 112- – Aqua-Premium-System 4583
3 17 7 2-pack surfacer 4590
3 17 8 2-pack HS Performance surfacer 4597
3 17 9 2-pack clear coat 4605
3 17 10 2-pack epoxy primer surfacer 4610
3 17 11 2-pack wash primer 4616
3 17 12 Silicone remover -LLS MAX 007- 4621
3 17 13 Slow-drying silicone remover -LLS MAX 008- 4624
3 17 14 Blender 4626
3 17 15 Adhesion promoter 4628
3 18 Additional materials 4631
3 18 1 Matting additive -ALN 775 106- 4631
3 18 2 Matting additive -LVM 769 810 A2- 4639
3 18 3 Texture additive 4642
3 18 4 Blending additive for Aquaplus 4648
3 18 5 Additive for Aqua Premium 4649
3 18 6 Clear coat colour additive 4649
4 Workshop equipment 4655
4 1 Tools 4655
4 1 1 Spray can filling device -VAS 6425- 4655
4 1 2 Paint thickness tester -VAS 6272- 4656
4 1 3 Paint thickness tester -VAS 6197- 4657
4 1 4 Paint thickness tester -VAS 5278- 4657
4 1 5 Stone chip tester -VAS 5102A- 4658
4 1 6 Pneumatic brush grinder set -VAS 6446- 4659
4 1 7 Brush grinder set -VAS 6776- 4659
4 1 8 Suction feed spray-gun -V A G 1538- 4661
4 1 9 Infrared heater -VAS 6873- 4662
4 1 10 Stand -VAS 6873/1- 4662
4 1 11 Infrared heater -VAS 6874- 4663
4 1 12 Infrared heater -VAS 6875- 4663
4 1 13 Infrared heater -VAS 6876- 4664
4 1 14 Infrared heater -VAS 6877- 4665
4 1 15 Infrared heater -VAS 6878- 4665
4 1 16 Infrared heater -VAS 6879- 4666
4 2 Tack cloths 4667
4 2 1 Tack cloth -VAS 6177- 4667
4 2 2 Buffing cloth, white -VAS 6176- 4667
4 2 3 Professional cleaning cloth -VAS 6006- 4668
D4B80670CC1 Vehicle specific paint information 4669
00 – Technical data 4673
1 Explanation of symbols 4673
1 1 Sanding 4673
1 2 Seam sealing 4673
1 3 Cavity sealing 4675
2 Areas exposed to stone chipping 4676
2 1 Areas exposed to stone chipping – overview 4676
3 Masked sectors 4677
3 1 Masking areas, underbody 4677
4 Seam sealing 4678
4 1 Seam seals, front body 4678
4 2 Seam seals, centre body 4683
4 3 Seam seals, rear body 4685
4 3 1 Seam seals, driver cabin 4685
4 3 2 Seam seals, cargo box 4687
5 Underseal 4693
5 1 Underseal, body – overview with differing layer thickness 4693
5 2 Underseal, protected areas 4694
5 2 1 Underseal, front protected areas 4694
5 2 2 Underseal, centre protected areas 4695
5 2 3 Underseal, rear protected areas 4698
6 Cavity sealing 4701
6 1 Cavity sealing, body – overview 4701
6 2 Cavity sealing, doors and tailboard 4702
7 Anti-corrosion wax 4704
7 1 Anti-corrosion wax overview 4704
7 2 Anti-corrosion wax, front 4705
7 3 Anti-corrosion wax, rear 4706
8 Contrasting colours 4708
8 1 Contrasting colours, equipment version Dark Label 4708
8 2 Contrasting colours, equipment version Canyon 4709
D4B804563F9 Fuel supply system diesel engines 4710
00 – Technical data 4714
1 Safety information 4714
1 1 Safety regulations for working on fuel supply 4714
1 2 Safety measures when working on vehicles with a start/stop system 4714
1 3 Safety precautions when using testers and measuring instruments during a road test 4715
1 4 Safety precautions when working on the cooling system 4715
1 5 Safety precautions when working on exhaust system 4715
2 Identification 4716
2 1 Engine number/engine data 4716
3 Repair notes 4718
3 1 Rules for cleanliness 4718
3 2 General information 4718
3 3 General repair instructions 4719
3 4 Foreign bodies in engine 4719
3 5 Contact corrosion 4719
3 6 Routing and attachment of lines 4720
3 7 Fitting radiator and condensers 4720
3 8 Checking vacuum system 4720
3 9 Assessing quality of diesel fuel 4721
20 – Fuel supply system 4722
1 Filling with incorrect fuel 4722
1 1 Procedure in event of misfuelling 4722
1 1 1 Step 1, engine was started with incorrect fuel 4723
1 1 2 Step 2, engine was not started with incorrect fuel 4723
1 1 3 Step 3, swarf in fuel delivery unit -GX1- and fuel tank 4724
1 1 4 Step 4, no swarf in fuel delivery unit -GX1- and fuel tank 4725
1 1 5 Step 5, there are metal particles in high-pressure pump 4725
1 1 6 Step 6, there are no metal particles in high-pressure pump 4726
2 Fuel 4727
2 1 Assembly overview – fuel tank 4727
2 2 Removing and installing fuel tank 4729
2 2 1 Removing and installing fuel tank, 4-cylinder engine 4729
2 2 2 Removing and installing fuel tank, 6-cylinder engine 4735
2 3 Removing and installing filling connection 4740
2 3 1 Removing and installing filling connection, 4-cylinder engine 4740
2 3 2 Removing and installing filling connection, 6-cylinder engine 4741
3 Fuel delivery unit, fuel gauge sender 4743
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 4743
3 2 Removing and installing fuel delivery unit, fuel gauge sender 4743
3 3 Removing and installing fuel gauge sender -G- 4745
3 3 1 Removing and installing fuel gauge sender -G-, version 1 4745
3 3 2 Removing and installing fuel gauge sender -G-, version 2 4746
3 4 Renewing seal for cap 4747
4 Plug-in connectors 4749
4 1 Separating plug-in connectors 4749
5 Fuel filter 4755
5 1 Assembly overview – fuel filter 4755
5 1 1 Assembly overview – fuel filter without water separator sender -G63-, 4-cylinder engine 4755
5 1 2 Assembly overview – fuel filter with water separator sender -G63-, 4-cylinder engine 4756
5 1 3 Assembly overview – fuel filter without water separator sender -G63-, 6-cylinder engine 4757
5 1 4 Assembly overview – fuel filter with water separator sender -G63-, 6-cylinder engine 4758
5 1 5 Assembly overview – fuel lines (engine), vehicles without water separator sender -G63-, 4-cylinder engine 4760
5 1 6 Assembly overview – fuel lines (engine), vehicles with water separator sender -G63-, 4-cylinder engine 4761
5 1 7 Assembly overview – fuel lines (engine), without water separator sender -G63-, 6-cylinder engine 4762
5 1 8 Assembly overview – fuel lines (engine), with water separator sender -G63-, 6-cylinder engine 4763
5 2 Removing and installing fuel filter 4765
5 2 1 Removing and installing fuel filter, 4-cylinder engine 4765
5 2 2 Removing and installing fuel filter, without water separator sender -G63-, 6-cylinder engine 4767
5 2 3 Removing and installing fuel filter, with water separator sender -G63-, 6-cylinder engine 4769
5 2 4 Removing and installing fuel filter bracket, 6-cylinder engine 4771
6 Accelerator pedal 4773
6 1 Assembly overview – accelerator module 4773
6 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 4773
7 Fuel supply 4775
7 1 Checking fuel system pressurisation pump -G6- 4775
7 1 1 Checking voltage supply of fuel pump (low pressure fuel), 4-cylinder engine 4775
7 1 2 Checking fuel delivery rate of fuel system pressurisation pump -G6-, 4-cylinder engine 4777
7 1 3 Checking low pressure of fuel at high-pressure pump, 4-cylinder engine 4781
7 1 4 Checking volumetric flow at high-pressure pump, 4-cylinder engine 4783
7 1 5 Checking low pressure of fuel at fuel filter, 4-cylinder engine 4787
7 1 6 Checking volumetric flow before fuel filter, 4-cylinder engine 4790
7 1 7 Checking fuel pressure, 6-cylinder engine 4793
7 1 8 Checking fuel delivery rate, 6-cylinder engine 4797
8 Senders and sensors 4802
8 1 Removing and installing water separator sender -G63- 4802
D4B8025555B Electrical system General information 4804
27 – Starter, current supply, CCS 4808
1 Battery 4808
1 1 Fundamentals for batteries 4808
1 2 Warning notices and safety regulations 4808
1 2 1 Dangers when handling vehicle batteries 4808
1 2 2 Safety markings on battery 4809
1 3 Battery load test 4810
1 3 1 Battery with »standard« colour indicator 4810
1 3 2 Battery with »enhanced« colour indicator 4811
1 3 3 Absorbent glass mat battery 4811
1 3 4 Lithium-ion battery (LiFePO4 battery) 4812
1 4 Battery load test 4812
2 Checking battery 4813
2 1 Checking the various types of batteries 4813
2 1 1 Checking a battery with colour indicator 4813
2 1 2 Absorbent glass mat battery 4814
2 1 3 Checking lithium-ion battery (LiFePO4 battery) 4814
2 2 Visual check 4815
2 3 Information about battery replacement and battery gas venting 4816
2 4 Checking colour indicator in battery cover 4817
2 4 1 Checking colour indicator, “3-colour” 4817
2 4 2 Checking colour indicator, “2-colour” 4818
2 5 Battery tester with printer -VAS 6161- 4820
2 5 1 General description – battery tester with printer -VAS 6161- 4820
2 5 2 Device description – battery tester with printer -VAS 6161- 4821
2 5 3 Perform battery test with battery tester with printer -VAS 6161- 4821
2 5 4 Checking genuine Volkswagen battery 4823
2 5 5 Checking non-Volkswagen battery 4823
2 5 6 Carrying out stock maintenance 4824
2 5 7 Comments concerning test print out 4824
2 5 8 Assessing test results 4825
2 6 Battery tester DSS-7814 SET -08 78024-0005-, MAN TGE 4826
2 6 1 Checking starter battery with battery tester DSS-7814 SET -08 78024-0005- 4826
2 6 2 Checking second battery -A1- with battery tester DSS-7814 SET -08 78024-0005- 4828
2 7 Current draw test 4828
2 8 No-load current measurement 4830
2 8 1 General description – no-load current measurement 4830
2 8 2 Inline measurement of no-load current 4832
2 8 3 No-load current measurement on fuses 4835
3 Charging the battery 4839
3 1 Totally discharged batteries 4839
3 2 Battery charger -VAS 5095 A- 4840
3 2 1 General description – battery charger -VAS 5095 A- 4840
3 2 2 Charging battery with battery charger -VAS 5095 A- 4841
3 2 3 Charging exhaustively discharged battery with battery charger -VAS 5095 A- 4843
3 2 4 Charging battery in support mode with battery charger -VAS 5095 A- 4843
3 2 5 Charging battery in trickle charge mode with battery charger -VAS 5095 A- 4845
3 3 Battery charger -VAS 5900- 4846
3 3 1 General description – battery charger -VAS 5900- 4846
3 3 2 Charging battery with battery charger -VAS 5900- 4847
3 3 3 Charging battery in service mode with battery charger -VAS 5900- 4849
3 3 4 Charging exhaustively discharged batteries with battery charger -VAS 5900- 4852
3 3 5 Charging battery in support mode with battery charger -VAS 5900- 4855
3 3 6 Charging battery in trickle charge mode with battery charger -VAS 5900- 4857
3 4 Battery charger -VAS 5900 A- 4858
3 4 1 General description – battery charger -VAS 5900 A- 4858
3 4 2 Charging battery with battery charger -VAS 5900 A- 4859
3 4 3 Charging totally discharged battery with battery charger -VAS 5900 A- 4861
3 4 4 Charging battery in support mode with battery charger -VAS 5900 A- 4864
3 4 5 Mains supply mode with battery charger -VAS 5900 A- 4865
3 5 Battery charger -VAS 5903- 4867
3 5 1 General description – battery charger -VAS 5903- 4867
3 5 2 Charging battery with battery charger -VAS 5903- 4868
3 5 3 Charging battery in refresh charge mode with battery charger -VAS 5903- 4871
3 5 4 Charging totally discharged battery with battery charger -VAS 5903- 4874
3 5 5 Charging battery in support mode with battery charger -VAS 5903- 4876
3 5 6 Charging battery in trickle charge mode with battery charger -VAS 5903- 4878
3 6 Battery charger -VAS 5906- 4879
3 6 1 General description – battery charger -VAS 5906- 4879
3 6 2 Charging battery with battery charger -VAS 5906- 4880
3 7 Battery charger -VAS 5908- 4882
3 7 1 General description – battery charger -VAS 5908- 4882
3 7 2 Auto mode on battery charger -VAS 5908- 4883
3 7 3 Charging battery with battery charger -VAS 5908- 4885
3 7 4 Charging battery in support mode with battery charger -VAS 5908- 4886
3 7 5 VAS I-CHECK current draw test with battery charger -VAS 5908- 4888
3 8 Midtronics INC 940 battery charger (USA/Canada only) 4891
3 8 1 General description of Midtronics INC 940 battery charger 4891
3 8 2 Charging battery with Midtronics INC 940 4892
3 8 3 Rectifying problems with Midtronics INC 940 battery charger 4894
3 9 Battery charger Fronius Acctiva Professional 35A, MAN TGE 4895
3 9 1 General description of battery charger Fronius Acctiva Professional 35A 4895
3 9 2 Charging battery using battery charger Fronius Acctiva Professional 35A 4896
3 10 Solar charger module -VAS 6102A- 4896
3 10 1 Charging battery in trickle charge mode with solar panel -VAS 6102A- 4896
3 11 Charging lithium-ion battery (LiFePO4 battery) 4898
3 11 1 Charging lithium-ion battery (LiFePO4 battery), battery chargers 4898
3 11 2 Charging lithium-ion battery (LiFePO4 battery) using battery charger -VAS 5908-, battery removed 4898
3 11 3 Charging lithium-ion battery (LiFePO4 battery) using battery charger -VAS 5908-, battery installed 4899
3 11 4 Charging lithium-ion battery (LiFePO4 battery) using battery charger -VAS 5908-, trickle charge mode 4901
4 Alternator 4903
4 1 Checking function of poly V-belt pulley with freewheel 4903
5 Alternator 4906
5 1 Checking function of poly V-belt pulley with freewheel 4906
6 Cruise control system (CCS) 4907
6 1 General description – cruise control system (CCS) 4907
6 2 Activating and deactivating cruise control system (CCS) 4907
90 – Gauges, instruments 4908
92 – Windscreen wash/wipe system 4909
1 Washer fluid line hose couplings 4909
1 1 Hose couplings – windscreen and rear window washer system 4909
1 2 Hose couplings – windscreen and rear window washer system 4910
1 3 Hose couplings – headlight washer system 4911
2 Hose repair 4912
2 1 General description – hose repair 4912
2 2 Repairing smooth pipe 4912
2 3 Repairing corrugated pipe 4912
94 – Lights, bulbs, switches – exterior 4915
1 Operation and safety notes for gas discharge lamps 4915
96 – Lights, bulbs, switches – interior 4918
1 Immobiliser 4918
1 1 General description – immobiliser 4918
1 2 Online system test 4919
1 3 Immobiliser control unit -J362- 4919
1 4 Engine control unit -J623- 4919
1 5 Immobiliser reader coil 4919
1 6 Replacement ignition key 4920
1 7 Ignition key – variable code transponder 4920
1 8 New lock set 4920
1 9 New identity on renewing all components 4921
1 10 Adapting ignition key 4921
1 10 1 Adapting ignition key, Caddy 2016 ►, Transporter and Amarok ► 2018 4921
1 10 2 Adapting ignition key, Transporter and Amarok 2019 ► 4921
1 10 3 Adapting ignition key, Amarok 2023 ► 4922
2 12 V socket 4923
2 1 Removing and installing 12 V socket 4923
2 2 Removing and installing socket illumination bulb -L42- 4926
3 Cigarette lighter -U1- 4927
3 1 General description – cigarette lighter -U1- 4927
3 2 Assembly overview – cigarette lighter -U1- 4927
3 3 Removing and installing cigarette lighter socket 4928
3 4 Removing and installing cigarette lighter illumination bulb -L28- 4932
97 – Wiring 4934
1 Vehicle diagnostic, testing and information systems 4934
1 1 General description – vehicle diagnosis, testing and information system 4934
1 2 Connecting vehicle diagnostic tester 4934
2 Wiring harness and connector repairs 4936
2 1 General notes concerning repairs to vehicle electrical system 4936
2 2 Wiring harness repair set 4938
2 2 1 Wiring harness repair set -VAS 1978- 4938
2 2 2 Upgrade kit -VAS 1978/50- 4939
2 2 3 Wiring harness repair set -VAS 1978A- 4939
2 2 4 Release tool set -VAS 1978/35- 4940
2 2 5 Wiring harness repair set -VAS 631 001- 4940
2 2 6 Wiring harness repair set -VAS 631 003- 4941
2 3 Tool descriptions 4942
2 3 1 Special pliers with insert 4942
2 3 2 Release tools for contacts 4942
2 3 3 Assembly tools for single wire seals 4943
2 3 4 Wire stripper -VAS 1978/3- 4943
2 3 5 Hot air blower -VAS 1978/14A- 4945
2 3 6 Crimping pliers -VAS 1978/1A- 4945
2 4 Repairs to electrical wiring harnesses 4947
2 4 1 Notes on repairs to airbag and belt tensioner wiring 4947
2 4 2 Repairing CAN bus wiring 4949
2 4 3 Repair of Flexray wires with sheath 4950
2 4 4 Repair of Flexray wires without sheath 4951
2 4 5 Renewal of aerial wiring 4952
2 4 6 Repairs to electrical wiring with cross sections up to 0 35 mm2 4953
2 4 7 Repairs to 10-mm2 or 16-mm2 wires with single crimp connector 4956
2 4 8 Repairs to 2 5 mm2, 4 mm2 or 6 mm2 aluminium wires with single crimp connector 4962
2 4 9 Wiring open circuit with one repair position 4969
2 4 10 Wiring open circuit with two repair positions 4972
2 5 Repairing fibre optic cables 4974
2 5 1 Notes on repairs to fibre optic cables 4974
2 5 2 Preparing fibre optic cable 4975
2 5 3 Detaching fibre optic cable from cable harness connector 4981
2 6 Repair of aerial wires 4982
2 6 1 General information 4982
2 6 2 Assembly overview – aerial wire 4983
2 6 3 Installing a new aerial wire 4983
2 6 4 Repair set, aerial cable -VAS 6720- 4984
2 7 Repairing connector housings and connectors 4996
2 7 1 Notes on repairs to connector housings and connectors 4996
2 7 2 Repairing contacts in connector housings 4996
2 7 3 Installing single wire seals 4998
2 7 4 Repairing connector housings using cut and clamp method 5001
2 8 Releasing and dismantling connector housings 5002
2 8 1 Notes on releasing and dismantling connector housings 5002
2 8 2 Secondary locking element 5002
2 8 3 Primary locking element 5003
2 8 4 Round connector systems 5004
2 8 5 Flat connector systems 5005
2 8 6 Special connector systems 5007
3 Cleaning contact surfaces 5010
3 1 General description – contact surface cleaning set -VAS 6410- 5010
3 2 Servicing ring terminals 5010
3 3 Repairing threaded electrical connections 5013
3 4 Cleaning battery terminal clamp and battery terminal 5015
3 5 Preserving threaded electrical connections 5016
4 Renewing lambda probe 5018
4 1 General notes – renewing lambda probe 5018
4 2 Types of protective tube on universal lambda probes 5018
4 3 Renewing LSF lambda probe (4-pin) 5019
4 4 Renewing LSU lambda probe (6-pin) 5020
5 ESD workplace -VAS 6613- 5022
5 1 Use of ESD workplace -VAS 6613- 5022
D4B8027068B Air conditioning systems with refrigerant R134a General information 5023
00 – Technical data 5029
1 Safety information 5029
1 1 Safety precautions when working on air conditioning systems 5029
1 2 Safety precautions when working on high-voltage system 5030
1 3 Safety precautions when working in the vicinity of high-voltage components 5030
1 4 Safety precautions when tow-starting or towing 5031
2 Repair instructions 5032
2 1 Rules for cleanliness when working on high-voltage system 5032
3 General information on air conditioning 5033
3 1 Other reference material 5033
3 2 Basics of air conditioning technology 5033
3 2 1 Physical principles: 5033
3 2 2 Heat always flows from a warmer to a colder substance 5034
3 2 3 Pressure and boiling point 5034
3 3 Vapour pressure table for refrigerant R134a 5035
3 4 Refrigerant R134a 5036
3 4 1 Physical data of refrigerant R134a 5036
3 4 2 Critical point 5036
3 4 3 Environmental aspects of refrigerant R134a 5037
3 5 Properties of refrigerant R134a 5037
3 5 1 Trade names and designations 5037
3 5 2 Colour 5037
3 5 3 Vapour pressure 5037
3 5 4 Physical properties of R134a 5038
3 5 5 Effects on metal 5038
3 5 6 Critical temperature and critical pressure 5038
3 5 7 Union 5038
3 5 8 Charge factor 5038
3 5 9 Detecting leaks 5038
3 6 Refrigerant oil 5039
3 6 1 Properties of refrigerant oil 5039
3 7 Comfort 5040
3 7 1 Environmental aspects 5040
3 8 How air conditioning works 5041
3 9 General work safety 5041
3 9 1 Product characteristics 5041
3 9 2 Handling refrigerants 5042
3 9 3 Wear safety goggles 5042
3 9 4 Wear protective gloves and apron 5042
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 5042
3 9 6 Do not breath in refrigerant vapour 5042
3 9 7 Absolutely NO SMOKING 5042
3 9 8 Welding and soldering on refrigeration systems 5042
3 9 9 Pungent smell 5043
3 9 10 First aid 5043
3 9 11 Handling pressure vessels 5043
3 9 12 Do not heat up above 50°C 5043
3 9 13 Do not expose to uncontrolled heat 5043
3 9 14 Seal empty tanks/containers 5043
3 9 15 Safety instructions for using extraction and charging equipment 5044
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 5044
3 11 Basics for working on refrigerant circuit 5045
3 11 1 O-ring 5046
3 11 2 Before operating the air conditioning system after recharging with refrigerant 5047
4 General information on refrigerant circuit 5048
4 1 Components of refrigerant circuit 5048
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 5048
4 1 2 Air conditioning system compressor with magnetic clutch: 5048
4 1 3 Air conditioner compressor without magnetic clutch 5049
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 5050
4 1 5 Electrical air conditioner compressor for high-voltage system 5051
4 1 6 Condenser 5052
4 1 7 evaporator 5052
4 1 8 Reservoir 5053
4 1 9 Restrictor 5053
4 1 10 Receiver 5054
4 1 11 Expansion valve 5055
4 1 12 O-ring 5056
4 1 13 Pipes and hoses of refrigerant circuit 5056
4 1 14 High-pressure safety valve 5056
4 2 Design of refrigerant circuit 5059
4 2 1 Refrigerant circuit with expansion valve and evaporator 5059
4 2 2 Refrigerant circuit with restrictor and reservoir 5059
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 5060
4 3 1 Evacuation and charging valve with Schrader valve 5060
4 3 2 Extraction and charging valve, high-pressure side 5061
4 3 3 Extraction and charging valve, low-pressure side 5062
4 4 Switches and senders in refrigerant circuit and related connections 5062
4 4 1 High-pressure switch for air conditioning system -F23- 5062
4 4 2 High-pressure switch for magnetic clutch -F118- 5063
4 4 3 Low-pressure switch for air conditioning system -F73- 5063
4 4 4 Connections with valve for switches in refrigerant circuit 5064
4 4 5 Air conditioning system pressure switch -F129- 5064
4 4 6 High-pressure sender -G65- 5065
4 4 7 Refrigerant pressure and temperature sender -G395- 5066
4 4 8 Air conditioner compressor regulating valve -N280- 5066
4 5 Electrical components not installed in refrigerant circuit 5067
4 5 1 Control and regulating unit for air conditioning system -J127- 5067
4 5 2 Radiator fan control unit -J293- 5067
4 5 3 Radiator fan control unit -J293- 5068
4 5 4 Temperature switch for evaporator -E33- 5069
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 5069
4 6 Pressures and temperatures in refrigerant circuit 5070
4 7 Refrigerant circuit with expansion valve 5070
4 8 Refrigerant circuit with restrictor and reservoir 5072
4 9 Test and measurement work that can be performed using a pressure gauge 5074
4 9 1 Pressure gauges enable the following test and measurement work 5074
4 10 Air conditioner service and recycling equipment 5075
4 10 1 Classification of extraction and charging devices in groups 5075
4 10 2 Charging devices that do not require a permit 5075
4 11 Notes to repairs on refrigerant circuit 5076
5 Laws and regulations 5077
5 1 Laws and regulations 5077
5 2 Recycling and refuse law 5082
5 2 1 Disposal of refrigerant and refrigerant machine oil 5082
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 5083
5 4 Maintaining records on refrigerant 5083
6 Refrigerant circuit 5084
6 1 Important repair notes on air conditioning 5084
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 5084
7 Working with the air conditioner service station 5085
7 1 Important instructions for working with the air conditioner service station 5085
7 2 Connecting a air conditioner service station for measuring and testing 5086
7 3 Drain the refrigerant circuit using the air conditioner service station 5087
7 4 Evacuating refrigerant circuit using air conditioner service station 5087
7 5 Filling refrigerant circuit with air conditioner service station 5089
7 6 Bringing air conditioning system into service after charging 5090
7 7 Charging the container in the air conditioning service station with refrigerant 5090
7 8 Emptying air conditioner service station 5091
8 Detecting leaks in refrigerant circuit 5092
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 5093
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 5094
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 5095
9 Clearing refrigerant circuit of contaminants 5103
9 1 Vehicles with high-voltage system (hybrid vehicles) 5103
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 5104
9 2 1 Flushing refrigerant circuit 5106
9 3 Flushing refrigerant circuit with refrigerant R134a 5106
9 3 1 Principle circuit diagrams for various purging circuits 5114
9 3 2 Purging electrical air conditioner compressor 5120
9 3 3 Adapters for setting up flushing circuits 5124
10 Clearing refrigerant circuit of contaminants, commercial vehicles 5138
10 1 Vehicles with high-voltage system 5138
10 2 Flushing refrigerant circuit with refrigerant R134a 5139
10 3 Adapters for setting up flushing circuits 5139
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 5143
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 5143
10 5 1 Connection diagram for flushing circuit 5143
10 5 2 Procedure for setting up and flushing refrigerant circuit 5144
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 5149
10 6 1 Connection diagram for flushing circuit 5149
10 6 2 Procedure for setting up and flushing refrigerant circuit 5150
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 5156
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 5156
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 5157
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 5158
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 5165
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 5173
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 5174
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 5175
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 5176
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 5181
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 5190
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 5190
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 5191
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 5192
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 5197
11 Complaints 5206
11 1 Possible complaints about refrigerant circuit 5206
11 1 1 Conditions for testing: 5206
11 1 2 Possible complaints 5206
11 2 Odours from heater and air conditioning unit 5207
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 5207
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 5208
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 5209
12 Connecting the air conditioning service station 5210
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 5210
12 1 1 Connecting a air conditioner service station for measuring and testing 5210
13 Checking pressures on vehicles 5211
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 5211
13 1 1 Conditions for testing 5211
13 1 2 Checking pressures 5212
13 1 3 Continuation of checking pressures 5214
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 5215
13 2 1 Specifications: 5215
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 5219
13 3 1 Specifications: 5219
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 5224
13 4 1 Conditions for testing 5224
13 4 2 Check 5224
13 4 3 Specified values 5224
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 5225
13 5 1 Specifications: 5225
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 5230
13 6 1 Specifications: 5230
13 7 With expansion valve, receiver and electrical air conditioner compressor 5241
14 Renewing components 5242
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 5243
14 1 1 If the refrigerant circuit was completely empty 5243
14 1 2 If there is still refrigerant in the refrigerant circuit 5245
14 2 Renew the air conditioner compressor 5245
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 5245
14 2 2 Leaks or internal damage (e g noises or lack of power) 5247
14 3 Replace receiver or reservoir and restrictor 5247
14 3 1 After flushing contaminants from refrigerant circuit, e g due to moisture intrusion (because refrigerant circuit was open for a longer period of time) or due to soiling 5247
14 3 2 Without needing to flush contaminants from refrigerant circuit (e g damage in an accident); no refrigerant has escaped and no moisture or dirt has entered refrigerant circuit 5249
15 Testing equipment and tools 5250
15 1 List of test equipment, tools and materials 5250
15 1 1 Tools and materials available from regional sales centre or importer 5250
15 1 2 Tools and materials commercially available 5251
15 1 3 Tools and materials available from regional sales centre or importer 5252
15 1 4 Tools and materials commercially available 5258
D4B80255564 Communication 5261
00 – Technical data 5265
1 Repair instructions 5265
1 1 General repair instructions 5265
1 2 Routing and attachment of lines 5265
1 3 Notes on repair of CAN bus wiring 5265
1 4 General information 5266
1 4 1 Notes on performing repair work on communication systems 5266
1 4 2 General notes on operating mobile telephones and two-way radios 5267
1 4 3 Implementation of suppression measures 5268
1 4 4 Assembly overview – battery, transmitter and receiver unit, fuse and wiring harness 5268
1 4 5 Transmitting power – aerial systems 5269
91 – Communication 5271
1 Components/control units 5271
1 1 Removing and installing emergency call module control unit and communication unit -J949- 5271
1 2 Removing and installing loudspeaker for emergency call module -R335- 5275
1 3 Removing and installing emergency assistance call button -E276- 5276
2 Sound system 5278
2 1 Components of sound system 5278
2 2 Removing and installing front treble loudspeakers -R20-/-R22- 5278
2 3 Removing and installing rear mid-range loudspeakers 5280
2 4 Removing and installing front bass loudspeakers -R21-/-R23- 5281
3 Aerial systems 5283
3 1 Components of aerial systems 5283
3 2 Overview of fitting locations – aerial systems 5283
3 2 1 Overview of fitting locations – aerial systems, up to model year 2016, with preparation for radio 5283
3 2 2 Overview of fitting locations – aerial systems, up to model year 2016, “CD MP3”, “CD MP3 SD USB Bluetooth”/“RCD 210”/“RCD 320 G” 5284
3 2 3 Overview of fitting locations – aerial systems, up to model year 2016, “RCD 310”/“RCD 510” 5285
3 2 4 Overview of fitting locations – aerial systems, up to model year 2016, “RNS 315” 5286
3 2 5 Overview of fitting locations – aerial systems, from model year 2017 onwards 5287
3 3 Removing and installing aerial module 5289
3 3 1 Removing and installing aerial for AM/FM radio reception in left exterior mirror 5289
3 3 2 Removing and installing aerial for FM 2 radio reception in right exterior mirror 5291
3 4 Removing and installing GPS aerial 5293
3 5 Removing and installing roof aerial 5295
4 Radio 5298
4 1 Overview of radio 5298
4 1 1 Overview of radio, up to model year 2016, “CD MP3” and “CD MP3 SD USB Bluetooth” 5298
4 1 2 Overview of radio, up to model year 2016, “RCD 210” 5300
4 1 3 Overview of radio, up to model year 2016, “RCD 310” 5301
4 1 4 Overview of radio, up to model year 2016, “RCD 320 G” 5302
4 1 5 Overview of radio systems up to model year 2016, “RCD 510” 5303
4 1 6 Overview of radio, from model year 2017 onwards, “RCD 230 G” 5305
4 1 7 Overview of radio, from model year 2017 onwards, “Composition Audio” 5307
4 1 8 Overview of radio, from model year 2017 onwards, “Composition Colour” 5308
4 1 9 Overview of radio, from model year 2017 onwards, “Composition Media and Discover Media” 5310
4 2 Overview of fitting locations – radio 5313
4 2 1 Overview of fitting locations – radio, up to model year 2016, “CD MP3” and “CD MP3 SD USB Bluetooth” 5313
4 2 2 Overview of fitting locations – radio, up to model year 2016, “RCD 210” 5314
4 2 3 Overview of fitting locations – radio, up to model year 2016, “RCD 310” 5315
4 2 4 Overview of fitting locations – radio, up to model year 2016, “RCD 320 G” 5316
4 2 5 Overview of fitting locations – radio, up to model year 2016, “RCD 510” 5317
4 2 6 Overview of fitting locations – radio, from model year 2017 onwards 5318
4 3 Assembly overview – radio 5319
4 3 1 Assembly overview – radio, from model year 2017 onwards 5319
4 4 Removing and installing radio 5320
4 4 1 Removing and installing radio, up to model year 2016, “CD MP3” and “CD MP3 SD USB Bluetooth” 5320
4 4 2 Removing and installing radio, up to model year 2016, “RCD 210”, “RCD 310”, “RCD 510”, “RCD 320 G” 5324
4 4 3 Removing and installing radio, from model year 2017 onwards 5328
4 5 Pin assignment 5330
4 5 1 Pin assignment, up to model year 2016, “CD MP3” and “CD MP3 SD USB Bluetooth” 5330
4 5 2 Pin assignment, up to model year 2016, “RCD 210” 5332
4 5 3 Pin assignment, up to model year 2016, “RCD 310” 5335
4 5 4 Pin assignment, up to model year 2016, “RCD 320 G” 5338
4 5 5 Pin assignment, up to model year 2016, “RCD 510” 5341
4 5 6 Pin assignment, from model year 2017 onwards, “RCD 230 G” 5345
4 5 7 Pin assignment, from model year 2017 onwards, “Composition Audio” 5348
4 5 8 Pin assignment, from model year 2017 onwards, “Composition Media and Discover Media” 5350
5 Telephone system 5355
5 1 Overview of telephone system 5355
5 1 1 Overview of telephone system, from model year 2017 onwards 5355
5 2 Preparation for mobile telephone 5355
5 2 1 Preparation for mobile telephone, from model year 2017 onwards 5355
5 3 Overview of fitting locations – telephone system 5356
5 3 1 Overview of fitting locations – telephone system, from model year 2017 onwards 5356
5 4 Removing and installing telephone microphone -R38- 5357
5 4 1 Removing and installing telephone microphone -R38-, up to model year 2016 5357
5 5 Removing and installing telephone controls control unit -J738- 5358
5 5 1 Removing and installing telephone controls control unit -J738-, vehicles up to 06 2012 5358
5 5 2 Removing and installing telephone controls control unit -J738-, vehicles from 07 2012 up to and inc model year 2016 5359
6 Navigation system 5362
6 1 Overview of navigation system 5362
6 1 1 Overview of navigation system, radio navigation system “RNS 315” 5362
6 1 2 Overview of navigation system, radio navigation system “RNS 510” 5364
6 1 3 Overview of navigation system, from model year 2017 onwards 5365
6 2 Overview of fitting locations – navigation system 5365
6 2 1 Overview of fitting locations – navigation system, radio navigation system “RNS 315” 5365
6 2 2 Overview of fitting locations – navigation system, radio navigation system “RNS 510” 5367
6 2 3 Overview of fitting locations – navigation system, from model year 2017 onwards 5369
6 3 Pin assignment 5370
6 3 1 Pin assignment, radio navigation system “RNS 315” 5370
6 3 2 Pin assignment, radio navigation system “RNS 510” 5375
6 3 3 Pin assignment, from model year 2017 onwards 5380
6 4 Removing and installing control unit for navigation system 5380
6 4 1 Removing and installing control unit for navigation system, radio navigation system “RNS 315” 5380
6 4 2 Removing and installing control unit for navigation system, radio navigation system “RNS 510” 5383
6 4 3 Removing and installing control unit for navigation system, from model year 2017 onwards 5387
7 Reversing camera system 5388
7 1 Overview of reversing camera system 5388
7 1 1 Overview of reversing camera system, up to model year 2016 5388
7 1 2 Overview of reversing camera system, from model year 2017 onwards 5389
7 2 Overview of fitting locations – reversing camera system 5389
7 2 1 Overview of fitting locations – reversing camera system, up to model year 2016 5389
7 2 2 Overview of fitting locations – reversing camera system, from model year 2017 onwards 5390
7 3 Removing and installing reversing camera -R189- 5392
7 3 1 Removing and installing reversing camera -R189-, up to model year 2016 5392
7 3 2 Removing and installing reversing camera housing, up to model year 2016 5393
7 3 3 Removing and installing reversing camera -R189-, from model year 2017 onwards 5394
7 3 4 Removing and installing reversing camera housing, from model year 2017 onwards 5395
7 4 Calibrating reversing camera system 5396
7 4 1 Calibrating reversing camera system, up to model year 2016 5396
7 5 Removing and installing reversing camera system control unit -J772- 5403
7 5 1 Removing and installing reversing camera system control unit -J772-, up to model year 2016 5403
7 5 2 Coding reversing camera system control unit -J772- 5405
8 Multifunction steering wheel 5406
8 1 Overview of multifunction steering wheel 5406
8 1 1 Overview of multifunction steering wheel, vehicles up to 06 2013 5406
8 1 2 Overview of multifunction steering wheel, vehicles from 07 2013 up to and inc model year 2016 5407
8 1 3 Overview of multifunction steering wheel, from model year 2017 onwards 5408
8 2 Assembly overview – multifunction steering wheel 5408
8 2 1 Assembly overview – multifunction steering wheel, vehicles up to 06 2013 5408
8 2 2 Assembly overview – multifunction steering wheel, vehicles from 07 2013 up to and inc model year 2016 5409
8 2 3 Assembly overview – multifunction steering wheel, as of model year 2017 5410
8 3 Removing and installing multifunction buttons in steering wheel -E441-/-E440- 5411
8 3 1 Removing and installing multifunction buttons in steering wheel -E441-/-E440-, vehicles up to 06 2013 5411
8 3 2 Removing and installing multifunction buttons in steering wheel -E441-/-E440-, vehicles from 07 2013 up to and inc model year 2016 5413
8 3 3 Removing and installing multifunction buttons in steering wheel -E441-/-E440-, as of model year 2017 5414
8 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 5418
8 4 1 Removing and installing Tiptronic switch in steering wheel -E439-/-E438-, as of model year 2017 5418
8 5 Removing and installing multifunction steering wheel control unit -J453- 5419
8 5 1 Removing and installing multifunction steering wheel control unit -J453-, vehicles up to 06 2013 5419
8 5 2 Removing and installing multifunction steering wheel control unit -J453-, vehicles from 07 2013 up to and inc model year 2016 5420
9 Connection for external multimedia devices 5422
9 1 Connectors – connection for external multimedia devices 5422
9 1 1 Connectors – connection for external multimedia devices, up to model year 2016 5422
9 1 2 Connectors – connection for external multimedia devices, from model year 2017 onwards 5422
9 2 Removing and installing connection for external audio sources -R199- 5423
9 2 1 Removing and installing connection for external audio sources -R199-, up to model year 2016 5423
9 2 2 Removing and installing connection for external audio sources -R199-, from model year 2017 onwards 5424
10 Online services 5425
10 1 Components of Car-Net 5425
10 2 Overview of fitting locations – mobile online services 5428
10 3 Commissioning ERA Glonass 5429
D4B80260554 4 cylinder diesel engine (2 0 l engine common rail) 5431
00 – Technical data 5437
1 Safety information 5437
1 1 Safety precautions when working on fuel system 5437
1 2 Safety regulations for working on fuel supply 5438
1 3 Safety precautions when working on the cooling system 5439
1 4 Safety precautions when using testers and measuring instruments during a road test 5440
2 Identification 5441
2 1 Engine number/engine data 5441
3 Repair instructions 5443
3 1 General notes 5443
3 2 Rules for cleanliness 5444
3 3 Instructions for working on fuel system 5444
3 4 Notes on hose connections with screw-type clips 5446
10 – Removing and installing engine 5448
1 Removing and installing engine 5448
1 1 Removing engine 5448
1 2 Securing engine on engine and gearbox support 5464
1 3 Installing engine 5466
2 Assembly mountings 5470
2 1 Assembly overview – assembly mountings 5470
13 – Crankshaft group 5474
1 Cylinder block (pulley end) 5474
1 1 Assembly overview – cylinder block (pulley end) 5474
1 2 Assembly overview – sealing flange, belt pulley end 5476
1 3 Assembly overview – poly V-belt drive 5477
1 3 1 Assembly overview – poly V-belt drive 5477
1 3 2 Assembly overview – poly V-belt drive, vehicles without A/C system 5480
1 3 3 Assembly overview – cover for poly V-belt 5483
1 4 Removing and installing poly-V belt 5483
1 4 1 Removing and installing poly-V belt 5483
1 4 2 Removing and installing cover for poly V-belt 5486
1 5 Removing and installing tensioner for poly V-belt 5487
1 6 Removing and installing bracket for ancillaries 5488
1 7 Removing and installing vibration damper 5489
1 8 Renewing crankshaft oil seal for pulley end 5490
1 9 Removing and installing sealing flange on pulley end 5493
2 Cylinder block, gearbox end 5498
2 1 Assembly overview – cylinder block, gearbox end 5498
2 2 Removing and installing flywheel 5500
2 3 Removing and installing sealing flange on gearbox side 5502
2 3 1 Removing and installing sealing flange, crankshaft flange with 6 bolting points 5502
2 3 2 Removing and installing sealing flange, crankshaft flange with 8 bolting points 5511
2 4 Removing and installing drive plate 5521
3 Crankshaft 5524
3 1 Assembly overview – crankshaft 5524
3 2 Crankshaft dimensions 5525
3 3 Measuring axial clearance of crankshaft 5526
3 4 Measuring radial clearance of crankshaft 5527
3 5 Renewing needle bearing in crankshaft 5527
4 Auxiliary drive 5530
4 1 Assembly overview – auxiliary drive 5530
4 2 Retrofitting preparation for ancillary drive 5530
5 Pistons and conrods 5533
5 1 Assembly overview – pistons and conrods 5533
5 2 Checking pistons and cylinder bores 5535
5 3 Measuring piston projection at TDC 5537
5 4 Checking radial clearance of conrods 5539
5 5 Separating new conrod 5539
15 – Cylinder head, valve gear 5541
1 Cylinder head 5541
1 1 Assembly overview – cylinder head 5541
1 2 Assembly overview – cylinder head cover 5545
1 3 Removing and installing cylinder head 5549
1 4 Removing and installing cylinder head cover 5559
1 5 Removing and installing injector seals 5567
1 6 Removing and installing vacuum pump 5568
1 7 Checking compression 5570
2 Toothed belt drive 5572
2 1 Assembly overview – toothed belt 5572
2 2 Removing and installing toothed belt 5574
3 Fully enclosing toothed belt guard 5586
3 1 Assembly overview – fully enclosing toothed belt guard 5586
3 2 Removing and installing front toothed belt guard (fully enclosing) 5589
3 2 1 Removing and installing front toothed belt guard (fully enclosing) 5589
3 2 2 Removing and installing lower toothed belt guard (fully enclosed) 5592
3 2 3 Removing and installing rear toothed belt guard (fully enclosing) 5593
4 Air supply for toothed belt drive 5598
4 1 Assembly overview – air supply for toothed belt drive 5598
4 2 Removing and installing blower of air supply for toothed belt drive 5598
4 3 Removing and installing air filter housing of air supply for toothed belt drive 5599
4 4 Removing and installing console of air supply for toothed belt drive 5600
5 Valve gear 5601
5 1 Assembly overview – valve gear 5601
5 2 Measuring axial play of camshaft 5604
5 3 Measuring radial play of camshaft 5605
5 4 Removing and installing camshaft 5605
5 5 Removing and installing camshaft oil seal 5615
5 5 1 Distinguishing between different camshaft oil seals 5615
5 5 2 Removing and installing camshaft oil seal, type A 5615
5 5 3 Removing and installing camshaft oil seal, type B 5618
5 6 Checking hydraulic compensation elements 5621
5 7 Removing and installing valve stem oil seals 5621
6 Inlet and exhaust valves 5627
6 1 Reworking valve seats 5627
6 2 Checking valve guides 5627
6 3 Valve dimensions 5628
17 – Lubrication 5629
1 Sump, oil pump 5629
1 1 Assembly overview – sump/oil pump 5629
1 2 Removing and installing oil sump 5631
1 3 Removing and installing oil pump 5639
1 3 1 Removing and installing oil pump, vehicles without balance shaft module 5639
1 3 2 Removing and installing oil pump, vehicles with balancer shaft module 5640
1 4 Removing and installing oil level and oil temperature sender -G266- 5641
1 5 Removing and installing dipstick tube 5642
2 Engine oil cooler 5644
2 1 Checking engine oil cooler for leaks 5644
3 Oil filter, oil pressure switch 5647
3 1 Assembly overview – oil filter 5647
3 2 Removing and installing oil filter housing 5649
3 3 Removing and installing oil pressure switch -F1- 5652
3 4 Checking oil pressure and oil pressure switch 5653
4 Oil circuit 5657
4 1 Removing and installing oil supply line, bi-turbo 5657
4 2 Removing and installing oil pressure line for turbocharger, mono-turbo 5660
5 Balancer shaft module 5663
5 1 Assembly overview – balancer shaft module 5663
5 2 Removing and installing balance shaft module 5667
5 2 1 Removing balancer shaft module 5667
5 2 2 Installing a new balancer shaft module 5669
5 2 3 Installing a previously used balancer shaft module again 5674
19 – Cooling 5676
1 Cooling system/coolant 5676
1 1 Connection diagram – coolant hoses 5676
1 1 1 Coolant hose schematic diagram for vehicles with auxiliary heater, 103 kW and 132 kW engines (emission standards EU 5 and EU 6) 5676
1 1 2 Coolant hose schematic diagram for vehicles with auxiliary heater, 90 kW and 120 kW engines (emission standard EU 5) 5677
1 1 3 Coolant hose schematic diagram for vehicles with auxiliary heater (EU 3 and EU 4 emissions standards) 5678
1 1 4 Coolant hose schematic diagram for vehicles with auxiliary heater (EU 5 and EU 6 emissions standards) 5679
1 1 5 Coolant hose schematic diagram for vehicles with auxiliary heater (EU 3 and EU 4 emissions standards) 5680
1 2 Assembly overview – coolant hoses 5681
1 3 Checking cooling system for leaks 5683
1 4 Draining and adding coolant 5685
1 4 1 Draining and adding coolant 5685
1 4 2 Charging the cooling system in the case of emergency 5692
2 Coolant pump, regulation of cooling system 5695
2 1 Assembly overview –coolant pump, thermostat 5695
2 2 Assembly overview – electric coolant pump 5696
2 2 1 Assembly overview – electric coolant pump, continued coolant circulation pump on radiator cowl 5696
2 2 2 Assembly overview – electric coolant pump, continued coolant circulation pump on engine 5696
2 2 3 Assembly overview – electric coolant pump, circulation pump 5697
2 3 Removing and installing coolant pump 5698
2 3 1 Removing and installing coolant pump 5698
2 3 2 Removing and installing coolant pump, vehicles with fully enclosing toothed belt guard 5700
2 4 Removing and installing 4/2-way valve with thermostat 5702
2 5 Removing and installing coolant temperature sender -G62- 5708
2 6 Removing and installing radiator outlet coolant temperature sender -G83- 5709
2 7 Removing and installing electric coolant pump 5711
2 7 1 Removing and installing continued coolant circulation pump -V51-, fitting location on radiator cowl 5711
2 7 2 Removing and installing continued coolant circulation pump -V51-, fitting location on engine 5713
2 7 3 Removing and installing recirculation pump -V55- 5715
2 8 Removing and installing Y-thermostat 5716
3 Radiator, radiator fan 5719
3 1 Assembly overview – radiator/radiator fan 5719
3 2 Assembly overview – radiator cowl and radiator fan 5721
3 3 Removing and installing radiator 5721
3 4 Removing and installing radiator cowl with radiator fan 5725
21 – Turbocharging/supercharging 5728
1 Turbocharger 5728
1 1 Assembly overview – turbocharger 5728
1 1 1 Assembly overview – turbocharger, bi-turbo 5728
1 1 2 Assembly overview – turbocharger, single turbo 5732
1 1 3 Assembly overview – dismantling turbocharger, bi-turbo 5735
1 2 Removing and installing turbocharger 5737
1 2 1 Removing and installing turbocharger, single turbo 5737
1 2 2 Removing and installing turbocharger, bi-turbo 5742
1 3 Renewing seal between bi-turbo turbine housings 5747
1 4 Checking vacuum unit for turbocharger, bi-turbo 5751
1 5 Checking regulating flap potentiometer -G584- 5753
1 6 Removing and installing charge pressure sender 2 -G447- 5756
1 7 Removing and installing vacuum unit for turbocharger 5758
1 7 1 Removing and installing regulating flap potentiometer -G584- 5758
1 7 2 Removing and installing vacuum unit for turbocharger 5766
1 8 Removing and installing charge pressure control solenoid valve -N75- 5773
2 Charge air system 5775
2 1 Assembly overview – charge air system 5775
2 2 Removing and installing charge air cooler 5776
2 3 Removing and installing charge air pressure sender -G31-/intake air temperature sender -G42- 5777
2 4 Removing and installing exhaust gas flap valve -N220- 5778
2 5 Checking charge air system for leaks 5779
23 – Mixture preparation – injection 5783
1 Injection system 5783
1 1 Schematic overview – fuel system 5783
1 2 Overview of fitting locations – injection system 5784
1 3 Assembly overview – fuel system 5793
1 4 Checking fuel system for leaks 5799
1 5 Filling/bleeding fuel system 5800
2 Vacuum system 5801
2 1 Connection diagram – vacuum system 5801
2 1 1 Vacuum hose schematic diagram, vehicles without 3/2 way valve 5801
2 1 2 Vacuum hose schematic diagram, vehicles with 3/2 way valve 5803
2 1 3 Vacuum hose schematic diagram, right side of engine, vehicles without 3/2 way valve 5805
2 1 4 Vacuum hose schematic diagram, right side of engine, vehicles with 3/2 way valve 5806
2 1 5 Vacuum hose schematic diagram, left side of engine, vehicles without 3/2 way valve 5806
2 1 6 Vacuum hose schematic diagram, left side of engine, vehicles with 3/2 way valve 5807
2 2 Checking vacuum system 5807
2 2 1 Quick check of vacuum system 5807
2 2 2 Checking vacuum hoses leading to non-return valve, solenoid valves -N220- and -N75- changeover valve-N345- 5810
2 2 3 Checking vacuum hose leading to changeover valve for exhaust gas recirculation cooler -N345- 5812
2 2 4 Checking vacuum hose to vacuum unit on turbocharger 5814
2 2 5 Checking vacuum hose to vacuum unit on exhaust gas recirculation cooler 5815
3 Injectors/high-pressure accumulator (rail) 5817
3 1 Overview of injectors 5817
3 2 Adapting correction values for injectors 5817
3 3 Removing and installing injectors 5818
3 3 1 Removing and installing injectors (piezo injectors) 5818
3 3 2 Removing and installing injectors (solenoid valves) 5824
3 4 Removing and installing high-pressure lines 5829
3 5 Removing and installing fuel rail 5832
3 6 Checking return flow rate of injectors with engine running 5836
4 Air filter 5840
4 1 Assembly overview – air filter housing 5840
4 2 Removing and installing air filter housing 5843
5 Intake manifold 5845
5 1 Assembly overview – intake manifold 5845
5 2 Removing and installing intake manifold 5846
5 3 Removing and installing throttle valve module -GX3- 5850
6 Senders and sensors 5852
6 1 Removing and installing air mass meter -G70- 5852
6 2 Removing and installing exhaust pressure sensor 1 -G450- 5853
6 3 Removing and installing fuel pressure regulating valve -N276- 5855
6 4 Checking fuel pressure regulating valve -N276- 5858
6 5 Removing and installing fuel pressure sender -G247- 5860
7 Engine/motor control unit 5864
7 1 Removing and installing engine control unit -J623- 5864
8 High-pressure pump 5865
8 1 Assembly overview – high-pressure pump 5865
8 2 Removing and installing high-pressure pump 5866
8 2 1 Removing and installing high-pressure pump 5866
8 2 2 Checking high-pressure pump 5869
26 – Exhaust system 5873
1 Exhaust pipes and silencers 5873
1 1 Assembly overview – silencers 5873
1 2 Checking exhaust system for leaks 5876
1 3 Aligning exhaust system free of stress 5876
2 Emission control 5878
2 1 Assembly overview – emission control 5878
2 1 1 Assembly overview – emission control, diesel particulate filter 5878
2 1 2 Assembly overview – emission control, catalytic converter 5880
2 2 Removing and installing particulate filter 5882
2 3 Removing and installing catalytic converter 5889
3 Exhaust gas recirculation 5893
3 1 Assembly overview – exhaust gas recirculation 5893
3 1 1 Assembly overview – exhaust gas recirculation, version A 5893
3 1 2 Assembly overview – exhaust gas recirculation, version B 5894
3 2 Removing and installing exhaust gas recirculation cooler 5895
3 2 1 Removing and installing exhaust gas recirculation cooler, version A 5895
3 2 2 Removing and installing exhaust gas recirculation cooler, version B 5901
3 3 Removing and installing exhaust gas recirculation valve 1 -GX5- 5904
3 4 Removing and installingchangeover valve for exhaust gas recirculation cooler -N345- 5905
3 5 Pressure loss test for exhaust gas recirculation cooler 5906
28 – Glow plug system 5910
1 Glow plug system 5910
1 1 Assembly overview – glow plug system 5910
1 2 Checking glow plug system 5912
1 3 Removing and installing glow plug 5912
1 4 Removing and installing engine speed sender -G28- 5915
1 5 Removing and installing Hall sender -G40- 5917
1 5 1 Removing and installing Hall sender -G40- 5917
1 5 2 Removing and installing Hall sender -G40-, vehicles with fully enclosing toothed belt guard 5919
D4B80331633 General body repairs interior 5921
00 – Technical data 5927
1 Safety information 5927
1 1 Safety measures when working on vehicles with a start/stop system 5927
1 2 Safety precautions when using testing and measuring instruments during a road test 5928
1 3 Safety precautions when working on passenger protection systems 5928
1 4 Specifications for transport, storage and installation of passenger protection components 5930
1 5 Additional safety regulations for side airbag 5930
1 6 Safety instructions for airbag 5931
1 7 Additional safety instructions for curtain airbag 5931
1 8 Safety regulations for crash sensors (pressure sensors) for front side airbags 5932
1 9 Checking seat belts 5932
1 9 1 Check belt webbing 5933
1 9 2 Checking inertia reel (locking mechanism) 5934
1 9 3 Visually checking belt buckle 5935
1 9 4 Check operation of belt buckle 5935
1 9 5 Checking belt relays, and buckle tongues 5935
1 9 6 Checking securing parts and anchorage points after an accident 5935
1 10 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 5936
1 10 1 Accident with airbag triggering 5936
1 10 2 Accident without airbag triggering 5937
1 11 Deactivating the airbag 5937
1 12 Safety instructions for automatic anti-dazzle interior mirror 5937
2 Repair notes 5939
2 1 General information 5939
2 2 Contact corrosion 5939
2 3 Routing and attachment of lines 5939
68 – Interior equipment 5941
1 Compartments/covers 5941
1 1 Removing and installing glove compartment 5941
1 2 Removing and installing lock cylinder for glove box opening mechanism 5942
1 3 Removing and installing footwell cover on driver side 5945
1 4 Removing and installing footwell cover on front passenger side 5947
1 5 Removing and installing dash panel cover on driver side 5949
1 6 Removing and installing dash panel trim on front passenger side 5951
1 7 Removing and installing upper steering column trim 5951
1 8 Removing and installing handbrake lever trim 5955
2 Equipment 5957
2 1 Removing and installing sun visor 5957
2 2 Removing and installing grab handle 5959
2 2 1 Removing and installing grab handle (A-pillar) 5959
2 2 2 Removing and installing grab handle (B-pillar) 5960
2 2 3 Removing and installing holding bracket for grab handle (A-pillar) 5962
2 3 Removing and installing roof grab handle 5963
3 Centre console 5966
3 1 Removing and installing centre console 5966
3 2 Removing and installing cup holder 5971
3 3 Removing and installing trim for operating and display unit 5973
3 3 1 Removing and installing trim for operating and display unit, to model year 2017 5973
3 3 2 Removing and installing trim for operating and display unit, from model year 2017 5975
3 3 3 Removing and installing Climatronic frame 5976
3 3 4 Removing and installing Climatronic trim 5977
3 3 5 Removing and installing ambient lighting trim 5979
4 Interior mirror 5981
4 1 Assembly overview – interior mirror 5981
4 2 Removing and installing interior mirror 5983
4 2 1 Removing and installing manual anti-dazzle interior mirror 5983
4 2 2 Removing and installing automatic anti-dazzle interior mirror with rain sensor to model year 2017 5984
4 2 3 Removing and installing automatic anti-dazzle interior mirror with rain sensor from model year 2017 5986
4 3 Bonding retaining plate for interior mirror 5987
4 3 1 Repairing interior mirror retaining plate, manual anti-dazzle 5987
4 3 2 Repairing retaining plate for interior mirror, automatic anti-dazzle with rain sensor to model year 2017 5990
4 3 3 Repairing retaining plate for interior mirror, automatic anti-dazzle with rain sensor from model year 2017 5992
69 – Passenger protection 5995
1 Seat belts 5995
1 1 Removing and installing front three-point seat belt 5995
1 2 Removing and installing belt height adjuster 5998
1 3 Removing and installing front belt buckle 5999
1 4 Removing and installing rear three-point seat belt 6000
1 4 1 Removing and installing rear outer three-point seat belt 6000
1 4 2 Removing and installing rear three-point seat belt, centre 6001
1 5 Removing and installing rear belt buckle 6003
2 Airbag system 6005
2 1 Overview of fitting locations – airbag system 6005
3 Airbag control unit 6006
3 1 Assembly overview – airbag control unit 6006
3 2 Removing and installing airbag control unit -J234- 6006
4 Front airbag 6010
4 1 Removing and installing airbag unit with igniter 6010
4 2 Removing and installing return spring with slip ring (coil connector) 6013
5 Front passenger airbag 6016
5 1 Removing and installing front passenger airbag unit with igniter 6016
5 1 1 Removing and installing front passenger airbag unit with igniter, up to model year 2017 6016
5 1 2 Removing and installing front passenger airbag unit with igniter, as of model year 2017 6020
5 2 Removing and installing key-operated switch to deactivate airbag on front passenger side 6021
6 Side airbags 6023
6 1 Removing and installing front side airbag with igniter 6023
7 Airbag crash sensors 6027
7 1 Overview of fitting locations – airbag crash sensors 6027
7 2 Removing and installing front side airbag crash sensor -G179-/-G180- 6027
7 3 Removing and installing crash sensor for front airbag -G283-/-G284- 6031
8 Seat occupied recognition 6035
8 1 Removing and installing front seat occupied sensor -G128- 6035
70 – Trim, insulation 6036
1 Front door trims 6036
1 1 Removing and installing front door trim 6036
1 1 1 Removing and installing front door trim, version A 6036
1 1 2 Removing and installing front door trim, version B 6040
1 1 3 Renewing front door trim, version B 6043
1 1 4 Removing impact padding of front door trim 6043
1 2 Removing and installing mirror cover trim 6044
2 Rear door trims 6045
2 1 Removing and installing rear door trim 6045
2 1 1 Removing and installing rear door trim, vehicles up to 2013 6045
2 1 2 Removing and installing rear door trim, vehicles as of 2013 6048
3 Dash panel 6053
3 1 Assembly overview – dash panel 6053
3 2 Removing and installing dash panel end cover 6055
3 3 Removing and installing radio/navigation system mounting frame 6057
3 4 Removing and installing dash panel trim 6059
3 4 1 Removing and installing dash panel trim on driver side 6059
3 4 2 Removing and installing dash panel trim on front passenger side 6060
3 5 Removing and installing dash panel 6061
3 5 1 Removing and installing dash panel up to model year 2017 6061
3 5 2 Removing and installing dash panel as of model year 2017 6065
3 5 3 Removing and installing holder for vehicle identification number 6070
3 6 Removing and installing centre dash panel trim 6071
3 6 1 Removing and installing centre dash panel trim with multi-purpose hooks for radio/CD, up to model year 2017 6071
3 6 2 Removing and installing centre dash panel trim without multi-purpose hooks for radio/CD, up to model year 2017 6073
3 7 Removing and installing dash panel storage compartment 6075
3 7 1 Removing and installing dash panel storage compartment up to model year 2017 6075
3 7 2 Removing and installing dash panel storage compartment as of model year 2017 6076
3 7 3 Removing and installing airbag storage tray 6077
3 8 Removing and installing outer dash panel vents 6079
3 8 1 Removing and installing outer dash panel vents 6079
3 8 2 Removing and installing vent housing 6079
3 9 Removing and installing centre vent 6081
3 10 Removing and installing side defroster vent 6082
4 Dash panel cross member 6084
4 1 Assembly overview – central tube for dash panel 6084
4 2 Removing and installing dash panel cross member 6084
5 Interior trims 6087
5 1 Removing and installing front sill panel moulding 6087
5 2 Removing and installing rear sill panel moulding 6088
5 2 1 Removing and installing rear step insert 6088
5 3 Removing and installing A-pillar trim 6088
5 3 1 Removing and installing upper A-pillar trims 6088
5 3 2 Removing and installing lower A-pillar trim (driver’s side) 6089
5 3 3 Removing and installing lower A-pillar trim (front passenger’s side) 6091
5 4 Removing and installing B-pillar trim 6092
5 4 1 Removing and installing lower B-pillar trims, double cab 6092
5 4 2 Removing and installing upper B-pillar trims, double cab 6093
5 4 3 Removing and installing lower B-pillar trim, single cab 6095
5 4 4 Removing and installing rear side trim, single cab 6096
5 4 5 Removing and installing upper B-pillar trim, single cab 6097
5 5 Removing and installing C-pillar trim 6098
5 6 Removing and installing foot rest 6100
5 7 Removing and installing floor covering 6101
5 7 1 Removing and installing front floor covering, double cab 6101
5 7 2 Removing and installing rear floor covering, double cab 6103
5 7 3 Removing and installing front floor covering, single cab 6104
5 7 4 Removing and installing rear floor covering, single cab 6106
5 8 Removing and installing back panel front trim 6108
6 Luggage compartment trims 6110
6 1 Removing and installing lower rear lid trim 6110
7 Roof trims 6112
7 1 Assembly overview – moulded headliner 6112
7 1 1 Assembly overview – filler pieces, double cab 6112
7 1 2 Assembly overview – filler pieces, single cab 6112
7 2 Removing and installing moulded headliner 6113
7 2 1 Removing and installing moulded headliner, double cab 6113
7 2 2 Removing and installing moulded headliner, single cab 6115
8 Insulation 6117
8 1 Assembly overview – plenum chamber bulkhead insulation 6117
8 2 Assembly overview – plenum chamber insulation 6117
8 3 Assembly overview – fresh air intake insulation 6118
8 4 Assembly overview – A-pillar insulation foam 6119
8 5 Assembly overview – tunnel insulation 6120
8 6 Assembly overview – inner plenum chamber bulkhead insulation 6121
8 7 Removing and installing tunnel insulation 6122
8 8 Removing and installing insulation mat 6123
72 – Seat frames 6125
1 Overview of seat variants 6125
1 1 Overview of fitting locations – seat variants 6125
2 Front seats 6126
2 1 Overview of fitting locations – electrical and electronic components 6126
2 2 Assembly overview – front seat 6128
2 2 1 Assembly overview – front seat, electrically adjustable seat 6128
2 2 2 Assembly overview – seat trims, without side airbag 6129
2 2 3 Assembly overview – seat trims 6130
2 2 4 Assembly overview – seat trims, with drawer 6132
2 2 5 Assembly overview – seat trims, with storage compartment 6132
2 2 6 Assembly overview – trims, electrically adjustable seat 6133
2 3 Assembly overview – seat pan 6135
2 3 1 Assembly overview – seat pan 6135
2 3 2 Assembly overview – seat pan, electrically adjustable seat 6135
2 3 3 Assembly overview – seat height adjustment motor 6137
2 4 Assembly overview – head restraint 6138
2 5 Assembly overview – front backrest 6139
2 5 1 Assembly overview – front backrest 6139
2 5 2 Assembly overview – front backrest, electrically adjustable lumbar support 6140
2 5 3 Assembly overview – seat depth adjustment 6141
2 6 Removing and installing front seat 6142
2 6 1 Removing and installing front seat 6142
2 6 2 Removing and installing front seat, electrically adjustable 6147
2 6 3 Removing and installing seat console, electrically adjustable seat 6149
2 7 Connecting and disconnecting airbag adapter 6149
2 8 Removing and installing seat height adjuster 6150
2 9 Removing and installing seat rake adjustment unit 6153
2 10 Removing and installing driver seat longitudinal adjustment motor -V28- 6154
2 11 Removing and installing backrest adjuster 6154
2 11 1 Removing and installing backrest adjuster, electrically adjustable seat 6154
2 12 Dismantling and assembling seat pan 6154
2 13 Removing and installing seat trim 6156
2 13 1 Removing and installing seat trims (with side airbag) 6156
2 13 2 Removing and installing seat trims (without side airbag) 6158
2 13 3 Removing and installing seat trims, Double Cab (with side airbag) 6160
2 13 4 Removing and installing seat trims, Double Cab (without side airbag) 6162
2 13 5 Removing and installing trims on electrically adjustable seat 6164
2 14 Removing and installing drawer 6166
2 14 1 Removing and installing guide frame 6166
2 14 2 Removing and installing storage compartment 6167
2 14 3 Removing and installing drawer 6168
2 15 Removing and installing fire extinguisher holder 6170
2 15 1 Removing and installing fire extinguisher holder, up to model year 2017 6170
2 15 2 Removing and installing fire extinguisher holder, as of model year 2017 6171
2 16 Removing and installing head restraint 6172
2 17 Removing and installing head restraint guide 6173
2 18 Removing and installing front backrest 6175
2 18 1 Removing and installing front backrest (with side airbag), 4-door model 6175
2 18 2 Removing and installing front backrest (without side airbag), 4-door model 6177
2 18 3 Removing and installing front backrest (with side airbag), 2-door model 6178
2 18 4 Removing and installing front backrest (without side airbag), 2-door model 6180
2 19 Removing and installing lumbar support adjuster 6182
2 20 Removing and installing backrest cover panel 6183
2 21 Removing and installing lumbar support 6184
2 21 1 Removing and installing lumbar support 6184
2 21 2 Removing and installing lumbar support adjustment motor -V125-/-V126-/-V129-/-V130- 6186
2 22 Removing and installing lumbar support adjustment switch -E176-/-E177- 6187
2 23 Removing and installing operating unit for rear seat adjustment -E470-/-E471- 6188
2 24 Removing and installing seat depth adjuster 6190
2 24 1 Removing and installing seat depth adjuster trim 6192
3 Rear seats 6194
3 1 Assembly overview – bench seat/individual seats 6194
3 2 Removing and installing bench seat/individual seats 6194
3 3 Removing and installing rear seat backrest 6195
3 4 Removing and installing head restraint guide 6197
3 5 Seat catches – attachments 6198
74 – Seat – padding, covers 6200
1 Front seat covers and padding 6200
1 1 Removing and installing seat pan cover and padding 6200
1 2 Removing and installing backrest cover and padding 6203
1 3 Removing and installing seat heating element -Z6-/-Z8- 6208
1 3 1 Removing and installing seat heater element (with side airbag) 6208
1 3 2 Removing and installing seat heater element (without side airbag) 6209
1 4 Removing and installing backrest heating element -Z7-/-Z9- 6211
1 5 Removing and installing head restraint cover and padding 6212
2 Rear seat covers and padding 6213
2 1 Separating rear bench seat cover from padding 6213
2 1 1 Removing and installing cover and padding for right bench seat 6213
2 1 2 Removing and installing cover and padding for left bench seat 6216
2 2 Removing and installing cover and padding of rear seat backrest 6219
D4B80456383 Fuel supply system petrol engines 6223
00 – Technical data 6227
1 Safety information 6227
1 1 Safety regulations for working on fuel supply 6227
1 2 Safety measures when working on vehicles with a start/stop system 6227
1 3 Safety precautions when using testers and measuring instruments during a road test 6228
1 4 Safety precautions when working on the cooling system 6228
1 5 Safety precautions when working on ignition system 6228
1 6 Safety precautions when working on exhaust system 6229
2 Identification 6230
2 1 Engine number/engine data 6230
3 Repair notes 6232
3 1 Rules for cleanliness 6232
3 2 General information 6232
3 3 General repair instructions 6233
3 4 Foreign bodies in engine 6233
3 5 Contact corrosion 6233
3 6 Routing and attachment of lines 6234
3 7 Fitting radiator and condensers 6234
3 8 Checking vacuum system 6234
3 9 Procedure in event of misfuelling 6235
20 – Fuel supply system 6237
1 Fuel 6237
1 1 Assembly overview – fuel tank 6237
1 2 Removing and installing fuel tank 6239
1 3 Removing and installing filling connection 6244
1 4 Releasing high pressure in fuel system 6246
1 5 Renewing seal for cap 6247
2 Fuel delivery unit, fuel gauge sender 6249
2 1 Removing and installing fuel delivery unit, fuel gauge sender 6249
2 2 Removing and installing fuel gauge sender -G- 6250
3 Plug-in connectors 6251
3 1 Separating plug-in connectors 6251
4 Fuel filter 6257
4 1 Assembly overview – fuel filter 6257
4 2 Removing and installing fuel filter 6257
5 Activated charcoal filter system 6260
5 1 Assembly overview – activated charcoal filter system 6260
5 2 Removing and installing activated charcoal filter 6260
5 3 Checking fuel tank breather 6261
6 Accelerator pedal 6263
6 1 Assembly overview – accelerator module 6263
6 2 Removing and installing accelerator module with accelerator position sender -G79-/-G185- 6263
7 Fuel supply 6265
7 1 Checking fuel system pressurisation pump -G6- 6265
7 1 1 Checking fuel pump 6265
7 1 2 Checking function and voltage supply 6266
7 1 3 Checking fuel pressure 6267
7 1 4 Checking fuel delivery rate 6270
7 1 5 Checking holding pressure 6270
7 2 Removing and installing fuel pump control unit -J538- 6272
K0056560120 Wheels and Tyres Guide – General Information 6274
44 – Wheels, tyres, vehicle geometry 6278
1 Instructions on using the guide 6278
1 1 Overview 6278
1 1 1 Wheels and Tyres Guide – General information 6278
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 6278
1 2 General information 6278
1 3 Notes 6279
1 4 Definition of tyre package 6279
1 5 Procedure for determining required tyre package in accordance with NEDC and vehicles with exhaust gas PR number “7MP” 6280
1 5 1 Determining the required tyre package via PR number 6280
1 5 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 6281
1 6 Procedure for determining the required wheel and tyre combination in accordance with WLTP 6281
1 6 1 Retrieving vehicle identification number via vehicle data 6282
1 6 2 Vehicle registration certificate, item K 6282
1 6 3 COC document, item 0 10 6283
1 7 Vehicle registration certificate part 1 6283
1 8 NEDC, WLTP and RDE 6284
1 8 1 What are NEDC, WLTP and RDE? 6284
1 8 2 What are the differences between WLTP and RDE? 6285
1 8 3 Since when are WLTP and RDE valid? 6285
2 General notes on wheels and tyres (commercial vehicles) 6286
3 Legislative and technical conditions for converting wheel and tyre combinations 6287
3 1 Legislative conditions for converting wheel and tyre combinations 6287
3 2 Technical conditions for converting wheel and tyre combinations 6288
3 3 Additional wheel housing extensions (flaps) 6288
3 4 “Series 80” tyres 6288
4 Documents and codes/designations 6290
4 1 New vehicle registration documents since 01 10 2005 6290
4 2 COC document (EEC Certificate of Conformity) 6291
5 Official type designations 6292
5 1 General information 6292
5 2 Official type approval, sales or trade designation 6292
6 EU tyre label 6295
6 1 EU tyre label, summary 6295
6 2 EU tyre label, objectives 6296
6 3 EU tyre label, categories 6296
6 3 1 EU tyre label, categories, rolling resistance 6296
6 3 2 EU tyre label, categories, wet grip 6298
6 3 3 EU tyre label, categories, noise emissions 6299
7 Facts about wheels and tyres (commercial vehicles) 6301
7 1 Useful information regarding tyres 6301
7 1 1 Identification markings on the tyre sidewall 6301
7 1 2 Explanation of tyre lettering 6303
7 1 3 Load rating code/Load Index (LI) 6303
7 1 4 Speed ratings for tyres 6305
7 1 5 Undulations 6305
7 1 6 Tyre storage 6306
7 1 7 Tyre ageing 6307
7 1 8 Tyres with flange protection 6308
7 1 9 M+S tyres 6309
7 1 10 Reinforced and Extra Load (XL) tyres 6312
7 1 11 All-season tyres 6312
7 1 12 Optimised rolling resistance tyres 6312
7 1 13 Snow chains 6313
7 1 14 Tyre sizes for vehicles with all-wheel drive 6313
7 2 Tyre wear/ mileage 6314
7 2 1 General information 6314
7 2 2 Requirements to be met by tyres 6314
7 2 3 Wear behaviour of high-speed tyres 6315
7 2 4 Factors influencing the service life of a tyre 6315
7 2 5 Driving style 6316
7 2 6 Tyre maintenance 6317
7 2 7 Evenly worn tyres 6318
7 2 8 Measuring tread depth 6319
7 2 9 One-sided wear 6320
7 2 10 Wear in middle of tyre 6322
7 2 11 Diagonal washout 6323
7 3 Tyre noise 6323
7 3 1 General notes on tyre noise 6323
7 3 2 Saw-tooth wear 6324
7 3 3 Flat spots (from locking wheels) 6326
7 4 Rough running caused by wheels/tyres 6327
7 4 1 Causes of rough running 6327
7 4 2 Conducting a road test before balancing wheels 6327
7 4 3 Balancing wheels 6328
7 4 4 Balancing wheels on stationary wheel balancing machine 6328
7 4 5 Vibration control system -VAS 6230B-/vibration control system -VAS 6230BE- 6330
7 4 6 Finish balancer 6331
7 4 7 Radial and lateral runout of wheels and tyres 6332
7 4 8 Checking radial and lateral runout on wheels and tyres with tyre gauge 6332
7 4 9 Checking radial and lateral runout on wheel rim 6333
7 4 10 Matching 6334
7 4 11 Flat spots caused by storage or handling 6336
7 5 Vehicle pulls to one side 6337
7 5 1 General information 6337
7 5 2 Conicity 6337
7 5 3 Remedies when vehicle pulls to one side 6339
7 5 4 Strategic rotation of wheels for non-directional tyres 6340
7 5 5 Strategic rotation of wheels having unidirectional tyres 6341
7 6 Tyre damage 6342
7 6 1 General information 6342
7 6 2 Construction of a radial belted tyre 6342
7 6 3 Impact damage 6343
7 6 4 Cuts 6345
7 6 5 Damage caused by foreign bodies 6345
7 6 6 Loss of air from tyre 6345
7 6 7 Tyre pressure 6346
7 6 8 Tyre damage due to insufficient tyre pressure 6346
7 6 9 Rising tyre temperature caused by insufficient inflation pressure 6348
7 6 10 Tyre damage due to fitting error (fitting damage) 6349
7 7 Useful information about rims 6351
7 7 1 Details on rims 6351
7 7 2 Rim – pitch circle diameter (PCD) 6351
7 7 3 Split rim wheels 6352
7 7 4 Half dual spacing and wheel offset 6352
7 7 5 Care and maintenance of alloy wheel rims 6352
7 7 6 Restoring alloy wheels 6353
7 7 7 The valve 6353
7 8 Fitting wheels and tyres 6355
7 8 1 Rotating wheels 6355
7 8 2 Changing tyres, fitting requirements 6355
7 8 3 Removing tyre sealant 6356
7 8 4 Tyre sealant disposal 6357
7 8 5 Pressing tyre off wheel rim 6357
7 8 6 Removing tyre from wheel 6358
7 8 7 Removing and installing valve 6359
7 8 8 Fitting tyre 6360
7 8 9 Fitting notes for changing and fitting wheels except LT from model year 1997 to model year 2005 6361
7 8 10 Fitting notes for changing and fitting wheels for LT, model year 1997 to model year 2005 6364
7 8 11 Wheel bolts – tightening torque 6364
7 8 12 Modified wheel bolts for Transporter 111 kW from model year 2001 6365
7 8 13 Modified wheel bolts for Amarok 2015 ►, Transporter and Multivan 2015 ► 6366
7 8 14 Notes on use of temporary spare wheels 6367
7 8 15 16″ running gear for Transporter type 7DZ; 65, 75 and 85 kW engines; model year 2002 6367
7 9 Breakdown set for VW Vehicles 6368
8 Identification plate 6369
K0056560420 Guide for increasing and decreasing load ratings 6370
00 – Technical data 6374
1 General information 6374
1 1 Parts certificates 6374
1 2 Load rating increase 6374
1 3 Load rating decrease 6374
1 4 Weights 6375
1 4 1 Transporter, Caravelle, Multivan, California from vehicle identification number 70 MH to vehicle identification number 70 SH or 70 SX 6375
1 4 2 Transporter, Caravelle, Multivan, California from vehicle identification number 70 TH 000 000 to 70 TH 199 999 or vehicle identification number 70 TX 000 000 to 70 TX 199 999 6375
1 4 3 Transporter, Caravelle, Multivan, California from vehicle identification number 70 TH 200 000 or 70 TX 200 000 6375
2 Load rating Amarok 6377
3 Increasing load rating for Caddy 6378
4 Increasing load rating for Transporter, model year 1991 to model year 1995 6379
4 1 Increasing load rating, model year 1991 from vehicle identification number 70 MH 000 000 6379
4 1 1 Appendix for parts certificate for panel van 6379
4 1 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6380
4 1 3 Appendix for parts certificate for dropside/chassis with single cab 6381
4 1 4 Appendix for parts certificate for dropside/chassis with double cab 6381
4 1 5 Appendix for parts certificate for California from vehicle identification number 70 MH 000 000 to 70 MH 078 749 6382
4 1 6 Appendix for parts certificate for California from vehicle identification number 70 MH 078 750 6383
4 2 Increasing load rating, model year 1992 from vehicle identification number 70 NH 000 000 6383
4 2 1 Appendix for parts certificate for panel van 6383
4 2 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6384
4 2 3 Appendix for parts certificate for dropside/chassis with single cab 6385
4 2 4 Appendix for parts certificate for dropside/chassis with double cab 6386
4 2 5 Appendix for parts certificate for California 6386
4 3 Increasing load rating, model year 1993 from vehicle identification number 70 PH 000 000 6387
4 3 1 Appendix for parts certificate for panel van 6387
4 3 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6388
4 3 3 Appendix for parts certificate for dropside/chassis with single cab 6389
4 3 4 Appendix for parts certificate for dropside/chassis with double cab 6390
4 3 5 Appendix for parts certificate for California 6391
4 4 Increasing load rating, model year 1994 from vehicle identification number 70 RH 000 000 6391
4 4 1 Appendix for parts certificate for panel van 6391
4 4 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6392
4 4 3 Appendix for parts certificate for dropside/chassis with single cab 6393
4 4 4 Appendix for parts certificate for dropside/chassis with double cab 6394
4 4 5 Appendix for parts certificate for California 6395
4 5 Increasing load rating, model year 1995 from vehicle identification number 70 SH 000 000 or 70 SX 000 000 6395
4 5 1 Appendix for parts certificate for panel van 6395
4 5 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6396
4 5 3 Appendix for parts certificate for dropside/chassis with single cab 6397
4 5 4 Appendix for parts certificate for dropside/chassis with double cab 6398
4 5 5 Appendix for parts certificate for California 6399
5 Increasing load rating for Transporter, model year 1996 6400
5 1 Increasing load rating, model year 1996 from vehicle identification number 70 TH 000 000 to 70 TH 199 999 or 70 TX 000 000 to 70 TX 199 999 6400
5 1 1 Appendix for parts certificate for panel van 6400
5 1 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6401
5 1 3 Appendix for parts certificate for dropside/chassis with single cab 6402
5 1 4 Appendix for parts certificate for dropside/chassis with double cab 6403
5 1 5 Appendix for parts certificate for California from vehicle identification number 70 TH 000 000 to 70 TH 199 999 6403
5 2 Increasing load rating, model year 1996 from vehicle identification number 70 TH 200 000 or 70 TX 200 000 6404
5 2 1 Appendix for parts certificate for panel van 6404
5 2 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6405
5 2 3 Appendix for parts certificate for dropside/chassis with single cab 6406
5 2 4 Appendix for parts certificate for dropside/chassis with double cab 6407
5 2 5 Appendix for parts certificate for California 6407
6 Increasing load rating for Transporter, model year 1997 to model year 2003 6409
6 1 Increasing load rating, model year 1997 from vehicle identification number 70 VH 000 000 or 70 VX 000 000 6409
6 1 1 Appendix for parts certificate for panel van 6409
6 1 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6410
6 1 3 Appendix for parts certificate for dropside/chassis with single cab 6411
6 1 4 Appendix for parts certificate for dropside/chassis with double cab 6411
6 1 5 Appendix for parts certificate for California 6412
6 2 Increasing load rating, model year 1998 from vehicle identification number 70 WH 000 000 or 70 WX 000 000 6413
6 2 1 Appendix for parts certificate for panel van 6413
6 2 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6414
6 2 3 Appendix for parts certificate for dropside/chassis with single cab 6415
6 2 4 Appendix for parts certificate for dropside/chassis with double cab 6415
6 2 5 Appendix for parts certificate for California 6416
6 3 Increasing load rating, model year 1999 from vehicle identification number 70 XH 000 000 or 70 XX 000 000 6417
6 3 1 Appendix for parts certificate for panel van 6417
6 3 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6418
6 3 3 Appendix for parts certificate for dropside/chassis with single cab 6419
6 3 4 Appendix for parts certificate for dropside/chassis with double cab 6419
6 3 5 Appendix for parts certificate for California 6420
6 4 Increasing load rating, model year 2000 from vehicle identification number 70 YH 000 000 or 70 YX 000 000 6421
6 4 1 Appendix for parts certificate for panel van 6421
6 4 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6422
6 4 3 Appendix for parts certificate for dropside/chassis with single cab 6423
6 4 4 Appendix for parts certificate for dropside/chassis with double cab 6423
6 4 5 Appendix for parts certificate for California 6424
6 5 Increasing load rating, model year 2001 from vehicle identification number 70 1H 000 000 or 70 1X 000 000 6425
6 5 1 Appendix for parts certificate for panel van 6425
6 5 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6426
6 5 3 Appendix for parts certificate Caravelle and Multivan (111 kW and 150 kW) 6427
6 5 4 Appendix for parts certificate for dropside/chassis with single cab 6427
6 5 5 Appendix for parts certificate for dropside/chassis with double cab 6428
6 5 6 Appendix for parts certificate for California 6429
6 6 Increasing load rating, model year 2002 from vehicle identification number 70 2H 000 000 or 70 2X 000 000 6430
6 6 1 Appendix for parts certificate for panel van 6430
6 6 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6431
6 6 3 Appendix for parts certificate Caravelle and Multivan (111 kW and 150 kW) 6432
6 6 4 Appendix for parts certificate for dropside/chassis with single cab 6432
6 6 5 Appendix for parts certificate for dropside/chassis with double cab 6433
6 6 6 Appendix for parts certificate for California 6434
6 7 Increasing load rating, model year 2003 from vehicle identification number 70 3H 000 000 or 70 3X 000 000 6434
6 7 1 Appendix for parts certificate for panel van 6434
6 7 2 Appendix for parts certificate for Kombi, Caravelle, Multivan 6435
6 7 3 Appendix for parts certificate Caravelle and Multivan (111 kW and 150 kW) 6436
6 7 4 Appendix for parts certificate for dropside/chassis with single cab 6437
6 7 5 Appendix for parts certificate for dropside/chassis with double cab 6438
6 7 6 Appendix for parts certificate for California 6439
7 Increasing load rating for Transporter, model years 2004 to 2009 6440
8 Increasing load rating for Transporter, from model year 2010 6441
9 Increasing load rating for Transporter, from model year 2016 6442
10 Increasing load rating for Transporter, from model year 2020 6443
11 Increasing load rating for Multivan as of model year 2022 6444
12 Increasing load rating for ID BUZZ, as of model year 2022 6445
13 Increasing load rating for LT, to model year 1996 6446
13 1 Increasing load rating for LT 28 (permitted gross weight 2800 kg) 6446
13 1 1 Appendix for parts certificate, LT 28 to model year 1995, official model designation 281, 281 – 363 6446
13 1 2 Appendix for parts certificate, LT 28 from model year 1996, official model designation 2DM, 2DX0AE, 2DX0FE 6447
13 2 Increasing load rating for LT 31 (permitted gross weight 3200 kg) to model year 1995 6447
13 2 1 Appendix for parts certificate, LT 31: official model designation 281, 283 6447
13 3 Increasing load rating for LT 35 (permitted gross weight 3100 kg, 3200 kg and 3500 kg) 6448
13 4 Increasing load rating for LT 40 (permitted gross weight 4,000 kg) to model year 1995 6448
13 4 1 Appendix for parts certificate, LT 40: official model designation 291 – 512, 293 – 512 6448
13 5 Increasing load rating for LT 45 (permitted gross weight 4,600 kg) to model year 1995 6449
13 5 1 Appendix for parts certificate, LT 45: official model designation 291 – 512, 293 – 512 6449
13 6 Increasing load rating for LT 46 (permitted gross weight 3500 kg, 4000 kg and 4600 kg) 6450
13 7 Increasing load rating for LT 50 (permitted gross weight 5,000 kg) to model year 1995 6450
13 7 1 Appendix for parts certificate, LT 50: official model designation 293 – 909 6450
14 Increasing load rating for LT, from model year 1997 6452
15 Increasing load rating for Crafter 6453

DESCRIPTION:

Volkswagen Amarok 2011-2022 Repair Manual – PDF DOWNLOAD 

Foreword:

• The contents of this guide are separated into two parts. The first part contains information and important notes on the subject of “Trailer towing”. The technical prerequisites for towing trailers or the function of the trailer control unit, for example, are explained here.
• Listed in the second part are the trailer loads (braked, unbraked and drawbar load) of the vehicles (categorised according to engine performance) and, where possible, the prerequisites that have to be met to uprate the trailer load on a vehicle. Volkswagen vehicles are built according to the latest findings in safety engineering.
• For this reason we recommend that only Volkswagen genuine replacement parts are used. It has been established that these parts are reliable, safe and suitable.
• Despite constant appraisal of the market, we cannot assess other products on these points, even when in isolated cases they have been passed by official inspectors or have been granted official approval. Therefore, we cannot, of course, assume  any liability if these products are installed.

S.V 25/01/2025