
Автор: Диез
Год издания: 0000
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

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