Contents

Operating instructions

• Before driving
• Keys
• Locking / unlocking doors
• Central door locking system
• Unlocking and locking doors
• Alarm system (if installed)
• Side sliding door (s)
• Rear doors
• Cab windows
• Seats
• Seat belts
• Seat belt care
• Airbags
• Controls and dashboard
• Sound signaling
• Dashboard switches
• Steering column switches
• Lever, turn signal and headlamp switch
• Sound signal
• Heating and ventilation
• Climate control (if available)
• Mirrors
• Interior lighting
• Cigarette lighter
• Ashtray
• Storage space
• Sun visors
• Starting the engine and driving the vehicle
• Car preparation
• Ignition / steering column lock
• Immobilizer
• Engine start / stop
• Car break-in
• Catalytic converter
• Parking brake
• Gear shifting
• Power steering
• Brakes
• Anti-lock braking system (ABS) (if equipped)
• Tires
• Fuel
• Crossing obstacles
• Cargo transportation
• Towing a trailer
• Vehicle Maintenance
• General car care
• Safety measures
• Required checks
• Weekly checks (or before long trip)
• Opening / closing the hood
• Engine cooling system
• Brakes
• Clutch
• Power steering
• Washer fluid reservoir
• Washer nozzles
• Wiper Blades
• Battery Precautions
• Tires
• Seat belts
• Body care
• Practical advice
• Wheel replacement
• Spare wheel
• Vehicle towing
• Draining water from the fuel filter
• Bleeding the fuel system
• Removal and installation of the storage battery (accumulator)
• Starting the engine from the battery of another car
• Fuses and relays
• Main fuse box
• Replacing fuses
• Replacing lamps
• Identification numbers
• Specifications
• Operating materials
• Headlight range control switch positions
• Wheels and tires
• Overall dimensions of the car

Diesel engine VM 2.5

• Links
• General precautions
• Operations to repair the engine without removing it from the car
• Abbreviations and acronyms
• Technical data
• Special tools
• Tightening torques in Nm
• Front accessory drive belt (FEAD) - (external drive belt)
• Removal / Installation
• Timing belt - access
• Removal / installation
• Withdrawal
• Checking
• Reinstall
• Timing belt - replacement
• Replacing the belt
• Timing gear housing - removal / reinstallation
• Timing gear housing - removing
• Removing / reinstalling
• Removing the front crankshaft oil seal
• Reinstalling the front crankshaft cover
• Crankcase
• Reinstall
• Camshaft oil seal - replacement
• Withdrawal
• Checking
• Installation
• Camshaft support - remove / reinstall
• Withdrawal
• Checkout
• Reinstall
• Camshafts
• Removing / reinstalling
• Withdrawal
• Checking
• Reinstall
• Cylinder head
• Removal, repair, re-installation
• Withdrawal
• Checking
• Cylinder head - repair
• Reinstalling the cylinder head
• Flywheel
• Flywheel - removal / installation
• Withdrawal
• Reinstall
• Rear crankshaft oil seal - replacement
• Withdrawal
• Installation
• Crankshaft
• Front crankshaft oil seal - replace
• Crankshaft repair
• Disassembly
• Checking
• Cylinder block
• Liner replacement
• Crankshaft and bearings
• Main bearing shell identification
• Front main bearing - replacement
• Rear main bearing - thrust washers
• Pistons and connecting rods
• Rods
• Pistons
• Rebuild
• Fuel System
• Safety
• Warnings
• Description of the system operation
• Bleeding the fuel system
• Fuel filter - removal / installation
• Injectors - removal / installation
• Checking
• Installing a nozzle
• Fuel pump - removal / installation
• Withdrawal
• Installation
• Lubrication system
• Oil circulation
• Oil filter - change
• Pressure reducing valve - removal / installation
• Oil pump - removal / installation
• Withdrawal
• Checking
• Installing the oil pump
• Cooling system
• Cooling system operation
• Thermostat - removal and installation
• Water pump - removal and installation
• Withdrawal
• Vacuum system
• Description
• Test procedure
• Possible system malfunctions
• Vacuum pump - removal and installation
• Withdrawal
• Checking
• Installing the vacuum pump

Transmission

• Technical data
• Gearbox with transmission
• Gear ratios
• Clearances and Tolerances
• Maintenance
• Special tools
• Tightening torques for threaded connections in NM
• Driving axle shafts Removal and installation
• Corrugated Covers of Universal Joints of Constant Velocity
• Replacement
• Disconnecting the CV joint
• Checking the CV joint
• Reinstall
• Constant Velocity Joints
• Repair
• Removal / disassembly
• Build
• Tripod joints and bellows
• Replacement
• Support bearing of the right axle shaft
• Replacement
• Axle oil seals
• Replacement
• Gear shifting mechanism
• Selector cable - change
• Withdrawal
• Reinstall
• Adjusting the cables
• Adjustment
• Transmission in the block by transmission
• Removal and installation
• Withdrawal
• Checking
• Reinstall
• Clutch - Removal / Installation
• Withdrawal
• Checking
• Reinstall
• Gearbox repair
• Withdrawal
• Transmission components in the transmission block
• Component check
• Clutch housing
• Transmission housing in the transmission block
• Input and output shafts
• Gears, bearings and bushings
• Synchronizers
• First / Second Gear Synchronizer
• Synchronizers for third / fourth gear and fifth / reverse gear
• Synchronizer Locking Rings
• Program Voters
• Reverse idler gear
• Fifth / reverse gear lock
• Gear Shift Components
• Reverse Gear Lever
• Gear Lever
• Transmission assembly
• Final drive repair
• Removal / disassembly
• Checking the main gear
• Check
• Build

Suspension, steering and braking system

• Specifications
• Front Springs Identification
• Maintenance
• Special tools
• Tightening torques of connections in NM
• Front pillar
• Withdrawal
• Repair
• Installation
• Control lever
• Withdrawal
• Shock absorbers
• Removal / Installation
• Rear shock absorbers
• Rear springs
• Removal / Installation
• Checking
• Installation
• Front anti-roll bar
• Removal / installation
• Checking
• Installation
• Technical data
• Maintenance
• Special tools
• Tightening torques of connections in NM
• Power steering hydraulic air fill / bleed
• Removal / installation
• Adjusting the steering rods
• Steering knuckle ball
• Withdrawal
• Installation
• Steering fist
• Withdrawal
• Repair
• Installation
• Corrugated steering rack covers
• Replacement
• Checking
• Installation
• Steering unit - removal and installation
• Withdrawal
• Installation
• Steering wheel - removal and installation
• Withdrawal
• Installation
• Steering column - removal and installation
• Withdrawal
• Installation
• Column connecting shaft
• Removal / installation
• Technical data
• Special tools
• Front wheel hubs - repair
• Dismantling
• Checking
• Rebuild
• Rear wheel hubs - adjustment
• Rear wheel hubs - removal / repair / installation
• Withdrawal
• Repair
• Installation
• Technical data
• Clearances and tolerances
• Maintenance
• Preventive maintenance
• Tightening torques in Nm
• Braking system operation (without ABS)
• General information
• Front brakes
• Bleeding the brakes
• Cars without ABS
• Brake linings
• Replacement
• Checking
• Installation
• Brake caliper
• Withdrawal
• Removing the staple
• Checking
• Installation
• Brake disc
• Withdrawal
• Checking
• Installation
• Rear brake pads
• Withdrawal
• Checking
• Installation
• Rear wheel brake cylinder
• Removal and installation
• Brake master cylinder - removal and installation
• Withdrawal
• Installation
• Handbrake-adjustment

Body, cab, air conditioner

• General precautions
• Precautions for supplemental restraint system (SRS)
• Repair and replacement
• Maintenance of the body and painted surfaces
• Underbody preservation
• Seats and interior trim
• Seat belts
• Door seals
• Glass
• Wiper blades
• Maintenance
• Tightening torques for threaded connections in NM
• Radiator grill
• Closing hood panel
• Removal and installation
• Bumpers
• Front bumper
• Removal and installation
• Rear bumper
• Headlights
• Cab doors
• Cab lining - removal and installation
• Door lock and lever mechanism
• Window regulator
• Door glass - removal / installation
• Withdrawal
• Reinstall
• Cab door - removal and installation
• Door hinge adjustment
• Side loading door
• Blocking mechanism
• Cable adjustment - extra high roof car door, rear upper latch
• Rear doors
• Adjusting the cover plate
• Seats - removal and installation
• Driver's seat - removal
• Seat installation
• Seat belts - removal and installation
• Driver's seat belt
• Withdrawal
• Driver's seat belt with pretensioner
• Reinstall
• Passenger seat belt
• Car headliner
• Removing / reinstalling
• Reinstall
• Exterior mirrors
• Removing the mirror glass
• Glass refitting
• Heater cable adjusters
• Steering column switches
• Withdrawal
• Panel trim
• Removing center panels
• Glove box
• Removal and installation
• Heating and ventilation
• Heater block - removal and installation (right hand drive)
• Withdrawal
• Reinstall
• Fan motor speed ??resistor - removal and installation
• Withdrawal
• Reinstall
• Wiper mechanism - removal and installation
• Withdrawal
• Reinstall
• Aligning wiper arms and blades
• Supplemental restraint system (SRS)
• Description
• Components of the secondary passive safety system
• Components of the primary (main) passive safety system
• Airbags
• Description
• Driver side airbag
• Removing the airbag module
• Reinstall
• Removing / reinstalling passenger airbag
• Withdrawal
• Reinstall
• Driver's seat belt tensioner
• Description
• Removing / reinstalling the pre-tensioner
• Steering wheel clock spring
• Location
• Description
• Removing and installing clock spring
• Electronic control unit for additional passive safety devices (ECU)
• Description
• Crash and safety sensors
• Removing / reinstalling the electronic control unit (ECU) of the supplementary restraint system (SRS)
• Withdrawal
• Installation
• Auxiliary restraint system (SRS) warning light
• Location
• Operation (no faults)
• Work in case of system malfunction
• Additional passive restraint system (SRS) wiring
• Description
• Safety, handling, storage and transportation
• Disposal of SRS components
• Air conditioning
• General Precautions
• Expansion tank / water separator
• Technical data
• Components
• Maintenance
• Tightening torques of connections in NM
• Principles of refrigeration
• Cooling (evaporation / expansion)
• Refrigerant
• Cooling cycle
• Air conditioning system MAXUS
• Description / operation
• Compressor
• Condenser
• Expansion tank / water separator
• Triple switch
• Expansion valve
• Evaporator
• Air conditioning control
• Air conditioning switch
• Maximum cooling
• Normal cooling
• Double level
• Ventilation
• Maximum heating
• Normal heating
• Misting / freezing
• Air conditioning system - operating tips
• Charging and draining refrigerant
• Removal and installation procedures
• Condenser - removal and installation
• Expansion tank / water separator - removal and installation
• Compressor - removal and installation
• Expansion valve (TXV) - removal and installation
• Triple switch - remove and reinstall
• Evaporator - removal and installation
• Refrigerant pipes - removal and installation
• Refrigerant pipe from compressor to condenser, removal and installation
• Refrigerant pipe from condenser to expansion tank / moisture separator, removal and installation
• Air conditioner wiring diagram
• Diagnostics
• Air conditioning requirements
• Air conditioning fuses
• Grounding air conditioning components
• Checking the functioning of the air conditioner switch, heater blower switch and wiring
• Troubleshooting
• Status
• Observation
• Result
• Checking the functioning of the A / C compressor clutch and wiring
• Status
• Observation
• Result
• Test A / C compressor relay and control circuit wiring
• Status
• Observation
• Result
• 32.102 Radiator and air conditioning fans 2,5 CRD double fan 2005
• 74.101 Heating / ventilation / air conditioning cargo van / combi 2005

Electrical equipment

• General security measures
• Devices for work
• Repairs and replacements
• How to use the guide
• Description of electrical diagrams
• Wire harness routing
• Wiring
• Car wiring
• Descriptions of electrical circuits
• Wire and connection color codes
• Basic characters
• Signal lamps and indicators
• Model / types
• Circuit numbering
• Designation of electrical circuits
• Cable color codes (additional information)
• Basic characters
• Diode
• Fuse
• Cable connection
• Plug (holder)
• Rhombus (solid line)
• Rhombus (dotted line)
• Special cables
• Shielded or coaxial cable
• Twisted cable
• Connectors
• Wire Harness Connectors
• Component connectors
• Special connectors (jumpers)
• Switch and relay positions
• Model / type (additional information)
• Dealer / accessory diagrams
• Cable harness (right-hand drive vehicles)
• Relay markings and locations
• Relays located in the main fuse box behind the dash
• Relays located in the under-hood auxiliary fuse box
• Relays located in the box with the relay for the cooling fan under the hood
• SRS additional safety device control unit
• Door release system and alarm module
• ETACS control unit
• VSS coupler
• Incandescent coil controller
• Grounding points ("mass")
• Engine ECM (electronic control unit)
• Component / connector index
• Main fuse box
• Relay
• Auxiliary fuse box
• Location of fuses and relays
• Connector reference
• Table of correspondence of electrical diagrams to circuits
• Wiring diagrams
• 10.101 Etacs control unit, cargo van / combi
• 15.101 Ignition key, cargo van / combi
• 16.101 Engine management / immobilizer, engine 2.5 CRD
• 17.101 Diagnostic system, cargo van / combi
• 30.101 Accumulator battery, starter, alternator, cargo van / combi
• 31.101 Grounding (earth connection), cargo van / combi
• 31.101 Grounding points ("weights"), cargo van / combi
• 32.101 Radiator fan, 2.5 CRD engine, single fan
• 32.102 Radiator and air conditioning fans, 2.5 CRD engine, double fan
• 34.101 Window regulator / adjustment of mirrors, cargo van / combi
• 44.101 ABS (Anti-lock braking system), cargo van / combi (option)
• 49.101 Direction indicators and hazard warning lights, van / combi
• 53.101 Windscreen wiper and washer, cargo van / combi
• 54.101 Brake and reversing lamps, cargo van / combi
• 55.101 Fog lights - front and rear, cargo van / combi
• 56.101 Headlamps (load-dependent headlamp directional control), cargo van / combi
• 57.101 Side lights, rear lights, license plate lights, combi van
• 58.101 Dashboard lighting, van / combi
• 60.101 Interior lamps, cargo van
• 60.103 Interior lamps, combi
• 61.101 Instrument panel lamps and warning lamps, cargo van / combi
• 71.101 Horn, additional passive safety system, van / combi
• 72.101 Cigarette lighter / heated mirrors / heated rear window, cargo van / combi
• 74.101 Heating / ventilation / air conditioning, cargo van / combi
• 75.101 Audio equipment, cargo van / combi
• 77.101 Central locking / burglar alarm, cargo van / combi