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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
61 - Convertible roof, hardtop, canopy
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63 - Bumpers olkswage es n
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64 - Glazing ir se
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66 - Exterior equipment
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg K0059030620

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Contents

50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Assembly overview - lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Detaching
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pressure hoses . . . . . . . . . . a.ra.n.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2 aut Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 s Assembly overview - front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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2.2 Assembly overview - elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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2.3 Removing and installing front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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2.4 Front wing replacement part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.5 Removing and installing elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Assembly overview - bonnet stay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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1.3 Assembly overview – bonnet lock and release components . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.4 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.5 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.6 Removing and installing bonnet stay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.7 Removing and installing lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.8 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.9 Removing and installing arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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1.10 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2 Fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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2.1 Assembly overview - fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2.2 Removing and installing fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.1 Assembly overview - front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2 Assembly overview – door hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4 Removing and installing front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.5 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.6 Adjusting striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.7 Removing and installing door hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.8 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.9 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.6 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.7 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.8 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1 Overview of fitting locations – central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2 Assembly overview - ignition key to 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3 Assembly overview - ignition key from 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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 Crafter 2006 ➤
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3.4 Removing and installing ignition key battery to 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.5 Removing and installing ignition key battery from 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

1 Sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Assembly overview - guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.2 Assembly overview – upper guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Removing and installing sliding door inner seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.4 Removing and installing sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.5 Adjusting sliding door . . . . . . . . . . . . . . . . . . . . . . .A.G.. V. o. lk. s.w.a.ge. n. A. . . . . . . . . . . . . . . . . . . . . 58
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1.7 Removing and installing upper guide rail ed . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.n. . . . . . . . . .
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2.1 Assembly overview – components ss of sliding door . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . 69

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2.2 Assembly overview - interior operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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2.3 Assembly overview – additional lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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2.4 Removing and installing upper roller guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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2.5 Removing and installing lower roller guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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2.6 Removing and installing hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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2.7 Removing and installing sliding door limit stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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2.8 Removing and installing opening restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.9 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.10 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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2.11 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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2.12 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

2.13 Removing and installing interior operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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2.14 Removing and installing additional lock at top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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2.15 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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2.16 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.17 Removing and installing guide wedge and slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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3 Electric sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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3.1 Assembly overview – sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cum 85

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3.2 Assembly overview - interior operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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3.3 Assembly overview - guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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3.4 Assembly overview – upper guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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3.5 Removing and installing sliding door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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3.6 Removing and installing sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.7 Adjusting sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.8 Motor release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.9 Checking and adjusting tension of drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.10 Removing and installing motor to open right sliding door V323 or motor to open left sliding
door V485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.11 Removing and installing upper roller guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.12 Removing and installing lower roller guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.13 Removing and installing roller carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.14 Removing and installing sliding door limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.15 Removing and installing power latching motor V329 on high sliding doors with additional
lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.16 Removing and installing right sliding door control unit J731 or left sliding door control unit
J558 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.17 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.18 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.19 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.20 Removing and installing rear right central locking lock unit F223 or rear left central locking
lock unit F222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.21 Removing and installing interior operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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3.22 Removing and installing anti-trapping mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.23 Removing and installing additional lock / upper power latching system . . . . . . . . . . . . . . . . 117
3.24 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.25 Removing and installing rear right power latching motor V308 or rear left power latching motor
V307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.26 Removing and installing guide wedge and slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.27 Removing and installing guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.28 Removing and installing upper guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.29 Electric sliding door switch in B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Right rear wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.1 Assembly overview - right rear wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2 Assembly overview – door hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Assembly overview – door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.4 Assembly overview - upper door lock and lower guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.5 Assembly overview - interior operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.6 Assembly overview - door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.7 Removing and installing wing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.8 Removing and installing rear right wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.9 Adjusting rear wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.10 Removing and installing door hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.11 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.12 Removing and installing - door upper lock and lower guide . . . . . . . . . . . . . . . . . . . . . . . . 144
4.13 Removing and installing interior operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.14 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.15 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.16 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.17 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.18 Removing and installing AG. Volupper
kswagenstriker
AG do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
agen
4.19 RemovingVoand lksw installing centring pin eand s no lower striker with centring pin . . . . . . . . . . . . . .
t gu 152
by ar
5 Leftorrear
ise wing door . . . . . . . . . . . . . . . . . . . a.n.te. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d
154
h e
5.1 Assembly
au
t overview - left rear wing door . . . . . . o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
ss
5.2 Assembly overview - interior lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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pt

5.3 Assembly overview - door arrester with opening angle of 250° . . . . . . . . . . . . . . . . . . . . . . 157
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5.4 Removing and installing upper door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

rm

ab
pe

5.5 Removing and installing lower door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

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wit

5.6 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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5.7 Removing and installing door opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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spec

5.8 Removing and installing interior lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

es, in part or in w

t to the co

5.9 Removing and installing door arrester with opening angle of 250° . . . . . . . . . . . . . . . . . . 161
6 Cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.1 Assembly overview - cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
rrectness of i

6.2 Assembly overview - hinges and hinge brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

l purpos

6.3 Removing and installing cab door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

6.4 Removing and installing cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
nform
ercia

6.5 Adjusting cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

m

6.6 Removing and installing hinges and hinge brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

a
com

tio

6.7 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

n in
r
te o

6.8 Removing and installing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

thi
s
iva

do

6.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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cum

6.10 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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ng

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6.11 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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Cop py
6.12 Removing and installing interior operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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6.13 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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Prote AG.
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1 Sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Contents iii
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1.2 Assembly overview - sliding/tilting sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . 181
1.3 Removing and installing sliding/tilting sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . 181
1.4 Removing and installing sliding glass roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.5 Removing and installing tilting arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.6 Removing and installing sliding sunroof motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.7 Removing and installing trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

61 - Convertible roof, hardtop, canopy . . . . . . . . . a.ge.n.AG. ..V.olk.s.wa.g.en.A.G.do. . . . . . . . . . . . . . 188

lksw es n
1 Three-way tipper . . . . . . . . . . . . . . . . . .by. V. o. . . . . . . . . . . . . . . . . . . . . . o. t .gu. a. . . . . . . . . . . 188
ed ran
oris tee
63 - Bumpers . . . . . . . . . . . . . . . . . . .s a.ut . . . .
h
....................... . . . o.r a.c . . . . 189
s
1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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1.1 Assembly overview - front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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1.2 Assembly overview - add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
erm

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ility
1.3 Removing and installing front bumper cover, vehicles up to 2012 . . . . . . . . . . . . . . . . . . . . 191
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1.4 Removing and installing front bumper cover, vehicles as of 2012 . . . . . . . . . . . . . . . . . . . . 193

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1.5 Removing and installing front bumper carrier, vehicles up to 2012 . . . . . . . . . . . . . . . . . . 195
hole

spec
1.6 Removing and installing front bumper carrier, vehicles as of 2012 . . . . . . . . . . . . . . . . . . 196
es, in part or in w

t to the co
1.7 Repairing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

rrectness of i
2.1 Assembly overview - rear bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.2 Assembly overview - rear bumper cover, add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
l purpos

2.3 Assembly overview - steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2.4 Removing and installing rear bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

nform
ercia

2.5 Removing and installing rear step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

m

2.6 Repairing rear bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

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64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
o

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1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

p

cum
or

1.1 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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1.2 Repairing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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1.3 Installation instructions for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pyri
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ht
207
1.4 Preparing old undamaged window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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1.5 Preparing new windows for installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Prote AG.

1.6 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

1.7 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.8 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.9 Preparing windscreen with inspection window for vehicles without vehicle identification
number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.1 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.2 Assembly overview - heated windscreen and rain sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.3 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3 Side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.1 Assembly overview - side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.2 Removing and installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4 Movable section of sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.1 Assembly overview – control mechanism for sliding window . . . . . . . . . . . . . . . . . . . . . . . . 221
4.2 Removal and installation of sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5 Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.1 Assembly overview – rear wing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.2 Removing and installing rear wing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
6 Rear sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6.1 Removing and installing rear sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

iv Contents
 n AG. Volkswagen AG do
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tho tee
Crafter
or 2006 ➤
u
ss
a
General body repairs, exterior - Edition ac
10.2014

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an
7 Roof window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

itte

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erm

ab
7.1 Assembly overview - roof window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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7.2 Removing and installing roof window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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8 Front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

hole

spec
8.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

es, in part or in w
8.2 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

t to the co
8.3 Adjusting door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.4 Removing and installing quarter light window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

rrectness of i
9 Windows having threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
l purpos

9.1 Assembly overview - rear vent window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

9.2 Assembly overview - cab rear door vent window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

nform
ercia

9.3 Removing and installing rear vent window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

9.4 Removing and installing cab rear door vent window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
m

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ion
c

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

in t
or

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ate

1 Radiator grille/front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

do
priv

cum
1.1 Assembly overview - radiator grille and emblem, vehicles up to 2012 . . . . . . . . . . . . . . . . 243
for

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ng

1.2 Assembly overview - radiator grille, vehicles as of 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . 244

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1.3 Removing and installing radiator grille and emblem, vehicles up to 2012 . . . . . . . . . . . . . . 244
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1.4 Removing and installing radiator grille and emblem, vehicles as of 2012 . . . . . . . . . . . . . . 245
p by
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2 Mouldings / trims / extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote AG.
250
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.2 Assembly overview - headlight trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.3 Removing and installing headlight trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.4 Removing and installing air intake grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.5 Removing and installing wing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.6 Removing and installing side panel trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.7 Removing and installing number plate light trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.8 Assembly overview - protective side strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.1 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.2 Removing and installing noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4 Drive assembly guard - Crafter 4MOTION with Achleitner all-wheel drive . . . . . . . . . . . . . . 264
4.1 Drive assembly guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
5 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
5.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
5.2 Removing and installing mirror glass, up to 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
5.3 Removing and installing mirror glass, from 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
5.4 Removing and installing auxiliary panoramic mirror, up to 2010 . . . . . . . . . . . . . . . . . . . . 274
5.5 Removing and installing auxiliary panoramic mirror, from 2010 . . . . . . . . . . . . . . . . . . . . . . 275
5.6 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.7 Removing and installing exterior mirror (electrically adjustable) . . . . . . . . . . . . . . . . . . . . 277
6 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
6.2 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
6.3 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7 Lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
7.1 Assembly overview - rear emblem and trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
7.2 Dimensions, lettering on rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
7.3 Removing and installing rear emblem and trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
7.4 Wing lettering - Crafter 4MOTION with Achleitner all-wheel drive . . . . . . . . . . . . . . . . . . . . 288
8 Special add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
8.1 Wheel housing extensions - Crafter 4MOTION with Achleitner all-wheel drive . . . . . . . . . . 289
8.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Contents v
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

8.3 Assembly overview - wheel housing extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

8.4 Removing and installing front bumper cover extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.5 Removing and installing wing extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
8.6 Removing and installing wing protective side moulding extension . . . . . . . . . . . . . . . . . . . . 296
9 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.2 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.3 Assembly overview - towing brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.4 Removing and installing rigid towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
9.5 Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
10 Spare wheel carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
10.2 Assembly overview - spare wheel carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
10.3 Removing and installing spare wheel carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
11 Mudflaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
11.2 Front mudflap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
11.3 Rear mudflap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
12 Loading floor body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
12.2 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
12.3 Assembly overview - dropside body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
12.4 Assembly overview - load floor and side boards/tail board . . . . . . . . . . . . . . . . . . . . . . . . 315
12.5 Side board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
12.6 Underride guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
12.7 Rear underride guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
12.8 Rear wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

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vi Contents
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

50 – Body - front
1 Lock carrier
(VRL006782; Edition 10.2014)
⇒ “1.1 Assembly overview - lock carrier”, page 1
⇒ “1.2 Removing and installing lock carrier”, page 2
⇒ “1.3 Detaching pressure hoses”, page 4

1.1 Assembly overview - lock carrier

Note

♦ The lock carrier is a safety-relevant component. It must not be repaired for this reason.
♦ If damaged, the lock carrier must be renewed.

1 - Lock carrier with add-on

parts
❑ Removing and installing
⇒ page 2 .
2 - Lid lock
❑ Removing and installing
⇒ page 23 .
3 - Bolt
❑ Left and right.
❑ 10 Nm
4 - Bolt
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1. Lock carrier
 Crafter 2006 ➤ olkswagen AG
General body repairs, exterior en AG. V 10.2014
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Special tools and workshop
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Removing
– Remove front bumper cover ▶ 2011 ⇒ page 191 .
– Remove front bumper cover 2012 ▶ ⇒ page 193 .

2 Rep. gr.50 - Body - front

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
n AG. Volkswagen AG do
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– Remove headlightsyV
olks⇒ Electrical system; Rep. gr.
s no
t gu 94 ; Re‐
moving andisinstalling
ed b headlights . ara
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ho
– Remove sa
uparts
t
of cooling system adjacent to lock carrier o-1-
ra ⇒
c
Engine cooling; Rep. gr. 19 ; Removing and installing parts of
s

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cooling system .
un

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– Remove expansion tank for hydraulic fluid and secure to pre‐
rm

ab
vent fluid escaping (e.g. cable tie).
pe

ility
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– Detach condenser (if fitted) ⇒ Heating and air conditioning

h re
system; Rep. gr. 87 ; Air conditioning system; Removing and
hole

spec
installing condenser .
es, in part or in w

t to the co
– Detach charge air cooler (if fitted) ⇒ Engines; Rep. gr. 21 ;
Charge air system with turbocharger; Assembly overview -
parts of charge air system .

rrectness of i
– Disconnect pressure hoses as necessary ⇒ page 4 .
l purpos

– Disconnect any electrical connectors.

– Unbolt bonnet lock -2- and/or detach cable ⇒ page 23 .

nform
mercia

– Undo and remove bolts -4- on left and right of guide.

a
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– Undo bolts -3- on right and left on top of lock carrier -1-.
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– Unscrew bolts -5- (qty. 2 each side) from middle of lock carrier

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Do not hang condenser and hydraulic oil cooler from lines.
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Do not kink lines for condenser and hydraulic systems.
Do not start the engine if the air conditioning system and/or the
coolant system lines are disconnected.

Installing
Installation is basically carried out in the reverse sequence; note
the following when doing this:
– Install lock carrier -1- and all attachments

Note

Lock carrier must be installed stress-free.

Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
pairs; Rep. gr. 00 ; Technical data; Body gaps/shut lines; Body –
front .
♦ ⇒ “1.1 Assembly overview - lock carrier”, page 1

1. Lock carrier 3
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.3 Detaching pressure hoses

1.3.1 Pressure hose with push-on coupling

Releasing pressure hose:
– Disengage retaining clip -1- in direction of -arrow a-.
– Pull pressure hose -2- in direction of -arrow b- out of coupling
-3-.
Fitting pressure hose so that it latches into place:

• Ensure that the retaining clip -2- is in the upper position.

– Insert pressure hose -3- in direction of -arrow- into coupling
-1-.
– Press retaining clip -2- all the way downwards.

Note

♦ If the retaining clip cannot be pushed

agen
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• Check plug-in connector by pulling on it.
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1.3.2 Pressure hose with and ribbed union

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Removing pressure hose:

hole

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– Loosen screw of hose clamp -A-.

t to the co

– Pull pressure hose together with hose clamp -A- off the ribbed
union.
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Fitting pressure hose:

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4 Rep. gr.50 - Body - front

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Push pressure hose together with hose clamp -A- onto ribbed
union as far as it will go.
– Tighten screw of hose clamp -A-.

Caution

The hose clamp screw -A- must be tightened as prescribed

⇒ page 5 . If the tightening torque is too low or too high, the
pressure hose may slip off the ribbed union when the vehicle
is being driven.

Specified torque for hose clamps

1- Hose clamp -a- = 13 mm wide: 5.5 Nm
2- Hose clamp -b- = 9 mm wide: 3 Nm

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1.3.3 Notes on hose connections with screw-
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It is essential that the screw-type clips on the charge air lines

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are tightened to 5.5 Nm. If the tightening torque is too low or

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too high, the charge air hose may slip off the charge air pipe
h re
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when the vehicle is being driven.

spec
urposes, in part or in wh

t to the co

There are conventional screw-type clamps at the hose connec‐

tions on the “intake side”.
rrectne

There are screw-type clamps with “barbs” -arrows- at the hose

connections on the “discharge side”.
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the hose. Risk of damage to hose!

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1. Lock carrier 5
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– It is only permissible to loosen the screw-type clamps with

“barbs” -arrows-. Loosen the screw of the screw-type clamps
just enough to remove the hoses.
Screw-type clamps that have only been loosened canabe
genre-used.
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Hose and clamp are supplied together as one
ed
byspare part.
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– When installing, does not use any fluid
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6 Rep. gr.50 - Body - front

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2 Wing
⇒ “2.1 Assembly overview - front wing”, page 7
⇒ “2.2 Assembly overview - elbow”, page 8
⇒ “2.3 Removing and installing front wing”, page 8
⇒ “2.4 Front wing replacement part”, page 11
⇒ “2.5 Removing and installing elbow”, page 11

2.1 Assembly overview - front wing

Note

Only the left side is shown. The right side is similar.

1 - Wing
❑ Removing and installing
⇒ page 8 . AG. Volkswagen AG d
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❑ Removing and installing

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⇒ page 11 .
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4 - Pop rivet

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❑ Qty. 2.
❑ Insert with special pop
rivet pliers - V.A.G
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5 - Wheel housing liner front
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❑ Removing and installing

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⇒ page 282 .
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❑ Removing and installing

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⇒ page 282 .
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⇒ page 310 .
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8 - Front mudflap
❑ Removing and installing
⇒ page 308 .

2. Wing 7
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.2 Assembly overview - elbow

Note

Only the left side is shown. The right side is similar.

1 - Elbow
❑ Removing and installing
⇒ page 11 .
2 - Bolt
❑ 7.0 Nm
3 - Hexagon nut
❑ 6.0 Nm

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8 Rep. gr.50 - Body - front

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

♦ Hot air blower - V.A.G 1416-

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2. Wing 9
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
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– Removing and installing front bumper cover, vehicles up to

2012 ⇒ page 191
– Removing and installing front bumper cover, vehicles as of
2012 ⇒ page 193
– Remove wheel housing liner ⇒ page 282 .
– Remove wing protective side strip ⇒ Item 1 (page 258) .
– Remove wing triangular cover ⇒ page 254 .
– Drill out pop rivet -5- using suitably sized drill bit.
– Remove bolts -2- and -3-.
– Open door and unscrew bolt -4-.
– Remove bolts -6- from lateral guide -7-.
– From exterior, lightly heat seal in area of wing -1- and elbow
piece using hot air blower - V.A.G 1416- .
– Prise apart transition between wing and elbow piece using a
screwdriver and remove wing -1-.
Installing
Install in reverse order, but note the following:

10 Rep. gr.50 - Body - front

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Install rivets -5- using special pop rivet

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– Ensure joints are parallel
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te
pairs; Rep. gr. 00 ;utTechnical data; Body gaps/shut lines; Body e or
ho
– front . ss
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– Re-seal transition between wing at elbow piece ⇒ Workshop

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Specified torques

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spec
Component Specified torques
urposes, in part or in wh

t to the co
Lateral guide 20 Nm

2.4 Front wing replacement part

rrectness
Note

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To keep the number of parts down to a minimum, wings are often
mer

supplied in the »basic version« only.

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Wing without hole for side repeater:

thi
te

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In this case, we recommend that a unique template is made from

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the damaged part by the workshop.

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Cut out a section for the side repeater using pneumatic sabre saw C py
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Deburr edges of template and protect with duct tape.
Thickness of template must be taken into account when position‐
ing template and scribing location of holes for drilling before new
part is painted.

Note

Check replacement part for damage before sending to paint shop

for painting.

2.5 Removing and installing elbow

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

2. Wing 11
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Hot air blower - V.A.G 1416-

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♦ Special pop rivet pliers - V.A.G 1753A-

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12 Rep. gr.50 - Body - front

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

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Removing
– Remove rear part of wheel housing liner ⇒ page 282 .
– Remove wing protective side strip ⇒ Item 1 (page 258) .
– Drill out pop rivets using suitably sized drill bit ⇒ page 8 .
– Remove bolts -2-.
– Unscrew hexagon nut -3- from underneath.
– From exterior, lightly heat seal in area of wing and sill using
hot air blower - V.A.G 1416- .
– Prise apart transition between wing and sill using a screwdriv‐
er and remove elbow piece -1-.
Installing
Install in the reverse order of removal, noting the following.
– Insert hollow rivets, using special pop rivet pliers - V.A.G
1753A- .
– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
pairs; Rep. gr. 00 ; Technical data; Body gaps/shut lines; Body
– front .

2. Wing 13
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Re-seal transition between wing and sill ⇒ Workshop manual

“Paint” .
Specified torques
Component Specified torques
Elbow 7.0 Nm

AG. Volkswagen AG d
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14 Rep. gr.50 - Body - front

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

55 – Bonnet, rear lid

1 Bonnet
⇒ “1.1 Assembly overview - bonnet”, page 15
⇒ “1.2 Assembly overview - bonnet stay”, page 16
⇒ “1.3 Assembly overview – bonnet lock and release compo‐
AG. Volkswagen AG d
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⇒ “1.4 Removing and installing bonnet”, rpage
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⇒ “1.5 Adjusting bonnet”, page 19 s au ac
s

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⇒ “1.6 Removing and installing bonnet stay”, page 20

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⇒ “1.7 Removing and installing lid hinge”, page 22

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⇒ “1.8 Removing and installing lid lock”, page 23
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⇒ “1.9 Removing and installing arrester”, page 24

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spec
⇒ “1.10 Removing and installing insulation”, page 25
urposes, in part or in wh

t to the co
1.1 Assembly overview - bonnet

rrectne
1 - Bonnet
❑ Removing and installing

ss
⇒ page 17 .

o
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f in
❑ Adjusting ⇒ page 19

form
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2 - Adjustment buffer
om

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❑ Adjusting ⇒ page 19

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⇒ page 25 .
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⇒ page 22 .
agen
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5 - Bonnet stay
❑ Removing and installing
⇒ page 16 .

1. Bonnet 15
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.2 Assembly overview - bonnet stay swage

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1 - Bonnet stay utho tee
or
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❑ Removing and installing ss
⇒ page 20 .

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2 - Bush

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3 - Circlip

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4 - Torsion spring

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5 - Washer
es, in part or in w

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6 - Bolt
❑ 22 Nm

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Prote AG.

16 Rep. gr.55 - Bonnet, rear lid

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.3 Assembly overview – bonnet lock and release components

1 - Bonnet
❑ Removing and installing
⇒ page 17 .
❑ Adjusting ⇒ page 19
2 - Lid lock
❑ Removing and installing
⇒ page 23 .
3 - Bolt
❑ Qty. 2.
❑ 10 Nm
4 - Cable
❑ Hooked into lid lock
❑ Hooked into release lev‐
er
5 - Arrester
❑ Removing and installing
⇒ page 24 .
Volkswagen AG
6 - Bolt agen
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7 - Bolt
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❑ Qty. 2.
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❑ 5.0 Nm
rm

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8 - Securing clip
ot

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9 - Release lever
hole

spec
es, in part or in w

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1.4 Removing and installing bonnet

nform
ercia

Special tools and workshop equipment required

m

♦ Torque wrench - V.A.G 1331-

com

tion in
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1. Bonnet 17
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

Spare parts are supplied without sealing due to various reasons.

In these cases, we recommend sealing the spare parts before
forwarding to the paintshop ⇒ Workshop Manual “Paint” .

n AG. Volkswagen AG do
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urposes, in part or in wh

t to the co
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cial p

f inform
mer

atio
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c

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t.
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Cop py
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Prote AG.

Removing
– Loosen hexagon nuts -2- (qty. 2) on left and right (do not re‐
move completely).
– Further dismantling requires the help of a second mechanic.
– Lever retaining clip -3- off bonnet -1- bracket with a screw‐
driver.
Securing torsion spring for bonnet stay ⇒ page 20 .
– Now remove hexagon nuts -2- and lift bonnet -1- out of hinges.
Installing
Install in reverse order, but note the following:

18 Rep. gr.55 - Bonnet, rear lid

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
Crafter 2006 ➤
ra
s c
s General body repairs, exterior - Edition 10.2014

ce
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Note

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Ensure retaining clip -3- has engaged correctly.

h re
hole

spec
es, in part or in w
– Adjusting bonnet -1- ⇒ page 19 .

t to the co
Specified torques

rrectness of i
Component Specified torques
Bonnet 22 Nm
l purpos

1.5 Adjusting bonnet

nform
ercia

Special tools and workshop equipment required

m

a
com

tion in
♦ Torque wrench - V.A.G 1331-
r
te o

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t.
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1. Bonnet 19
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
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byV gu
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pt
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an
– For basic adjustment of bonnet, vehicle must be parked on
itte

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hard, level standing and latch hook -3- must be removed.

erm

ab
ility
ot p

– Loosening bolts -8- (qty. 2) allows bonnet to be aligned be‐

wit
, is n

tween wings by moving bonnet hinges -5-.

h re
hole

spec

– At rear, the height of bonnet can be adjusted by loosening bolts

es, in part or in w

-6- (qty. 2).

t to the co

– Stop buffers -1- (qty. 4) are not designed for adjustment of

bonnet. They have the function of damping the bonnet.
rrectness of i

– Stop -7- dampens the bonnet hinge.

l purpos

– Loosen guide pin -2- to adjust bonnet height in front area.

– The latch hook -3- can be moved to the left or right within its
nform
ercia

elongated holes by loosening bolts -4- (qty. 2).

m

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Specified torques
on
c

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1.6 Removing and installing bonnet stay

his
ate

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or

Special tools and workshop equipment required

f

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Prote AG.

20 Rep. gr.55 - Bonnet, rear lid

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

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Removing
– Prevent bonnet from falling down.
– Lever retaining clip -3- off bonnet bracket with a screwdriver.

Note

Ensure torsion spring -4- does not spring away when removing bonnet stay -1-.

1. Bonnet 21
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Unscrew bolt -6- and remove bonnet stay -1-.

Installing
Install in reverse order, but note the following:
Specified torques

1.7 Removing and installing lid hinge

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Note
. Volkswagen AG
gen AG d
Removal and installation sequence
olks is only for the left side.
wa oes
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right side is similar. byV ua
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urposes, in part or in wh

t to the co
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mer

atio
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Prote AG.

22 Rep. gr.55 - Bonnet, rear lid

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
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es, in part or in w

t to the co
rrectness of i
l purpos

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ercia

Removing
m

– Removing bonnet -1- ⇒ page 17

com

tion in

– Unscrew bolts -3- and remove bonnet hinge -2-.

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Installing
do
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Install in reverse order, but note the following:

en
ng

t.
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op
– Adjusting bonnet -1- ⇒ page 19 .
C py
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Specified torques
op Vo
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Prote AG.
Component Specified torques
Lid hinge 22 Nm

1.8 Removing and installing lid lock

Special tools and workshop equipment required

1. Bonnet 23
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

Removing
– Remove bolts -2- (Qty. 2).
– Remove lid lock -1- upwards out of lock carrier -4- and unclip
Bowden cable -3-. agen
AG. Volkswagen AG d
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Installing ed
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Install in reverse tho note the following:
order,aubut eo
ra
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Specified torques

ce
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an
d

♦ Bolts ⇒ Item 3 (page 17)

itte

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ility
ot

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h re
hole

spec
1.9 Removing and installing arrester
es, in part or in w

t to the co

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1783-
rrectness of i
l purpos

nform
mercia

a
com

tion in
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Removing
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Prote AG.
– Remove bolts -3- (Qty. 2).
– Remove arrester -2- from bonnet -1-.
Installing
Install in reverse order, but note the following:
– Adjust latch hook -2- ⇒ page 19 .
Specified torques
♦ Bolts ⇒ Item 6 (page 17)

24 Rep. gr.55 - Bonnet, rear lid

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.10 Removing and installing insulation

AG. Volkswagen AG d
agen oes
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d b ara
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nl

pt
du

an
itte

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ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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en
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t.
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Removing
p by
co Vo
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– Using 2 screwdrivers, lever out clips -2- (qty. 12) from insula‐
Prote AG.

tion -1-.
– Remove insulation -1-.
Installing
Install in reverse order, but note the following:

Note

♦ Before installing, check all clips -2- for damage and renew if necessary.
♦ When installing insulation -1-, ensure that clips -2- engage properly.

1. Bonnet 25
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2 Fuel tank flap

⇒ “2.1 Assembly overview - fuel tank flap”, page 26
⇒ “2.2 Removing and installing fuel tank flap”, page 26

2.1 Assembly overview - fuel tank flap

1 - Fuel tank flap

❑ Removing and installing
⇒ page 26 .
2 - Stop
❑ Qty. 2.
3 - Retaining strap for tank flap
4 - Tank flap
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❑ Qty. 4. ir se
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❑ 6.0 Nm aut or
ac
ss
6 - Moulded cover
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7 - Bolt
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❑ Qty. 2. ab
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❑ 6.0 Nm wit
, is n

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es, in part or in w

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2.2 Removing and installing fuel tank flap
Prote AG.

Special tools and workshop equipment required

26 Rep. gr.55 - Bonnet, rear lid

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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nl

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du

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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
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Removing
nf
ercia

orm

– Open fuel tank flap -1-.

m

atio
om

n in

– Remove bolts -7- and remove fuel tank flap -1-.

or c

thi
e

– Remove bolt -5-.

t

sd
iva

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cu

– Twist cap -4- of fuel tank off.

o

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f

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t.
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– Remove moulded cover -6- from cut-out in B-pillar. t. Cop py
rig
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Vo
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27
agen
Prote AG.
2. Fuel tank flap
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
Installing agen oes
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Install in reverse order, but note the following: rised
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Specified torques ss a ra
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t to the co
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mer

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Vo
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Prote AG.

28 Rep. gr.55 - Bonnet, rear lid

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

57 – Front doors, door components, central locking

1 Door
⇒ “1.1 Assembly overview - front door”, page 29
⇒ “1.2 Assembly overview – door hinge”, page 31
⇒ “1.3 Removing and installing door inner seal”, page 31
⇒ “1.4 Removing and installing front door”, page 33
⇒ “1.5 Adjusting door”, page 35
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⇒ “1.6 Adjusting striker”, gen AG35
apage does
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⇒ “1.7 Removing ed band installing door hinge”, page 36 aran
ris tee
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⇒ “1.8 Removing
aut and installing door arrester”, page 38 or ac
ss
⇒ “1.9 Removing and installing striker”, page 38

ce
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1.1 Assembly overview - front door

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Note
hole

spec
es, in part or in w

♦ Spare parts are supplied without sealing due to various rea‐

t to the co
sons. In these cases, we recommend sealing the spare parts
before forwarding to the paintshop ⇒ Workshop Manual
“Paint” .
rrectness of i

♦ Only the left side is shown. The right side is similar.

l purpos

nform
mercia

a
com

tion in
r
te o

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s
iva

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cum
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t.
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Cop py
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Vo
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by c lksw
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Prote AG.

1. Door 29
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Front door
❑ Removing and installing
⇒ page 33 .
❑ Adjusting ⇒ page 35
2 - Door upper hinge n AG. Volkswagen AG do
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❑ Removing and installing olks es n
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⇒ page 33 se
d b ua
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3 - Door arrester au
t or
ac
ss
❑ Removing and installing

ce
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⇒ page 38 .

pt
an
d
itte

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4 - Door lower hinge
rm

ab
pe

ility
❑ Removing and installing
ot

wit
, is n

⇒ page 33

h re
hole

5 - Bearing bracket

spec
es, in part or in w

❑ Removing and installing

t to the co
⇒ page 46 .
6 - Door lock

rrectness of i
❑ Removing and installing
l purpos

⇒ page 47 .
7 - Seal

nform
ercia

❑ For door handle -10-

m

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8 - Seal
com

tion in
❑ For lock cylinder hous‐
r
te o

ing -9- thi

s
iva

do
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9 - Lock cylinder housing

um
fo

en
ng

❑ Removing and installing

t.
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op
⇒ page 45 .
C py
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10 - Door handle cop Vo
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❑ Removing and installing Prote AG.
⇒ page 46 .
11 - Exterior mirror
❑ Removing and installing ⇒ page 277

30 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.2 Assembly overview – door hinge

Note

Only the left side is shown. The right side is similar.

AG. Volkswagen AG d
1 - Door lksw
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not
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❑ Removing and installing ed b ara
nte
is
⇒ page 33 hor eo
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❑ Adjusting ⇒ page 35 ss a c

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2 - Door upper hinge

pt
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d
itte

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❑ Hinge is split.
erm

ab
ility
❑ Greasing new door
ot p

hinges ⇒ page 38

wit
is n

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❑ Removing and installing
ole,

spec
⇒ page 36
urposes, in part or in wh

t to the co
3 - Bolt
❑ Qty. 2.

rrectne
❑ 23 Nm
4 - Door lower hinge

ss
❑ Hinge is split.

o
cial p

f in
❑ Greasing new door

form
mer

hinges ⇒ page 38

atio
m

❑ Removing and installing

o

n
c

i
⇒ page 36
or

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sd
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5 - Bolt
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❑ Qty. 3.
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t.
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❑ 23 Nm
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1.3 Removing and installing door inner seal

During production, a sealant is applied to the door inner seals,
which are then placed on the door flange and rolled on.

1. Door 31
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

♦ The removal and installation sequence is only for the right door
inner seal. The removal and installation of the left door inner
seal is similar.
♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, sealing and firm seating are no longer guaran‐
teed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting. AG. Volkswagen AG d
agen oes
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ility
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
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Vo
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Prote AG.

– Remove front step insert ⇒ General body repairs, interior;

Rep. gr. 68 ; Step inserts; Front step insert .
– Pull door inner seal -1- off body flange.

32 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Installing

Note

The vulcanised point -arrow- on the door inner seal -1- must be positioned centrally on the body flange to entry
step.

– Press inner door seal -1- onto body flange.

Further installation is performed in the reverse order of removal.

Note

After installing, check whether beading of door inner seal -1- reaches completely over adjoining trim.

1.4 Removing and installing front door

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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un

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an
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erm

ab
ility
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wit
is n

h re
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urposes, in part or in wh

t to the co
Removing
rrectne

Note
ss o

The removal and installation procedure is for the left side. The right side is similar.
cial p

f inform
mer

atio
om

n
c

i
or

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pr

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t.
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Cop py
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by
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Prote AG.

1. Door 33
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

n AG. Volkswagen AG do
lkswage es n
o ot g
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– Pull bellows off retaining ring on A-pillar and disconnect multi-

ility
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pin connections -4-.

wit
, is n

h re
– Loosen clamping screw -2- on upper and lower hinge.
hole

spec
es, in part or in w

– Unscrew bolt -3- for door arrester. t to the co

– Further dismantling requires the help of a second mechanic.

– Lift door -1- upwards out of hinges.
rrectness of i

Installing
l purpos

– Guide door -1- into hinge brackets and tighten clamping screw
-2-.
nform
ercia

– Tighten bolt -3- for door arrester.

m

at
om

ion

– Unclip bellows retaining ring from A-pillar and fit retaining ring
c

in t
or

on bellows.
his
ate

do
riv

– Reconnect multi-pin connections and clip retaining ring onto

p

cum
or

A-pillar.
f

en
ng

t.
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op
Specified torques C py
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pyri by
Component Specified torques
co Vo
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Prote AG.
Clamping bolt -2- 18 ± 2.0 Nm
Bolt -3- 23 Nm

34 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.5 Adjusting door

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
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tho eo
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Note

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♦ Vehicle must be standing on its wheels to enable front door to
erm

ab
be adjusted.

ility
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wit
♦ The front door is adjusted correctly if the gaps/shut lines are
is n

h re
even all around, the door is not too deep or does not stand
ole,

spec
proud and all contours align when the is door closed.
urposes, in part or in wh

t to the co
♦ To check or adjust the gaps/shut lines ⇒ Body Repairs; Rep.
gr. 00 ; Technical data; Body gaps/shut lines; Body - front .
♦ After installing or adjusting, carry out corrosion protection rrectne
measures to hinge and bolts.
s

♦ To ensure a correct door adjustment the door hinge must be

s o

loosened on the door. Other measures such as raising the

cial p

f in

door have no effect. Subsequent pressure from above will

form
mer

cause the door to sack again.

atio
om

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c

Adjusting front door at door hinge

or

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te

sd
a

– Loosen bolts -1- from door hinge -2-.

iv

o
pr

cum
r
fo

– After loosening bolts -1- the door gap to the wing can be ad‐
en
ng

t.
yi
justed horizontally and vertically.
Co
Cop py
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– Tighten bolts -1- on door hinge -2-.
ht
pyri by
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cted
Adjust striker ⇒ page 35 .
agen
Prote AG.

Specified torques
♦ ⇒ “1.2 Assembly overview – door hinge”, page 31

1.6 Adjusting striker

Special tools and workshop equipment required

1. Door 35
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

Note

♦ Only adjustment of the right door is described. Adjustment of

the left door is similar.
♦ The door must lock fully when closing without any additional
force being required and must not have any play.
♦ The door must not be pushed up or down due to striker ad‐
justment.

The following can be adjusted at the striker:

• If door adjustment is not aligned to B-pillar:
– Loosen striker -1- by loosening bolts -2- on B-pillar.
– After loosening bolts -2-, movement of U-shaped striker -1- in
horizontal and vertical plane -arrows- is possible.
– Adjust front door with U-shaped striker -1- so that recess of
door lock with rotary latch is positioned in middle of U-shaped
striker and front door aligns with B-pillar when closed.
– Tighten bolts -2- of U-shaped striker -1-. n AG. Volkswagen AG do
lkswage es n
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Specified torques ir se
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ran
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th or
Component Specified torques
ss
au ac
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e

Striker 20 Nm
nl

pt
du

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itte

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erm

ab

1.7 Removing and installing door hinge

ility
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wit
, is n

Special tools and workshop equipment required

h re
hole

spec

♦ Torque wrench - V.A.G 1331-

es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
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36
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Rep. gr.57 - Front doors, door components, central locking Prote AG.
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

The removal and installation procedure is for the left side. The
right side is similar.

Removing
Door upper hinge
– Remove door ⇒ page 33 .
– Unscrew bolt -3- of door hinge -2- (upper) and remove door
hinge.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

Door lower hinge

– Unscrew bolt -5- of door hinge -4- (lower) and remove door
hinge.
Installing
Install in reverse order, but note the following:
– Adjust door ⇒ page 35 .

1. Door 37
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Greasing new door hinges

Note

The new door hinge is greased after painting.

– Door upper hinge should be greased on pin and in hole lithium

grease - G 000 150- .
– The lower door hinge should be greased on the pin and hole
with lithium grease - G 000 150- .

1.8 Removing and installing door arrester

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing

Note

The removal and installation procedure is for the left side. The
right side is similar.
AG. Volkswagen AG d
agen oes
olksw not
– Remove front door trim d by V⇒ General body repairs, interior; gu Rep.
ara
gr. 70 ; Trims/insulation;
orise Door trims . nte
eo
h
ut ra
– Unscrew bolts -2- from A-pillar.
s a c
ce
le

– Unscrew bolts -3- (qty. 3) from door.

un

pt
an
d
itte

y li

– Take out door arrester -1- through opening in door inner panel.
erm

ab
ility
ot p

Installing
wit
is n

h re

Install in reverse order, but note the following:

ole,

spec
urposes, in part or in wh

Specified torques
t to the co

Component Specified torques

Bolts -3- 12 Nm
rrectne

Bolt -2- 23 Nm
ss o
cial p

1.9 Removing and installing striker

inform
mer

Special tools and workshop equipment required

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
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t.
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Cop py
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38
copy Vo
by lksw
Rep. gr.57 - Front doors, door components, central locking
cted agen
Prote AG.
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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Removing

ce
e
nl

pt
du

an
– Unscrew bolts -2- and remove striker -1-.
itte

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erm

ab
Installing

ility
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wit
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Install in reverse order, but note the following:

h re
hole

spec
– Adjust striker -1- ⇒ page 35 .
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

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Prote AG.

1. Door 39
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2 Door components
⇒ “2.1 Assembly overview - window regulator”, page 40
⇒ “2.2 Assembly overview - door handle and door lock”,
page 41
⇒ “2.3 Removing and installing window regulator”, page 41
⇒ “2.4 Removing and installing window regulator motor”,
page 43
⇒ “2.5 Removing and installing lock cylinder housing”,
page 45
⇒ “2.6 Removing and installing door handle”, page 46
⇒ “2.7 Removing and installing mounting bracket”, page 46
⇒ “2.8 Removing and installing door lock”, page 47

2.1 Assembly overview - window regulator

Note

Only the left side is shown. The right side is similar.

1 - Window regulator
❑ Removing and installing
⇒ page 41
2 - Hexagon nut
AG. Volkswagen AG d
❑ Qty. 2. lksw
agen oes
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❑ 7.0 Nm ed by ara
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3 - Bolt aut
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❑ Qty. 2.
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nl

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❑ 7.0 Nm
an
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4 - Connector
ility
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❑ For window regulator

wit
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motor
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spec
es, in part or in w

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rrectness of i
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m

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t.
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Cop py
t. rig
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Vo
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by c lksw
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Prote AG.

40 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
olkswagen AG
en AG. V
2.2 Assembly
yV
olks
wag overview - door
does
not handle and door lock
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1- Bearing
au bracket ac
ss
❑ Removing and installing

ce
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⇒ page 46 .

an
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itte

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2 - Door handle

ab
ility
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❑ Removing and installing

wit
is n

⇒ page 46 .

h re
ole,

spec
3 - Bolt
urposes, in part or in wh

❑ Qty. 2.

t to the co
❑ 1.5 Nm
4 - Base

rrectne
❑ For rear of door handle

ss
5 - Bowden cable

o
cial p

f in
❑ For interior opening

form
mer

mechanism.

atio
m

6 - Bowden cable
o

n
c

i
or

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❑ For exterior actuation
thi
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sd
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bearing bracket
iv

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7 - Door lock
en
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t.
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❑ Removing and installing . Cop py
⇒ page 47 .
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8 - Bolt
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Prote AG.
❑ Qty. 3.
❑ Specified torque: 10 Nm
9 - Operating rod
❑ To lock cylinder housing
10 - Locking rod
❑ To door lock
11 - Lock cylinder housing
❑ Removing and installing
⇒ page 45 .
12 - Bolt
❑ 3.0 Nm
13 - Base
❑ For front of door handle

2.3 Removing and installing window regula‐

tor
Special tools and workshop equipment required

2. Door components 41
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

Note AG. Volkswagen AG d

agen oes
olksw not
The removal and installation procedure
ed byV is for the left side. The gu
ara
right side is similar. horis nte
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ss c
Removing

ce
le
un

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an
d

– Remove front door trim panel ⇒ General body repairs, interior;

itte

y li
Rep. gr. 70 ; Trims/insulation; Door trim panels .
rm

ab
pe

ility
ot

– Remove electrical components (if fitted) from front door ⇒

wit
, is n

Electrical system; Rep. gr. 96 ; Lights, bulbs, switches - inte‐

h re
hole

rior .

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

42 Rep. gr.57 - Front doors, door components, central locking

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Crafter nte2006 ➤
h eo
aut General body repairs, exterior - Edition 10.2014 ra
c
ss

ce
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ility
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wit
is n

h re
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

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mer

atio
om

n
c

i
or

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te

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iva

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pr

cum
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fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.

– Carefully pull sealing foil off front door.

– Push up door window and secure in this position using com‐
mercially available adhesive tape.
– Disconnect connections -4- on window regulator motor.
– Remove hexagon nut -2-.
– Unscrew bolts -3-.
– Remove window regulator -1- from door inner part.
Installing
Install in reverse order, but note the following:

2.4 Removing and installing window regula‐

tor motor
Special tools and workshop equipment required

2. Door components 43
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

Removing

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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cu
o

m
f

en
ng

t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
– Remove window regulator ⇒ page 41 .
– Remove bolts -arrows- from back of window regulator -1-.
– Carefully pull window regulator -2- off relay roller -3-.
Installing
– Carefully guide window regulator -2- into relay roller -3-.

44 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Fit bolts -arrows- from back of window regulator -1-, and tight‐
en them.
– Install window regulator ⇒ page 41 .
Specified torques
Component Specified torques
Window regulator motor 7.0 Nm

2.5 Removing and installing lock cylinder

housing
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

Note

Removal and installation are described for the right side. The left
side is similar.
AG. Volkswagen AG d
agen
Removing olksw
oes
not
byV gu
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– Lever cap -5- out of opening inorifront
se door -1-. nte
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h
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– Remove bolt -4- located below.
ss a c
ce
e
nl

– Unclip operating rod -3- from lock cylinder housing -2-.

pt
du

an
itte

y li
erm

ab
ility
ot p

Note
wit
, is n

h re

Operating rod -3- must be secured to prevent it falling into door.

hole

spec
es, in part or in w

t to the co

– Carefully pull lock cylinder housing -2- out at right angles to

front door -1-.
Installing
rrectness of i

Install in reverse order, but note the following:

l purpos

Specified torques
nf
ercia

Component Specified torques

rm
m

atio
m

Lock cylinder housing 3.0 Nm

o

n in
or c

thi
te

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Cop py
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by lksw
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Prote AG.

2. Door components 45
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.6 Removing and installing door handle

Note

Removal and installation are described for the right side. The left
side is similar.

Removing
. Volkswagen AG
gen AG does
– Remove lock cylinder housing
Vol
k⇒ page 149 .
swa not
by gu
d ara
– Pull door handle to rearoris and swivel handle out of door.
e nte
h eo
ut ra
Installing ss a c

ce
e
nl

Install in reverse order of removal.

pt
du

an
itte

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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
2.7 Removing and installing mounting

rrectness of i
bracket
l purpos

Special tools and workshop equipment required

nform
ercia

♦ Torque wrench - V.A.G 1783-

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note

The removal and installation procedure is for the left side. The
right side is similar.

46 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Remove door handle ⇒ page 150 .
– Remove door lock ⇒ page 47 .
– Remove bolts -1- along with seal -2- from outer side of door.

– Remove bearing bracket -1- from door inner part.

– Unclip Bowden cable -2-.
Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torques
Door lock 2.0 Nm

. Volkswagen AG
gen AG
2.8 Removing and installing doory Vlock wa does
olks not
gu
b ara
ed
Special tools and workshop equipment required
tho
ris nte
eo
au ra
♦ Torque wrench - V.A.G 1783- ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform

Note
mer

atio
m

The removal and installation procedure is for the left side. The
o

n
c

right side is similar.

or

n thi
te

sd
iva

o
pr

Removing
um
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

2. Door components 47
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove front door trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Trims/insulation; Door trims .
– Remove electrical components (if fitted) from front door ⇒
Electrical system; Rep. gr. 96 ; Lights, bulbs, switches - inte‐
rior .
– Carefully pull sealing foil off front door -1-.
– Unscrew bolts -4- for door lock -2-.
– Prise operating rod -5- off lock cylinder housing -6-.
– Remove door lock -2- from front door -1-.
– Unhook Bowden cable -3- from bearing bracket and discon‐
nect electrical connections.
Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torques
Door lock 10 Nm

48 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3 Central locking
⇒ “3.1 Overview of fitting locations – central locking”, page 49
⇒ “3.2 Assembly overview - ignition key to 2010”, page 50
⇒ “3.3 Assembly overview - ignition key from 2010”, page 51
⇒ “3.4 Removing and installing ignition key battery to 2010”, page
51
⇒ “3.5 Removing and installing ignition key battery from 2010”,
page 52

3.1 Overview of fitting locations – central locking

1 - Electronic ignition lock - D9-

❑ Removing and installing
⇒ Electrical system;
Rep. gr. 94 ; Lights,
bulbs, switches - exteri‐
or; Electronic ignition
lock .
AG. Volkswagen AG d
2 - Front passenger side cen‐ ksw
agen oes
not
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tral locking lock unit - F221- byV
o gu
ara
ed
❑ Electric central locking horis nte
eo
is integrated into door s aut ra
c
lock. s

ce
e
nl

pt
❑ Removing and installing
du

an
itte

door lock ⇒ page 47

y li
erm

ab
ility
3 - Rear wing door lock
ot p

wit
, is n

❑ Electric central locking

h re
is integrated into door
hole

spec
lock.
es, in part or in w

t to the co
❑ Removing and installing
door lock ⇒ page 148
4 - Rear left central locking lock

rrectness of i
unit - F222-
l purpos

❑ Electric central locking

is integrated into door
lock.
nform
ercia

❑ Removing and installing

m

at
door lock ⇒ page 77
om

ion
c

in t
r

5 - Driver side central locking

o

his
te

lock unit - F220-

a

do
priv

❑ Electric central locking

um
for

en
g

is integrated into door

n

t.
yi Co
lock. ht. Cop py
rig
❑ Removing and installing rig ht
py by
Vo
door lock ⇒ page 47
co lksw
by
cted agen
Prote AG.
6 - Door control unit
❑ Secured to inside of door ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim; Removing and
installing front door trim
7 - Central switch for window regulators in driver door - E189-
❑ Location: installed in door panel
❑ Removing and installing central switches for window regulators ⇒ Vehicle electrics; Rep. gr. 96 ; Elec‐
trical system; Interior lights, lamps, switches; Lights and switches in doors .

3. Central locking 49
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

8 - Bonnet contact switch - F266-

❑ Bonnet contact switch - F266- is attached under bonnetwcatch
agen on lock carrier
AG. Volkswagen AG d
oe
ks s no
Vol t gu
d by ara
e nte
ris
ho eo
3.2 Assembly overview - ignition key to 2010
t
au ra
c
ss

ce
le
un

pt
an
d
itte
1 - Key with variable code

y li
rm

ab
transponder

pe

ility
ot
2 - Transmitter unit - upper part

wit
, is n

h re
hole
3 - LED

spec
es, in part or in w

❑ When remote control is

t to the co
operated, this LED must
flash briefly.
❑ If LED does not flash

rrectness of i
during remote control
operation, the battery is
l purpos

dead and must be re‐

newed.

nform
ercia

4 - Battery
m

a
com

t
❑ Removing and installing

ion in
battery ⇒ page 51
r
te o

thi
s
iva

5 - Transmitter unit - lower part

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

50 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3.3 Assembly overview - ignition

Volkswa
key from 2010
AG. gen AG
agen does
olksw not
yV gu
1 - Key with transmitter unit
rise
db ara
nte
tho
❑ Individual transmitter
eo
au ra
units cannot be
s re‐
s c

ce
placed le
un

pt
an
d
itte

2 - LED

y li
rm

ab
pe

❑ When remote control is

ility
ot

operated, this LED must

wit
, is n

flash briefly.

h re
hole

spec
❑ If LED does not flash
es, in part or in w

during remote control

t to the co
operation, the battery is
dead and must be re‐
newed.

rrectness of i
3 - Cap
l purpos

4 - Battery
❑ Removing and installing

nform
ercia

battery ⇒ page 52
m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3.4 Removing and installing ignition key bat‐

tery to 2010
Removing
– Insert screwdriver in slot between transmitter unit -1- and key
-2-.
– Turn screwdriver in direction of -arrow- to separate transmitter
unit from key.

3. Central locking 51
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Press transmitter unit -1- apart using profile section of key

-2-.

– Unclip battery -1- from the retainers -2- with a screwdriver in

direction of -arrow-.
Installing

Note

♦ Before installing battery, always press any key once.

olkswagen AG
en AG. V
♦ Thus transmitter unit is reset and can recognize a new obattery
lksw
ag does
not
only now. db
yV gu
ara
ir se nte
ho eo
aut ra
ss c

ce
le

Ensure correct polarity and mounting position when installing bat‐

un

pt
an
d

tery.
itte

y li
rm

ab
– Lay battery -1- with positive pole downwards in transmitter unit
pe

ility
-2- (positive pole is marked on housing).
ot

wit
, is n

h re
– Gently press -arrow- battery into transmitter unit until it en‐
hole

spec
gages.
es, in part or in w

t to the co
– Join lid and transmitter unit (make sure not to damage seal).
– Then engage transmitter unit in key.

rrectness of i
Keys with remote control are adapted using ⇒ Vehicle diagnostic
tester.
l purpos

– In the vehicle diagnostics tester, select “Guided Fault Finding”.

nform
ercia

– Press GoTo button and select “Function/component selec‐

m

tion”.
a
com

tion in
r
te o

3.5 Removing and installing ignition key bat‐

thi
s
iva

do

tery from 2010

r
rp

cum
fo

en
ng

t.
yi
Removing
Co
Cop py
t. rig
– Insert a small screwdriver in the gap between cap -1- and key
gh ht
pyri by
-2-.
co Vo
by lksw
cted agen
Prote AG.
– Push the screwdriver in -direction of arrow- and prise cap off
key.

52 Rep. gr.57 - Front doors, door components, central locking

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Push battery -1- in -direction of arrow- and withdraw it from key

-2- upwards -arrow b-.
Installing

Note
AG. Volkswagen
♦ Before installing battery,
lkswalways press any key once.
agen AG do
es n
o ot g
yV
♦ Thus transmitter ed b is reset and can recognize a newuabattery
unit ran
ris tee
only now. utho or
a ac
ss
♦ Note polarity and correct position when installing battery.

ce
e
nl

pt
du

an
itte

y li
erm

– Insert battery -1- in key -2- in -direction of arrow- with the pos‐

ab
ility
itive pole underneath.
ot p

wit
, is n

– Press lightly on the battery to engage it in the key.

h re
hole

spec
– Now fit cover to the key.
es, in part or in w

t to the co
Keys with remote control are adapted using ⇒ Vehicle diagnostic
tester.

rrectness of i
– In the vehicle diagnostics tester, select “Guided Fault Finding”.
l purpos

– Press GoTo button and select “Function/component selec‐

tion”.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Central locking 53
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

58 – Rear doors, door components

olks
wage
n AG. Volkswagen AG do
es n
o
yV t gu
db ara
ise
1 Sliding door r nte
tho eo
au ra
c
ss
⇒ “1.1 Assembly overview - guide rail”, page 54

ce
le
un

pt
an
d
⇒ “1.2 Assembly overview – upper guide rail”, page 55

itte

y li
erm

ab
⇒ “1.3 Removing and installing sliding door inner seals”,

ility
ot p
page 55

wit
is n

h re
⇒ “1.4 Removing and installing sliding door”, page 56 ole,

spec
urposes, in part or in wh

⇒ “1.5 Adjusting sliding door”, page 58

t to the co
⇒ “1.6 Removing and installing guide rail”, page 66
⇒ “1.7 Removing and installing upper guide rail”, page 67

rrectne
1.1 Assembly overview - guide rail

ss o
cial p

f in
1 - Guide rail

form
mer

❑ Removing and installing

atio
m

⇒ page 66
o

n
c

i
or

n thi
e

2 - Hexagon nut
t

sd
iva

o
r

❑ Qty. 6.
p

cum
r
fo

en
ng

❑ 8.0 Nm yi
t.
Co
op py
3 - Cap
t. C rig
gh ht
yri by
❑ Qty. 6.
op Vo
by c lksw
cted agen
Prote
4 - Bolt
AG.

❑ 8.0 Nm
5 - End piece
❑ Clipped into guide rail
-1-

54 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.2 Assembly overview – upper guide rail

1 - Upper guide rail

❑ Removing and installing
⇒ page 67
2 - Hexagon nuts
❑ Qty. 6.
❑ 8.0 Nm
3 - Opening restrictor
❑ Removing and installing
⇒ page 74 .
4 - Upper roller guide
❑ Removing and installing
⇒ page 72 . AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

1.3 Removing and installing sliding door in‐

cu
o

m
f

en
ng

ner seals
t.
yi Co
Cop py
t. rig
gh
During production a sealant is applied to the sliding door inner
ht
pyri by
Vo
o
seals, which are then placed on the sliding door flange and rolled by c lksw
cted agen
on. Prote AG.

Note

♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
refitted, there is no guarantee that it will sit securely or provide
adequate sealing properties.
♦ Therefore each seal which is removed completely should be
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.

Removing

1. Sliding door 55
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Pull off sliding door inner seals -1- from body flange.
Installing
– The vulcanised point -arrow- on the sliding door inner seal
-1- must be positioned on the rear radius of the body flange.
– Press sliding door inner seals -1- onto body flange.

Note

After installing, check beading of sliding door inner seal -1- is completely over adjoining trim.

1.4 Removing and installing sliding door

Special tools and workshop equipment required

56 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
. Volkswagen AG
General
kswagen AGbody repairs, exterior
doesn - Edition 10.2014
ol ot g
yV ua
db ran
♦ Torque wrench - V.A.G 1331- ris
e
tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Note

nform
ercia

The removal and installation sequence is only for the right sliding
m

door. The removal and installation of the left sliding door is similar.

at
om

ion
c

in t
or

Removing

his
ate

do
riv

– Remove sliding door trim ⇒ General body repairs, interior;

p

cum
or

Rep. gr. 70 ; Trims/insulation; Removing and installing sliding

f

en
ng

t.
yi
door trim .
Co
Cop py
ht. rig
– Release locking lug -arrow- upwards using a screwdriver. rig ht
py by
co Vo
by lksw
– Pull off cover strip -1- to rear from guide rail. cted agen
Prote AG.

– Open coupling cover -3- of Bowden cable coupling -1- up‐

wards.
– Unhook door arrester Bowden cable -2- from Bowden coupling
-1- and feed Bowden cable -2- out of sliding door.

1. Sliding door 57
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Further dismantling requires the help of a second mechanic.

– Mark position of bolts -2-.
– Remove bolts -2- (qty. 3) from retainer -1-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
– Pull out wiring harness -2- from sliding door sufficiently to allow

ility
ot p

wiring connections -1- of installed electrical components to be

wit
disconnected.
is n

h re
ole,

– Pull out Bowden cable -2- from bottom opening of sliding door.

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
– Remove bolt -2- from upper retainer -1-.
om

n
c

i
or

n
– Move sliding door back until hinge fitting is completely pushed

thi
te

sd
out of guide rail.
iva

o
pr

cum
r

Installing
fo

en
ng

t.
yi Co
Install in reverse order, but note the following: Cop py
t. rig
gh ht
yri
• Then check function of sliding door. p by
co Vo
by lksw
cted agen
Specified torques Prote AG.

Component Specified torques

Bracket 23 Nm

1.5 Adjusting sliding door

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

58 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

⇒ “1.5.1 Basic setting, sliding door”, page 59

Volkswagen AG
⇒ “1.5.2 Hinge fitting and roller guides”, page 61swagen AG. does
olk not
yV gu
⇒ “1.5.3 Locking system”, page 62 edb ara
nte
ris
ho eo
⇒ “1.5.4 End position engagement”, apage
ut 64 ra
c
ss
1.5.1 Basic setting, sliding door

ce
le
un

pt
an
d
itte

y li
Prerequisites for adjusting sliding door
rm

ab
pe

ility
ot

wit
, is n

Note

h re
hole

spec
es, in part or in w

♦ Vehicle must be parked on hard, level standing for adjustment

t to the co
to be performed.
♦ Doors must be fully equipped.

rrectness of i
♦ Windows must be closed.
l purpos

♦ Only the adjustment for the right sliding door is described. The
adjustment of the left sliding door is similar.

nform
ercia

♦ The sliding door is adjusted correctly if the gaps/shut lines are

m

even all around, the door is not too deep or does not protrude

a
com

tio
and all contours align when the is door closed ⇒ Body Repairs;

n in
Rep. gr. 00 ; Body gaps/shut lines; Body, middle.
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Sliding door 59
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

A - Swage line offset max. 1

mm
B - Shut line top/bottom 5.5
mm ± 1 mm wage
n AG. Volkswagen AG do
es n
lks ot g
Vo
C - Shut line C-pillar 7 mm ± 1 ed by ua
ran
mm tho
ir s tee
or
au ac
C - Shut line B-pillar ≥ 7 mm,
ss

ce
e

aligning not permissible

nl

pt
du

an
itte

Tapering up to 0.5 mm permis‐

y li
erm

ab
sible

ility
ot p

wit
, is n

Align sliding door evenly

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Preparatory measures
– Wedges and U-shaped strikers have not yet been fitted or
have only been tightened »hand-tight«.
– Rubber buffers -1- at top and bottom must be preadjusted.
Specified rubber buffer height
♦ Bottom rubber buffer 22 mm - 23 mm
♦ Top rubber buffer 13 mm - 14 mm
♦ Top rubber buffer, high sliding door, 19 mm - 20 mm
Adjusting gaps and shut lines
• Roller guides ⇒ page 61
• Locking system ⇒ page 62
• End position engagement ⇒ page 64

60 Rep. gr.58 - Rear doors, door components

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Crafter 2006 ➤
ris
ut
ho General
eo
ra
body repairs, exterior - Edition 10.2014
s a c
s
1.5.2 Hinge fitting and roller guides

ce
e
nl

pt
du

an
itte

y li
Shut lines on B and C-pillar (dimension C) ⇒ Item C (page 60)
erm

ab
ility
ot p

– Adjust shut lines on C-pillar joint via hinge fitting -1-. Loosening

wit
, is n

bolts -2- makes simple adjustment (sliding door back/forth)

h re
possible because a guide is integrated in hinge fitting -1- that
hole

spec
prevents twisting.
es, in part or in w

t to the co
– It is acceptable to assume that B-pillar gap ≥ 7 mm, therefore
alignment is not permissible.

rrectness of i
– Then, tighten bolts -2-.
l purpos

Specified torques
Component Specified torques

nf
ercia

o
Hinge 23 Nm ± 2.0 Nm

rm
m

atio
m

Shut line in roof frame and sill (dimension B) ⇒ Item B (page 60)
o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
– Adjust shut line at hinge fitting -1-.
by lksw
cted agen
Prote AG.
– Loosen hexagon nut -2-.
– Raise or lower sliding door using adjustment screw -3-.
– Then, tighten hexagon nut -2-.
Specified torques
Component Specified torques
Hinge 25 Nm ± 5.0 Nm

Adjusting shut line at upper roller guide

– Upper roller guide can be adjusted once bolts -1- (qty. 3) have
been loosened.
– Then, tighten bolts -1-.
Specified torques
Component Specified torques
Upper roller guide 23 Nm ± 2.0 Nm
– If necessary, loosen lower roller guide and align between ad‐
justing box trim and portal seal.
– The up/down adjustment of lower roller guide is important for
arrester function.
Aligning swage line at B-pillar (dimension A); tolerance of up to
-0.5 mm ⇒ Item A (page 60)

1. Sliding door 61
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Match surfaces via upper roller guide (adjust in/out at B-pillar/

sill/roof frame).
– Upper roller guide -1- can be adjusted once bolt -2- has been
loosened.
– Then, tighten bolt -2-.
Specified torques
Component Specified torques
Upper roller guide 20 Nm ± 5.0 Nm

G. Volkswagen AG d
– Match surfaces via lower roller guide (adjust in/out at B-pillar/ lkswagen A oes
not
sill/roof frame). by
Vo gu
ara
ed nte
ris
– Lower roller guide can be adjusted once bolt -1- has beentho eo
loosened. s au ra
c
s

ce
e
nl

– Then, tighten bolts -1-.

pt
du

an
itte

y li
Specified torques
erm

ab
ility
ot p

Component Specified torques

wit
, is n

h re
Lower roller guide 10 Nm ± 5.0 Nm
hole

spec
es, in part or in w

t to the co
1.5.3 Locking system

rrectness of i
l purpos

Note

nform
ercia

♦ The sliding door must not be raised or lowered via the U-sha‐
ped striker -1- as otherwise the sliding door will catch when it
m

at
om

is opened, causing superficial or permanent damage to the

ion
c

door lock.

in t
or

his
ate

♦ After adjusting to character lines, ensure that the gaps at the

do
priv

c
top and bottom of the door lie with tolerances.
um
for

en
ng

t.
yi
♦ For optical reasons a slightly wedge shaped gap at the top and
Co
op py
bottom of the door is more acceptable than an offset character t. C rig
gh ht
line. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Aligning swage line at C-pillar (dimension A), tolerance of
+0.5 mm to +1.0 mm ⇒ Item C (page 60)
– Match surfaces via striker -1- (adjust in/out at sliding door on
C-pillar).
– Fit U-shaped striker -1-, tighten bolts -2- lightly.
– Adjust U-shaped striker -1- so that engagement in rotary latch
is smooth.
– Then, tighten bolts -2-.
Specified torques
Component Specified torques
Striker 20 Nm ± 2.0 Nm
– Adjust extra striker pin for additional lock.

62 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Striker pin -1- can be adjusted by loosening.

– Adjust striker pin -1- in such a way that recess of door upper
lock with rotary latch is centred relative to striker pin -1-.
– Then, tighten striker pin -1-.
Specified torques
Component Specified torques
Striker pin 20 Nm ± 2.0 Nm
Door arrester function on lower roller guide

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu

– Lower roller guide -1- can be adjusted once bolts -2- have
o

m
f

en
ng

been loosened.
t.
yi Co
Cop py
– To ensure arrester catch -3- moves centrally into rotating pin, ht. rig
rig ht
up/down adjustment of lower roller guide -1- must be per‐
py by
co Vo
by lksw
formed with sliding door open. Prote
cted AG.
agen

– When doing this, ensure that arrester catch -3- is located cen‐
trally in rotating sleeve.
– Then, tighten bolts -2-.

1. Sliding door 63
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques
Component Specified torques
Lower roller guide 23 Nm ± 2.0 Nm

1.5.4 End position engagement

Limit stops and arrester function

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
Adjust limit stops -1-:
co Vo
by lksw
cted agen
Prote AG.
– Limit stop -1- can be adjusted once bolts -2- have been loos‐
ened.
Both buffers must engage at same time.
In relation to this, note that arrester function depends on adjust‐
ment of sliding door (back/forth) and limit stops.
When arrester catch -3- is engaged and sliding door is pulled in
direction of travel, a gap of 2 - 3 mm must be assured at contact
surface of buffers to C-pillar to allow smooth disengagement.
– Then, tighten bolts -2-.

64 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques
Component Specified torques
Lower roller guide 23 Nm ± 2.0 Nm
Upper and lower rubber buffers
Adjust rubber buffers -1- at top and bottom again as necessary.
– Adjust rubber buffers -1- at top and bottom of sliding door by
screwing them in or out.

Note

♦ When adjusting the rubber buffers -1- at the top and bottom,
make absolutely sure that these are set with 1.0 mm to 1.5 mm
overlap.
♦ If they are too loose, rattling or knocking noises will be caused.
♦ If the sliding door is misaligned, the force necessary at the
handles to open and close will be increased.

Caution

The rubber buffers must not be used to adjust the door.

Guide wedges and slides

– Fit guide wedges -1- on sliding door, align centrally to indicator

markings and tighten bolts -2- lightly.

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65
Prote AG.
1. Sliding door
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Fit slides -1- on B-pillar, align centrally and tighten bolts -2-
lightly.
– Open and close sliding door to centre wedges.
– When doing this, pay special heed to ensure that crash pin
engages in mounting hole of slide without contact.
– Retighten via tapered pin on guide wedge if necessary.
– Then, tighten bolts -2-.
Specified torques
Component Specified torques
Guide wedges and slides 8.0 Nm ± 1.0 Nm

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1.6 Removing and installing guide rail
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and installing trim strip for side window . cted agen
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– Release locking lug -arrow- upwards using a screwdriver.

– Pull off cover strip -5- to rear from guide rail -1-.
– Remove sliding door ⇒ page 56 .
– Lever off cap -3- using a screwdriver and unscrew hexagon
nuts -2-.
– Unscrew bolt -4- and remove guide rail -1-.

66 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
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Installing
m

Install in reverse order, but note the following:

com

tion in

Specified torques
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thi
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1.7 Removing and installing upper guide rail

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rp

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Special tools and workshop equipment required

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Prote AG.

1. Sliding door 67
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Remove roof trim ⇒ General body repairs, interior; Rep. gr.
70 ; Trim, insulation; Roof trim .
– Remove opening restrictor -3- ⇒ page 74 .
– Remove upper roller guide -4- ⇒ page 72 .
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– Unscrew hexagon nuts -2-, and removeVoupper
lksw guide rail -1-. not
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Installing
Install in reverse order, but note the following:
Specified torques

68 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
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2 Components of sliding door
d ara
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⇒ “2.1s Assembly overview – components of sliding door”,c
s
page 69

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⇒ “2.2 Assembly overview - interior operating mechanism”, page

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71

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⇒ “2.3 Assembly overview – additional lock”, page 72
, is n

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⇒ “2.4 Removing and installing upper roller guide”, page 72

spec
es, in part or in w

⇒ “2.5 Removing and installing lower roller guide”, page 73

t to the co
⇒ “2.6 Removing and installing hinge”, page 73

rrectness of i
⇒ “2.7 Removing and installing sliding door limit stop”,
page 74
l purpos

⇒ “2.8 Removing and installing opening restrictor”, page 74

nf
ercia

⇒ “2.9 Removing and installing lock cylinder housing”,

or
page 75

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⇒ “2.10 Removing and installing door handle”, page 75

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or c

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⇒ “2.11 Removing and installing bearing bracket”, page 75

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⇒ “2.12 Removing and installing door lock”, page 77
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⇒ “2.13 Removing and installing interior operating mechanism”,
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⇒ “2.14 Removing and installing additional lock at top”,
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page 80
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⇒ “2.15 Removing and installing striker pin”, page 81

⇒ “2.16 Removing and installing striker”, page 82
⇒ “2.17 Removing and installing guide wedge and slide”,
page 82

2.1 Assembly overview – components of sliding door

Note

♦ Spare parts are supplied without sealing due to various reasons. In these cases, we recommend sealing
the spare parts before forwarding to the paint shop ⇒ Workshop Manual “Paint” .
♦ The right side is shown. The left side is similar.

2. Components of sliding door 69

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Sliding door
❑ Removing and installing
⇒ page 56 .
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2 - Rubber buffer agen oes
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❑ Upper and lower rised ara
nte
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❑ Adjusting ⇒ page 65 aut
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ra
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3 - Additional lock at top

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❑ Removing and installing

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⇒ page 80 erm

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4 - Hinge

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❑ Removing and installing
hole

⇒ page 73 .

spec
es, in part or in w

❑ Adjusting ⇒ page 61

t to the co
5 - Door lock
❑ Removing and installing

rrectness of i
⇒ page 77 .
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6 - Lower roller guide

❑ Removing and installing

nform
ercia

⇒ page 73 .
m

❑ Adjusting ⇒ page 61

at
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ion
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7 - Sliding door limit stop

in t
or

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❑ Bottom
a

do
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❑ Removing and installing

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⇒ page 74 .
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❑ Adjusting ⇒ page 64
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8 - Guide wedge
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❑ Upper and lower Prote AG.

❑ Removing and installing

⇒ page 82 .
❑ Adjusting ⇒ page 64
9 - Bearing bracket
❑ Removing and installing ⇒ page 75 .
10 - Seal
❑ For door handle
11 - Seal
❑ For lock cylinder housing.
❑ Removing and installing ⇒ page 75
12 - Door handle
❑ Removing and installing ⇒ page 75 .
13 - Lock cylinder housing
❑ Removing and installing ⇒ page 75 .
14 - Interior opening mechanism
❑ Removing and installing ⇒ page 78
15 - Sliding door limit stop
❑ Top
❑ Removing and installing ⇒ page 74 .
❑ Adjusting ⇒ page 64

70 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

16 - Upper roller guide

❑ Removing and installing ⇒ page 72 .
❑ Adjusting ⇒ page 61

2.2 Assembly overview - interior operating mechanism

1 - Trim
2 - Interior opening mechanism
❑ Removing and installing
⇒ page 78
3 - Cap
❑ Qty. 3.
4 - Bolt
❑ Qty. 3.
❑ 10 Nm
5 - Bowden cable
❑ To door lock
6 - Bowden cable
❑ To locking knob wage
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2. Components of sliding door 71

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.3 Assembly overview – additional lock

1 - Additional lock
❑ Removing and installing
⇒ page 80
2 - Bolts
❑ Qty. 2.
❑ 10 Nm
3 - Bowden cable
❑ To door lower lock

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2.4 Removing and installing upper roller

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t to the co

Removing
– Mark position of bolts -1-.
rrectne

– Remove bolts -1- (Qty. 3) and remove upper roller guide.

– Move upper roller guide backwards out of guide rail.
ss o
cial p

Installing
inform
mer

Install in reverse order, but note the following:

atio
om

Specified torques
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Component Specified torques

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Upper roller guide 23 Nm

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72 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.5 Removing and installing lower roller

guide
Removing
– Remove step of sliding door ⇒ General body repairs, interior;
Rep. gr. 68 ; Step inserts .
– Further removal is only possible with a second mechanic hold‐
ing the sliding door while the lower roller guide -1- is being
fitted.
– Separate connector -3- and unclip cable ties.
– Remove lower roller guide -1- with wiring guide -2- from entry/
access.
Installing
Install in reverse order of removal.

2.6 Removing and installing hinge

Removing
– Release locking lug -arrow- upwards using a screwdriver.
– Pull off cover strip -1- to rear from guide rail.
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– Remove bolts -1- (Qty. 4).
es, in part or in w

t to the co
– Guide hinge fitting -2- completely out of guide rail.
Installing
rrectness of i

Hinge -2- installation is carried out in reverse order of removal.

l purpos

– Adjust sliding door ⇒ page 58 .

Specified torques
nform
mercia

Component Specified torques

at
om

ion
c

Hinge 23 Nm
in t
or

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Prote AG.

2. Components of sliding door 73

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.7 Removing and installing sliding door lim‐

it stop
Removing
Sliding door upper limit stop
– Remove bolts -2- (Qty. 3).
– Remove sliding door upper limit stop -1-.

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– Remove bolts -2- (Qty. 3). rised
nte
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– Remove sliding door lower limit stop -1-. ss a ra
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un

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Install in reverse order, but note the following:
erm

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– Adjust sliding door upper and lower limit stops. ⇒ page 64

wit
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spec
Note
urposes, in part or in wh

t to the co
Apply specified torque when tightening bolts -2-. 2 different ver‐
sions may be installed.

rrectne
Specified torques

ss
Sliding door limit stop Specified torques

o
cial p

f inform
Bolts M8 x 16 (strength rating: 8.8) 23 Nm
mer

atio
Bolts M8 x 16 (strength rating: 10.9) 32 Nm
om

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2.8 Removing and installing opening restric‐

t

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Removing Cop py
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– Remove roof trim ⇒ General body repairs, interior; Rep. gr. py by
co Vo
70 ; Trim, insulation; Roof trim .
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Prote AG.
– Unscrew hexagon nuts -2- and remove opening restrictor -1-.
Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torques
Opening restrictor 10 Nm

74 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.9 Removing and installing lock cylinder

housing
Removing
– Lever out cap -5- from opening in sliding door.
– Unscrew bolt -4- located beneath.
– Carefully pull out lock cylinder housing -2- with seal -3- from
door handle bearing bracket perpendicular to sliding door.
Remove door handle -1- ⇒ page 75 .
Installing
Install in reverse order, but note the following:
Specified torques
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Component Specified yV
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Lock cylinder housing 3.0 Nmor is tee
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2.10 Removing and installing door handle

h re
ole,

spec
urposes, in part or in wh

Removing

t to the co
– Removing lock cylinder housing ⇒ page 75 .
– Pull back door handle and swing out of door.

rrectne
Installing

s
Install in reverse order of removal.

s o
cial p

f inform
mer

atio
om

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2.11 Removing and installing bearing bracket
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Special tools and workshop equipment required
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Prote AG.
♦ Torque wrench - V.A.G 1783-

2. Components of sliding door 75

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Remove door handle ⇒ page 75 .
– Unscrew bolts -1- from outside door with seal -2-.

AG. Volkswagen AG d
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– Remove bolt -2-.

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– Remove bearing bracket -1- from door inner part and unclip t. C rig
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Installing Prote AG.

Install in reverse order, but note the following:

76 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques
Component Specified torques
Mounting bracket 2.0 Nm

2.12 Removing and installing door lock

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

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Removing aut or
ac
ss
– Remove sliding door trim ⇒ General body repairs, interior;

ce
le
un

pt
Rep. gr. 70 ; Trim, insulation; Door trims .

an
d
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– Remove additional lock ⇒ page 80 .
pe

ility
ot

– Remove bolts -1- from door lock -2-.

wit
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es, in part or in w

t to the co
rrectness of i
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mercia

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Prote AG.

2. Components of sliding door 77

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
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es, in part or in w

t to the co
rrectness of i
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nform
ercia

– Remove door lock -1- from door inner part and separate con‐
m

nector -6-.
a
com

tion in

– Release locking device -arrow- using a screwdriver and pull

r
te o

thi

off Bowden cable retainer from door lock -1-.

s
iva

do
r
rp

– Unhook Bowden cables -2-, -3-, -4- and -5- from door lock
um
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-1-.
en
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Install in reverse order, but note the following:
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Prote AG.
Specified torques
Component Specified torques
Door lock 10 Nm

2.13 Removing and installing interior operat‐

ing mechanism
Special tools and workshop equipment required

78 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
AG. Volkswagen AG d
General
lkswagen body repairs, exterior
oes
n - Edition 10.2014
o ot g
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♦ Torque wrench - V.A.G 1783- ris tee
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spec
es, in part or in w

t to the co
rrectness of i
Removing
l purpos

– Lever caps -3- out of opening in trim -1-.

nf
ercia

– Unscrew bolt -4- located beneath.

orm
m

atio
– Carefully pull interior opening mechanism -2- upwards out of
om

n in
opening in sliding door.
or c

thi
te

sd
– Unhook Bowden cables -5- and -6- out of interior opening
iva

o
r

mechanism -2-.
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Prote AG.

2. Components of sliding door 79

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Installing
Install in reverse order, but note the following:
Specified torques

2.14 Removing and installing additional lock

at top
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

AG. Volkswagen AG d
agen oes
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Removing
pe

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wit
– Unscrew bolts -2- and pull out additional lock -1- from sliding
, is n

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door.
hole

spec
– Unclip Bowden cable -3- from additional lock -1-.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
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tion in
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Prote AG.

80 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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nl

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es, in part or in w

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at
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in t
or

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t. rig
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Install in reverse order, but note the following:
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Specified torques

2.15 Removing and installing striker pin

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

2. Components of sliding door 81

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Unscrew striker pin -1- and remove.
Installing
– Fit striker pin -1-.
– Adjust striker -1- ⇒ page 62 .

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2.16 Removing and installing striker ir se
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Special tools and workshop equipments arequired
ut or
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♦ Torque wrench - V.A.G 1331-

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, is n

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

Removing

nf
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orm
– Unscrew bolt -2- and remove striker -1-.
m

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– Fit U-shaped striker -1-.

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– Adjust striker -1- ⇒ page 35 .

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Prote AG.

2.17 Removing and installing guide wedge

and slide
Special tools and workshop equipment required

82 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

Removing
Guide wedge:
– Unscrew bolts -2- and remove guide wedge -1-.

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– Unscrew bolts -2- and remove slide -1-. ss

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Installation is carried out in the reverse sequence, when doing this

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note the following:
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– Adjust guide wedge -1- ⇒ page 64 .

h re
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– Adjust slide -1- ⇒ page 64 .
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2. Components of sliding door 83

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

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Cop py
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Prote AG.

84 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3 Electric sliding door

⇒ “3.1 Assembly overview – sliding door”, page 85
⇒ “3.2 Assembly overview - interior operating mechanism”, page
88
⇒ “3.3 Assembly overview - guide rail”, page 89
⇒ “3.4 Assembly overview – upper guide rail”, page 90
⇒ “3.5 Removing and installing sliding door inner seal”,
page 90
⇒ “3.6 Removing and installing sliding door”, page 92
⇒ “3.7 Adjusting sliding door”, page 94
⇒ “3.8 Motor release mechanism”, page 101
⇒ “3.9 Checking and adjusting tension of drive belt”, page 102
⇒ “3.10 Removing and installing motor to open right sliding door
V323 or motor to open left sliding door V485 ”, page 103
⇒ “3.11 Removing and installing upper roller guide”, page 104
⇒ “3.12 Removing and installing lower roller guide”, page 105
⇒ “3.13 Removing and installing roller carriage”, page 105
⇒ “3.14 Removing and installing sliding door limit stops”,
page 107
⇒ “3.15 Removing and installing power latching motor V329 on
high sliding doors with additional lock”, page 108
⇒ “3.16 Removing and installing right sliding door control unit
J731 or left sliding door control unit J558 ”, page 109 agen
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⇒ “3.17 Removing and installing lock cylinder housing”, ed by gu
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⇒ “3.18 Removing and installing door handle”, page
ss 111 c

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⇒ “3.19 Removing and installing bearing bracket”, page 111

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⇒ “3.20 Removing and installing rear right central locking lock unit
erm

ab
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F223 or rear left central locking lock unit F222 ”, page 113
ot p

wit
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⇒ “3.21 Removing and installing interior operating mechanism”,

h re
ole,

page 114
spec
urposes, in part or in wh

⇒ “3.22 Removing and installing anti-trapping mechanism”, page t to the co

116
⇒ “3.23 Removing and installing additional lock / upper power
rrectne

latching system”, page 117

⇒ “3.24 Removing and installing striker pin”, page 118
ss o
cial p

⇒ “3.25 Removing and installing rear right power latching motor

f in

V308 or rear left power latching motor V307 ”, page 119

form
mer

atio

⇒ “3.26 Removing and installing guide wedge and slide”,

om

page 120
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⇒ “3.27 Removing and installing guide rail”, page 121

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⇒ “3.28 Removing and installing upper guide rail”, page 122

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⇒ “3.29 Electric sliding door switch in B-pillar”, page 124 t. Cop py
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3.1 Assembly overview – sliding door pyri by
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Note

3. Electric sliding door 85

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Only the left side is shown. The right side is similar.

Sliding door, replacement parts

Note

♦ Spare parts are supplied without sealing due to various rea‐

sons. In these cases, we recommend sealing the spare parts
before forwarding to the paint shop ⇒ Workshop Manual
“Paint” .
♦ To keep the number of parts down to a minimum, sliding doors
are often supplied in the »basic version« only.
♦ Check new replacement parts for damage before sending
them to the paint shop.

Sliding door without cut-out for motor release mechanism:

In this case, we recommend that a unique template is made from
the damaged part by the workshop.
Using pneumatic jig-saw - V.A.G 1523A- , make a cut-out for mo‐
tor release mechanism.
Deburr edges of template and protect with duct tape.
Note thickness of template when positioning template and mark‐
ing location of holes before painting new part.

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Prote AG.

86 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Sliding door
❑ Removing and installing
⇒ page 92
2 - Sliding door limit stops
❑ Upper and lower
❑ Removing and installing
⇒ page 107
❑ Adjusting ⇒ page 99
3 - Interior operating mecha‐
nism
❑ Removing and installing
⇒ page 114
4 - Motor release mechanism
❑ Removing and installing
⇒ page 101
5 - Locking knob
6 - Mounting bracket
❑ Removing and installing
⇒ page 111
7 - Lower roller guide
❑ Removing and installing
⇒ page 105
8 - Power latching motor -
V329-
❑ Removing and installing
⇒ page 108
9 - Right sliding door control
unit - J731-
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10 - Rear left centralVol
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11 - Motor to open right sliding door - V323- Motor to open left sliding door - V485-
un

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❑ Removing and installing ⇒ page 103

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12 - Roller carriage
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❑ Removing and installing ⇒ page 105

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13 - Additional lock / upper power latching system

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❑ Removing and installing ⇒ page 117

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3. Electric sliding door 87

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
G. Volkswage
3.2 Assembly overview - interior
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❑ Removing and installing

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⇒ page 114 erm

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4 - Bolt

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❑ Qty. 3.
❑ 10 Nm

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5 - Bowden cable
❑ To door lock

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88 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
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❑ Removing and installing

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⇒ page 121

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5 - End piece
❑ Clipped into guide rail
-1-

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3. Electric sliding door 89

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3.4 Assembly overview – upper guide rail

1 - Upper guide rail

❑ Removing and installing
⇒ page 122
2 - Hexagon nuts
❑ Qty. 6.
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⇒ page 104 .

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3.5 Removing and installing sliding door in‐

ner seal

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

During production, a sealant is applied to the sliding door inner

seals, which are then placed on the sliding door flange and rolled
on.

90 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

♦ When removing the seal, the sealant is distributed across the

inside of the seal. The seal edges are bent up slightly. If the
seal is refitted, there is no guarantee that it will sit securely or
provide adequate sealing properties.
♦ Therefore each seal which is removed completely should be
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.

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Removing
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Pull sliding door inner seal -1- off body flange.
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Installing
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– The vulcanised point -arrow- on sliding door inner seal -1-
Prote AG.

must be positioned on the rear radius of the body flange.

– Press sliding door inner seal -1- onto body flange.

3. Electric sliding door 91

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

After installing, check whether beading of sliding door inner seal -1- is completely fitted over adjacent trims.

3.6 Removing and installing sliding door

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

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Note t to the co

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.
rrectne

Removing
ss o
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– Switch off ignition and all electrical consumers.

inform
mer

– Release motor coupling ⇒ page 101 .

atio
om

– Remove sliding door trim ⇒ General body repairs, interior;

c

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or

Rep. gr. 70 ; Trims/insulation; Removing and installing sliding

thi
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door trim .
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– Using a screwdriver, carefully unclip cover cap -1- on end of

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guide rail and swivel it out upwards.
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– Unscrew tensioning bolt -3-.
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– Remove rear tensioning retainer -2- together with drive belt cted agen
Prote AG.
-4-.

92 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Push front tensioning bracket -2- towards vehicle interior out

of guide.
– Pull tensioning bracket -2- together with drive belt -1- towards
front (direction of -arrow-) and out of guide rail -3-.

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– Release and disconnect connectors -1-. thor eo
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– Guide wiring harness out of sliding door. ss

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Further dismantling requires the help of a second mechanic.

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– Mark position of bolts -2-.
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– Remove bolts -2- (qty. 3) from retainer -1-.

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– Pull wiring harness -1- out of sliding door.

3. Electric sliding door 93

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove bolt -2- from upper retainer -1-.

– Move sliding door back until roller carriage is completely push‐
ed out of guide rail.
Installing
Install in reverse order, but note the following:
– Release motor coupling ⇒ page 101 .
– Check and adjust drive belt ⇒ page 102 .
• Then check function of sliding door.
Specified torques
Component Specified torques
Bracket 23 Nm

3.7 Adjusting sliding door lkswage

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⇒ “3.7.1 Basic setting, sliding door”, page 94

nform
ercia

⇒ “3.7.2 Roller carriage”, page 96

m

⇒ “3.7.3 Locking system”, page 97 at

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ion
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⇒ “3.7.4 End position engagement”, page 99

in t
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3.7.1 Basic setting, sliding door

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Prerequisites for adjusting sliding door

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♦ For adjustment work, the vehicle must be resting on its wheels
on a level surface.
♦ Doors must be fully equipped.
♦ Windows must be closed.
♦ Only the adjustment for the right sliding door is described. The
adjustment of the left sliding door is similar.
♦ The sliding door is correctly adjusted when all shut lines are
even when closed. The sliding door must not protrude too far
inwards or outwards. The contours must be flush with each
other. ⇒ Body Repairs; Rep. gr. 00 ; Body gaps/shut lines;
Body, middle.

94 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

A - Swage line offset max. 1

mm
B - Shut line top/bottom 5.5
mm ± 1 mm
C - Shut line C-pillar 7 mm ± 1
mm
C - Shut line B-pillar ≥ 7 mm,
aligning not permissible
Tapering up to 0.5 mm is per‐
missible

Align sliding door evenly

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• Wedges and U-shaped strikers have not yet been fitted or

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• Rubber buffers -1- at top and bottom must be preadjusted.
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Adjusting rubber buffers to specifications
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♦ Top rubber buffer 13 mm - 14 mm

♦ Top rubber buffer (high sliding door) 19 mm - 20 mm
Adjusting gaps and shut lines
• Roller guides ⇒ page 96
• Locking system ⇒ page 97
• End position engagement ⇒ page 99

3. Electric sliding door 95

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3.7.2 Roller carriage

Shut lines on B and C-pillar (dimension C) ⇒ Item C (page 95)
– Adjust shut lines on C-pillar joint via hinge fitting -1-. When
bolts -2- are loosened, the sliding door can be adjusted further
towards front/back. Hinge fitting -1- is provided with a guide to
prevent it from turning.
– Specified dimension of B-pillar shut line: ≥ 7 mm.
– Then, tighten bolts -2-.
Specified torques
Component Specified torques
Hinge 23 Nm ± 2.0 Nm
Shut line in roof frame and sill (dimension B) ⇒ Item B (page 95)

– Adjust shut line at hinge fitting -1-.

– Loosen hexagon nut -2-.
– Raise or lower sliding door using adjustment screw -3-.
– Then, tighten hexagon nut -2-.
Specified torques
Component Specified torques
Hinge 25 Nm ± 5.0 Nm

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– Adjust shut line at upper roller guide.

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– Upper roller guide can be adjusted once bolts -1- (qty. 3) have
spec

been loosened.
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t to the co

– Then, tighten bolts -1-.

Specified torques
rrectness of i

Component Specified torques

l purpos

Upper roller guide 23 Nm ± 2.0 Nm

nform
ercia

– If necessary, loosen lower roller guide and align between ad‐

m

justing box trim and portal seal.

a
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tion in

– The up/down adjustment of lower roller guide is important for

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Align swage line at B-pillar (dimension A); tolerance of up to

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0.5 mm is permissible ⇒ Item A (page 95) .

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96
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Rep. gr.58 - Rear doors, door components Prote AG.
 AG. Volkswagen AG d
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ris
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ss a General body repairs, exterior -r aEdition
c 10.2014

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– Match surfaces via upper roller guide (adjust in/out at B-pillar/

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sill/roof frame).

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– Upper roller guide -1- can be adjusted once bolt -2- has been

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loosened.

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– Then, tighten bolt -2-.

spec
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Specified torques

t to the co
Component Specified torques

rrectne
Upper roller guide 20 Nm ± 5.0 Nm

ss o
cial p

f in
– Match surfaces via lower roller guide (adjust in/out at B-pillar/

form
mer

sill/roof frame).

atio
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– Lower roller guide can be adjusted once bolt -1- has been

n
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loosened.

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– Then, tighten bolts -1-.

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Specified torques
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Component Specified torques
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Lower roller guide 10 Nm ± 5.0 Nm
lksw
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Prote AG.

3.7.3 Locking system

Note

♦ The sliding door must not be raised or lowered via the U-sha‐
ped striker -2- as otherwise the sliding door will catch when it
is opened, causing superficial or permanent damage to the
door lock.
♦ After adjusting to character lines, ensure that the gaps at the
top and bottom of the door lie with tolerances.
♦ For optical reasons a slightly wedge shaped gap at the top and
bottom of the door is more acceptable than an offset character
line.

Align swage line at C-pillar (dimension A) + 0.5 mm; deviation of

up to + 1.0 mm permissible ⇒ Item C (page 95) .
– Match surfaces of sliding door and C-pillar by adjusting ad‐
justment plate -1- in and out.
– Loosen bolts -1- of adjustment plate -2-.
– Close and open electric sliding door in order to centre rear right
power latching motor - V308- .
– Then, tighten bolts -1-.
Specified torques
Component Specified torques
Striker 20 Nm ± 2.0 Nm
– Adjust extra striker pin for additional lock.

3. Electric sliding door 97

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Striker pin -1- can be adjusted by loosening and turning.

– Adjust striker pin -1- in such a way that recess of door upper
lock with rotary latch is centred relative to striker pin -1-. wage
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– Then, tighten striker pin -1-. ed by ara
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Specified torques au
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Component Specified torques

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itte
Striker pin 20 Nm ± 2.0 Nm

y li
erm

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ility
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Adjusting door arrester function on lower roller guide

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

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c

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or

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te

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pr

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fo

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t.
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Prote AG.

– Lower roller guide -1- can be adjusted once bolts -2- have
been loosened.
– The up/down adjustment of lower roller guide -1- is carried out
with sliding door opened. In this way the arrester catch -3- will
engage centrally in the rotating pin.
– When doing this, ensure that arrester catch -3- is located cen‐
trally in rotating sleeve.
– Then, tighten bolts -2-.

98 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques
Component Specified torques
Lower roller guide 23 Nm ± 2.0 Nm

3.7.4 End position engagement

Adjusting limit stops and door arrester function

AG. Volkswagen AG d
agen oes
olksw not
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ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Adjusting upper and lower limit stops:

– Loosen bolts -2- in order to allow for adjustment of limit stop
-1-.
Both buffers must engage at same time.
Please note that also the arrester function depends on the ad‐
justment of the sliding door limit stops (towards front/rear).
The arrester catch -3- must be engaged and the sliding door must
be pulled in direction of travel. There must still be a gap of 2 to
3 mm between buffers and contact surface on C-pillar in order to
allow the mechanism to operate free of stress.
– Then, tighten bolts -2-.

3. Electric sliding door 99

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques
Component Specified torques
Lower roller guide AG. Volkswagen AG d
a23
genNm oes
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b ara
Adjusting upper and lower rubber
rise
d buffers nte
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Adjust rubber buffers -1-
ss a at top and bottom again as necessary.
u ra
c

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le

– Adjust rubber buffers -1- at top and bottom of sliding door by

un

pt
an
screwing them in or out.
d
itte

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ility
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Note

wit
is n

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spec
♦ When adjusting the rubber buffers -1- at the top and bottom,
urposes, in part or in wh

make absolutely sure that these are set with 1.0 mm to 1.5 mm

t to the co
overlap.
♦ If they are too loose, rattling or knocking noises will be caused.

rrectne
♦ If the sliding door is misaligned, the force necessary at the
handles to open and close will be increased.

ss o
cial p

f inform
Caution
mer

atio
om

n
The rubber buffers must not be used to adjust the door.
c

i
or

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te

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iva

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Adjusting guide wedges and slides
um
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op
– Fit guide wedge -1- to sliding door.
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yri by
– Align it centrally relative to markings and tighten bolts -2- light‐ cop Vo
by lksw
cted
ly.
agen
Prote AG.

100 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Fit slides -1- to B-pillar, align them centrally and tighten bolts
-2- lightly.
– Open and close sliding door to centre wedges.
– When doing this, pay special heed to ensure that crash pin
engages in mounting hole of slide without contact.
– Retighten via tapered pin on guide wedge if necessary.
– Then, tighten bolts -2-.
Specified torques
Component Specified torques
Guide wedges and slides 8.0 Nm
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
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♦ The guide wedges are simply locating elements
s au to keep the ra
c
sliding door secure while the vehicle is in motion. s

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♦ Making use of them to adjust gaps is inappropriate!

an
itte

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ility
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3.8 Motor release mechanism

wit
, is n

h re
hole

⇒ “3.8.1 Releasing motor coupling”, page 101

spec
es, in part or in w

t to the co
⇒ “3.8.2 Removing and installing motor release mechanism”,
page 101

3.8.1 Releasing motor coupling

rrectness of i
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Note

nf
ercia

or
♦ The motor coupling can be released using the ignition key.

m
m

atio
m

♦ If the switch is set to “MAN”, the electric sliding door can only
o

n in
or c

be operated by hand.

thi
te

sd
iva

♦ If the switch is set to “AUTO”, the electric sliding door is opened

o
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rp

and closed by electrical means. cu

o

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To unlock the electric drive release mechanism, turn it clockwise
. C rig
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rig
by 180° (switch position: “MAN”). py by
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To lock the electric drive release mechanism, turn it anticlockwise Prote AG.
by 180° (switch position: “AUTO”).
Adjusting electric sliding door
– With switch on centre console or on sill panel moulding (B-
pillar) pressed, close sliding door completely.
– Then, open sliding door completely by briefly pressing one of
the switches, and close it again.

3.8.2 Removing and installing motor release

mechanism

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

3. Electric sliding door 101

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Release motor coupling ⇒ page 101 .
– Unscrew the two bolts -2-.
– Carefully pull motor release mechanism AG-1-
. Voland
kswagframe
en AG -3- out
of sliding door. agen does
olksw not
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db ara
rise nte
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au ra
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ss

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nl

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itte

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erm

ab
ility
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wit
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hole

spec
es, in part or in w

– Detach Bowden cable -2- from motor release mechanism -1-.

t to the co
Installing
Install in reverse order, but note the following:

rrectness of i
– Releasing motor coupling ⇒ page 101 .
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

3.9 Checking and adjusting tension of drive

en
ng

t.
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op
belt
C py
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pyri by
Vo
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Special tools and workshop equipment required by c lksw
cted agen
Prote AG.
♦ Commercially available spring balance (measurement range
up to 50 N)

Note

Checking and adjusting are described for the right side. Checking
and adjusting on the left side are analogous.

Testing
– Release motor coupling ⇒ page 101 .
– Move electric sliding door to position right before closed posi‐
tion.
– Attach a commercially available spring balance (measurement
range up to 50 N) to drive belt (in the middle of the guide rail).
– Pull on spring balance until the drive belt is aligned flush with
the outer edge of the guide rail.
– Read value on spring balance.
Specifications:
♦ New drive belt: 20 N
Adjusting
– Turn tensioning bolt in desired direction using a suitable tool.
– Check tension of drive belt after 1 full turn.

102 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3.10 Removing and installing motor to open

right sliding door - V323- or motor to
open left sliding door - V485-

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

Removing
– Switch off ignition and all electrical consumers.
– Release motor coupling ⇒ page 101 .
– Remove sliding door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Removing and installing sliding
door trim .
– Remove motor release switch ⇒ page 101 .
– Unclip cover -1- from right sliding door control unit - J731- .
– Release and disconnect the two connectors -1- on right sliding
door control unit - J731- .

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
s a ac
– Unscrew bolts -1-.
s
ce
le
un

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an
d
itte

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erm

ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Electric sliding door 103

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Shaft locking elements -4- on assembly funnel -3- in sliding door

are difficult to access.
– Therefore, drive unit -1- must be pulled out of drive shaft -2-
in -direction of arrow- making sure not to use excessive force.
– Remove drive unit -1- together with Bowden cable and wiring
harness from sliding door.
Installing
Install in reverse order, but note the following:

Note

The drive unit -1- must engage audibly in the drive shaft -2-.

– Release motor coupling ⇒ page 101 .

Specified torques
Component Specified torques
Motor for opening sliding door 12 Nm

3.11 Removing and installing upper roller

guide gen AG
. Volkswagen AG
d a oes
lksw not
Special tools and workshop equipment
db
y V required
o gu
ara
e nte
ris
♦ Torque wrench - V.A.G 1331-
ut
ho eo
ra
a c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Note
nf
ercia

orm

Removal and installation sequence is only described for the right

m

atio
m

side. Removal and installation on the left side are analogous.

o

n in
or c

thi
e

Removing
t

sd
iva

o
r
rp

cu

– Mark position of bolts -1-.

o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

104 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove screws -1-. Remove upper roller guide.

– Guide upper roller guide backwards out of guide rail.
Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torques
Upper roller guide 23 Nm

3.12 Removing and installing lower roller

guide

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

Removing
– Release motor coupling ⇒ page 101 .
olkswagen AG
en AG. V
– Remove step of sliding
ksw door ⇒ General body
ag does repairs, interior;
not
Vol
Rep. gr. 68 ;d Step
by inserts . gu
ara
e nte
ris
– Furtherauremoval
tho is only possible with a second mechanic e o hold‐
ra
ing thess sliding door while the lower roller guide -1- is being c
fitted.
ce
e
nl

pt
du

an
itte

– Disconnect connector -3-, and unclip cable ties.

y li
erm

ab

– Remove lower roller guide -1- with wiring guide -2- from entry/
ility
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access.
wit
, is n

h re
hole

Installing
spec
es, in part or in w

Install in reverse order, but note the following:

t to the co

– Release motor coupling ⇒ page 101 .

rrectness of i
l purpos

3.13 Removing and installing roller carriage

Special tools and workshop equipment required
nform
ercia

♦ Torque wrench - V.A.G 1331-

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Electric sliding door 105

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

♦ Removal and installation sequence is only described for the

right side. Removal and installation on the left side are analo‐
gous.
olkswagen AG
en AG. V
♦ The roller carriage can only be removed
olks together with the drive s no
wag doe
belt. db
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ara
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ho eo
ut
Removing ss
a ra
c

ce
le

– Release motor coupling ⇒ page 101 .

un

pt
an
d
itte

y li
– Remove sliding door trim ⇒ General body repairs, interior;
erm

ab
Rep. gr. 70 ; Trims/insulation; Removing and installing sliding

ility
ot p

door trim .

wit
is n

h re
– Using screwdriver, carefully unclip cap -1- from below, and
ole,

spec
swivel it out upwards.
urposes, in part or in wh

t to the co
– Unscrew tensioning bolt -3-.
– Remove rear tensioning retainer -2- together with drive belt.

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
a

– Push front tensioning bracket -2- towards vehicle interior.

iv

o
pr

cum
r
fo

– Pull tensioning bracket -2- together with drive belt -1- towards
en
ng

t.
yi
front (direction of -arrow-) and out of guide rail -3-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.

Secure the electric sliding door against falling down.

– Remove bolts -2-.

– Move roller carriage -1- back until it is completely pushed out
of guide rail.

106 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Shaft locking elements -4- on assembly funnel -3- in sliding door

are difficult to access.
– Therefore, drive shaft -2- of roller carriage must be pulled out
of drive unit -1- in -direction of arrow- making sure not to use
excessive force.
Installing
Install in reverse order, but note the following:

Note

The drive shaft must engage audibly in the drive unit.

– Release motor coupling ⇒ page 101 .

– Adjust roller carriage ⇒ page 96 .
– Check and adjust drive belt ⇒ page 102 .
Specified torques AG. Volkswagen AG d
agen oes
lksw not
d
Component
byV
o
Specified
gu torques
ara
ise nte
r
h Roller carriage
o 23 Nm eo
aut ra
ss c
ce
le

3.14 Removing and installing sliding door lim‐

un

pt
an
d
itte

it stops
y li
rm

ab
pe

ility

Special tools and workshop equipment required

ot

wit
, is n

h re

♦ Torque wrench - V.A.G 1331-

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

Note
en
ng

t.
yi Co
Cop py
. rig
Removal and installation sequence is only described for the right
ht ht
rig by
py
side. Removal and installation on the left side are analogous.
co Vo
by lksw
cted agen
Prote AG.

3. Electric sliding door 107

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
Removing sliding door upper limit stop
– Remove bolts -2-.
– Remove sliding door upper limit stop -1-.
Remove sliding door lower limit stop.

– Remove bolts -2-.

– Remove sliding door lower limit stop -1-.
Installing
AG. Volkswagen AG d
Install in reverse order, but note the following: lksw
agen oes
not
Vo gu
by ara
d
rise nte
o eo
Note auth
ra
ss c
ce
le

Apply specified torque when tightening bolts -2-. Different types

un

pt
an
d

of bolts may be installed.

itte

y li
rm

ab
pe

ility

– Adjusting sliding door upper and lower limit stops ⇒ page 99 .

ot

wit
, is n

h re

Specified torques
hole

spec

Component of sliding door limit stop Specified torques

es, in part or in w

t to the co

Bolts M8 x 16 (strength rating: 8.8) 23 Nm

Bolts M8 x 16 (strength rating: 10.9) 32 Nm
rrectness of i
l purpos

3.15 Removing and installing power latching

motor - V329- on high sliding doors with
nform
ercia

additional lock
m

a
com

tion in
r
te o

Note
thi
s
iva

do
r
rp

cum

Removal and installation sequence is only described for the right

fo

en
g

side. Removal and installation on the left side are analogous.

n

t.
yi Co
Cop py
t. rig
gh ht
Removing yri
p by
co Vo
by lksw
cted
– Switch off ignition and all electrical consumers.
agen
Prote AG.

– Release motor coupling ⇒ page 101 .

– Remove sliding door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Removing and installing sliding
door trim .

108 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove additional lock ⇒ page 117 .

– Unclip -arrows- cover -1- from right sliding door control unit -
J731- and remove it.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

– Release and disconnect all connectors -6- on right sliding door

h re
control unit - J731- -1- and connector -3- on motor -4-.
hole

spec
es, in part or in w

t to the co
Note

The bolts -7- are used to secure the right sliding door control unit

rrectness of i
- J731- -1- to the retaining plate -2- ⇒ page 109 .
l purpos

– Unscrew bolts -5- from retaining plate -2-.

nform
ercia

– Remove retaining plate -2- together with motor -4- and right
m

sliding door control unit - J731- -1- from sliding door.

at
om

ion
c

in t
or

– Unscrew bolts -2- on rear of retaining plate -3-. his

ate

do
riv

– Remove motor -1- from retaining plate -3-.

p

cum
for

en
ng

Installing
t.
yi Co
Cop py
t. rig
Install in reverse order, but note the following: opyri
gh by
Vo
ht
c
– Release motor coupling ⇒ page 101 .
by lksw
cted agen
Prote AG.

3.16 Removing and installing right sliding

door control unit - J731- or left sliding
door control unit - J558-

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

Note

Depending on the installed version of the control unit, different

ports may be used. The connectors have different shapes and
cannot be interchanged.

Removing
– Switch off ignition and all electrical consumers.

3. Electric sliding door 109

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove sliding door trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Trims/insulation; Removing and installing sliding
door trim .
– Unclip -arrows- cover -1- from right sliding door control unit -
J731- and remove it.

– Release and disconnect all connectors -6- on right sliding door

control unit - J731- -1-.
– Unscrew bolts -7- (qty. 3). Remove right sliding door control
unit - J731- -1-.
AG. Volkswagen AG d
Installing agen oes
olksw not
V gu
d by ara
Install in reverse order of removal. orise nte
h eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

3.17 Removing and installing lock cylinder

h re
hole

housing

spec
es, in part or in w

t to the co
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Note Prote AG.

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

110 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
agen oes
Removing olksw not
V gu
d by ara
e
– Lever out cap -5- from opening in sliding door.
horis nte
eo
aut ra
– Unscrew bolt -4- located beneath. ss c

ce
le
un

pt
– Carefully pull out lock cylinder housing -2- with seal -3- from

an
d
itte
door handle bearing bracket perpendicular to sliding door.

y li
erm

ab
ility
Remove door handle -1- ⇒ page 111 .

ot p

wit
is n
Installing

h re
ole,

spec
Install in reverse order, but note the following:
urposes, in part or in wh

t to the co
Specified torques
Component Specified torques

rrectne
Lock cylinder housing 3.0 Nm

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
3.18 Removing and installing door handle
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Removal and installation sequence is only described for the right
p by
o Vo
by c lksw
side. Removal and installation on the left side are analogous. Prote
cted AG.
agen

Removing
– Removing lock cylinder housing ⇒ page 110 .
– Pull back door handle and swing out of door.
Installing
Install in reverse order of removal.

3.19 Removing and installing bearing bracket

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

3. Electric sliding door 111

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

Removing
– Remove door handle ⇒ page 111 .
– Unscrew bolts -1- from outer side of door. Remove seal -2- on
right side.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove bolt -2-.

112 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove bearing bracket -1- from inner part of door and unclip
Bowden cable -3-.
Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torques
Mounting bracket 2 Nm

3.20 Removing and installing rear right cen‐

tral locking lock unit - F223- or rear left
central locking lock unit - F222-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

Note

Removal and installation sequence is only described for the right

AG. Volkswagen AG d
side. Removal and installation
olkswagen on the left side are
oes analogous.
no
yV t gu
db ara
ise nte
Removing tho
r eo
au ra
c
– Remove ss sliding door trim ⇒ General body repairs, interior;
ce
e

Rep. gr. 70 ; Trim, insulation; Door trims .

nl

pt
du

an
itte

y li

– Remove additional lock ⇒ page 117 .

erm

ab
ility
ot p

– Remove bolts -1- from door lock -2-.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
113
AG.
3. Electric sliding door
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Remove door lock -1- from inner part of door and separate s
ce
e
nl

connector -6-.
pt
du

an
itte

y li

– Release locking device -arrow- using a screwdriver and pull

erm

ab

off Bowden cable retainer from door lock -1-.

ility
ot p

wit
, is n

– Unhook Bowden cables -2-, -3-, -4- and -5- from door lock
h re

-1-.
hole

spec
es, in part or in w

Installing
t to the co

Install in reverse order, but note the following:

Specified torques
rrectness of i

Component Specified torques

l purpos

Door lock 10 Nm
nform
ercia

3.21 Removing and installing interior operat‐

m

at
om

ing mechanism
ion
c

in t
or

his
e

Special tools and workshop equipment required

at

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

114 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
Note
erm

ab
ility
ot p

wit
Removal and installation sequence is only described for the right
, is n

h re
side. Removal and installation on the left side are analogous.
hole

spec
es, in part or in w

Removing

t to the co
– Lever caps -3- out of opening in trim -1-.

rrectness of i
– Unscrew bolt -4- located beneath.
l purpos

– Carefully pull interior opening mechanism -2- upwards out of

opening in sliding door. nform
ercia

– Detach Bowden cable -5- from interior opening mechanism

-2-.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Electric sliding door 115

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
Installing
m

atio
om

n in
Install in reverse order, but note the following:
or c

thi
e

Specified torques
t

sd
iva

o
r
rp

cu

3.22 Removing and installing anti-trapping

o

m
f

en
ng

t.
yi
mechanism
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.

♦ Removal and installation sequence is only described for the

right side. Removal and installation on the left side are analo‐
gous.
♦ The anti-trapping mechanism cannot be removed without be‐
ing damaged.

Removing
– Release motor coupling ⇒ page 101 .
– Remove sliding door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Removing and installing sliding
door trim .

116 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Close sliding door partly.

– Release and disconnect connector -1-.

– Carefully lever out plastic grommet -1-. Pull wiring harness out
of sliding door.

– Carefully pull anti-trapping mechanism off sliding door.

Installing
– Remove any adhesive residues from sliding door.

AG. Volkswagen AG d
agen oes
Note Volksw not
gu
by ara
d
rise nte
♦ Use uadhesive
tho remover as cleaning agent. Observe ethe
o appro‐
a safety precautions when performing this work.r ac
priate
s
s
ce
le

♦ If the paint is damaged, the paint structure must be restored

un

pt
an
d

according to specifications in the ⇒ “Paint” workshop manual .

itte

y li
erm

ab
ility
ot p

– Slide anti-trapping mechanism -1- at front edge of sliding door

wit
is n

onto door fold, and remove protective film.

h re
ole,

spec

– Firmly press anti-trapping mechanism -1- onto front edge of

urposes, in part or in wh

sliding door along entire length of anti-trapping mechanism.

t to the co

Further installation is performed in the reverse order of removal.

Check function of anti-trapping mechanism.
rrectne

– Close sliding door via switch on B-pillar or ignition key.

ss

– Slightly strike against anti-trapping mechanism with your

o
cial p

f i

hand. The sliding door must open immediately, after doing so.
nform
mer

atio
m

3.23 Removing and installing additional lock /

o

n
c

i
or

upper power latching system

thi
te

sd
iva

o
r

Special tools and workshop equipment required

p

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Electric sliding door 117

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
Removal and installation sequence is only described for the right

rrectness of i
side. Removal and installation on the left side are analogous.
l purpos

Removing
– Unscrew bolts -2- and pull additional lock -1- out of sliding

nform
ercia

door.
m

a
com

ti
– Detach Bowden cable -3- from additional lock -1-.

on in
r
te o

thi
Installing

s
iva

do
r

Install in reverse order, but note the following:

rp

cum
fo

en
ng

Specified torques
t.
yi Co
Cop py
ht. rig
Component Specified torques
rig ht
py by
co Vo
by lksw
Additional lock cted 10 Nm
agen
Prote AG.

3.24 Removing and installing striker pin

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

118 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

Removing
– Unscrew striker pin -1- and remove.
Installing
– Fit striker pin -1-.
– Adjust striker -1- ⇒ page 97 .

3.25 Removing and installing rear right power

latching motor - V308- or rear left power
latching motor - V307-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab

Note
ility
ot p

wit
, is n

Removal and installation sequence is only described for the right

h re

side. Removal and installation on the left side are analogous.

hole

spec
es, in part or in w

t to the co

Removing
– Remove rear side panel trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Removing and installing rear
rrectness of i

side panel trim .

l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

119
co Vo
by lksw
cted 3. Electric sliding door
agen
Prote AG.
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove screws -2-.

– Remove cover -1- from C-pillar.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Unscrew bolts -1- of adjustment plate -2-. aut ra
ss c

ce
– Release and disconnect connector -3-.
e
nl

pt
du

an
itte

– Remove rear right power latching motor - V308- from cut-out

y li
erm

ab
in C-pillar.

ility
ot p

wit
Installing
, is n

h re
hole

Install in reverse order, but note the following:

spec
es, in part or in w

– Adjust sliding door ⇒ page 94 .

t to the co
rrectness of i
l purpos

3.26 Removing and installing guide wedge

and slide

nf
ercia

orm
Special tools and workshop equipment required
m

atio
om

n in
♦ Torque wrench - V.A.G 1783-
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

120 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
Guide wedge:
– Unscrew bolts -2- and remove guide wedge -1-.

Slide:
– Unscrew bolts -2- and remove slide -1-.
Installing
Install in reverse order, but note the following:
– Adjust guide wedge ⇒ page 99 .
– Adjust slide ⇒ page 99 .

3.27 Removing and installing guide rail

Special tools and workshop equipment
wage required
n AG. Volkswagen AG
doe
ks s no
Vol t gu
♦ Torque wrench - V.A.G
ed 1783-
by ara
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Note

Removal and installation sequence is only described for the right

nf
ercia

side. Removal and installation of the left side are similar.

rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Electric sliding door 121

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

Removing
l purpos

– Remove trim strip for rear side window (if fitted) ⇒ General
body repairs, interior; Rep. gr. 70 ; Trims/insulation; Removing
nf
ercia

and installing trim strip for side window .

orm
m

– Release locking lug -arrow- upwards using a screwdriver.

atio
om

n in
c

– Unclip end piece -5- from guide rail -1-.

or

thi
te

sd
a

– Remove sliding door ⇒ page 92 .

iv

o
r
rp

cu
o

– Lever off cap -3- using a screwdriver and unscrew hexagon

f

en
ng

t.
yi
nuts -2-.
Co
Cop py
t. rig
gh
– Unscrew bolt -4- and remove guide rail -1-.
ht
pyri by
Vo
o
by c lksw
Installing
cted agen
Prote AG.

Install in reverse order, but note the following:

Specified torques
♦ ⇒ “3.3 Assembly overview - guide rail”, page 89

3.28 Removing and installing upper guide rail

Special tools and workshop equipment required

122 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

Note

wit
, is n

h re
hole

spec
Removal and installation sequence is only described for the right
es, in part or in w

side. Removal and installation on the left side are analogous.

t to the co
Removing

rrectness of i
– Remove roof trim ⇒ General body repairs, interior; Rep. gr.
70 ; Trim, insulation; Roof trim .
l purpos

– Remove upper roller guide ⇒ page 104 .

nform
ercia

– Remove hexagon nuts -2-.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Electric sliding door 123

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Unbolt opening restrictor -3-, and remove upper guide rail
-1-.
ss o

Installing
cial p

f inform

Install in reverse order, but note the following:

mer

atio
m

Specified torques
o

n
c

i
or

n thi

3.29 Electric sliding door switch in B-pillar

te

sd
iva

o
pr

cum
r

⇒ “3.29.1 Removing and installing electric sliding door switch in

fo

en
ng

B-pillar”, page 124

t.
yi Co
Cop py
⇒ “3.29.2 Removing and installing electric sliding door switch in ht. rig
rig ht
by
B-pillar, Crafter panel van”, page 125 copy Vo
by lksw
cted agen
Prote
3.29.1 Removing and installing electric sliding
AG.

door switch in B-pillar

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

124 Rep. gr.58 - Rear doors, door components

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua Crafter 2006 ➤
d ran
ir se
tho General body repairs, exterior
tee
or - Edition 10.2014
au ac
ss
Removing

ce
le
un

pt
an
d
– Detach switch -1- from B-pillar trim -arrow- using a suitable

itte

y li
rm
plastic wedge.

ab
pe

ility
ot
– Disconnect connector.

wit
, is n

h re
Installing hole

spec
es, in part or in w

Install in reverse order of removal.

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
op
3.29.2 Removing and installing electric sliding
C py
t. rig
gh ht
yri by
door switch in B-pillar, Crafter panel van cop Vo
by lksw
cted agen
Prote AG.
Special tools and workshop equipment required
♦ Removal wedge - 3409-

Note

Removal and installation sequence is only described for the right

side. Removal and installation on the left side are analogous.

Removing
– Release switch -1- from mounting -arrows- using removal
wedge - 3409- -2-.
– Separate electrical connector -3-.
Installing
Install in reverse order of removal.

3. Electric sliding door 125

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
4 Right rear wing doorVolkswagen oes
not
gu
by ara
d
⇒ “4.1 Assembly overview - right rearorise wing door”, page 126 nte
eo
th
u ra
⇒ “4.2 Assembly overview – door
ss a
hinge”, page 128 c

ce
le
un
⇒ “4.3 Assembly overview – door arrester”, page 129

pt
an
d
itte

y li
⇒ “4.4 Assembly overview - upper door lock and lower guide”,
rm

ab
pe

page 130

ility
ot

wit
, is n

⇒ “4.5 Assembly overview - interior operating mechanism”, page

h re
131
hole

spec
es, in part or in w

⇒ “4.6 Assembly overview - door lock”, page 132

t to the co
⇒ “4.7 Removing and installing wing door inner seal”, page 132
⇒ “4.8 Removing and installing rear right wing door”, page 133

rrectness of i
⇒ “4.9 Adjusting rear wing door”, page 135
l purpos

⇒ “4.10 Removing and installing door hinge”, page 141

nform
ercia

⇒ “4.11 Removing and installing door arrester”, page 142

m

a
⇒ “4.12 Removing and installing - door upper lock and lower
com

tion in
guide”, page 144
r
te o

thi
s
⇒ “4.13 Removing and installing interior operating mechanism”,
iva

do
r

page 146
rp

cum
fo

en
ng

⇒ “4.14 Removing and installing door lock”, page 148

t.
yi Co
Cop py
t. rig
⇒ “4.15 Removing and installing lock cylinder housing”, yri
gh by
ht
page 149 cop Vo
by lksw
cted agen
Prote
⇒ “4.16 Removing and installing door handle”, page 150
AG.

⇒ “4.17 Removing and installing bearing bracket”, page 150

⇒ “4.18 Removing and installing upper striker”, page 151
⇒ “4.19 Removing and installing centring pin and lower striker with
centring pin”, page 152

4.1 Assembly overview - right rear wing door

Note

♦ The procedure is for a high rear wing door. The procedure for a standard rear wing door is basically the
same as that for a high sliding door.
♦ Spare parts are supplied without sealing due to various reasons. In these cases, we recommend sealing
the spare parts before forwarding to the paintshop ⇒ Workshop Manual “Paint” .
♦ The right side is shown. The left side is similar.

126 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
1 - Right rear wing door agen oes
olksw not
yV gu
❑ Removing and installing ed b ara
nte
is
⇒ page 133 . hor eo
aut ra
❑ Adjusting ⇒ page 135 ss c

ce
e
nl
2 - Right trim

pt
du

an
itte

y li
❑ For emblem

erm

ab
ility
ot p
3 - Emblem

wit
, is n
❑ Removing and installing

h re
hole
⇒ page 286 .

spec
es, in part or in w
4 - Seal

t to the co
❑ For door handle
5 - Door handle

rrectness of i
❑ Removing and installing
l purpos

⇒ page 150 .
6 - Lock cylinder housing

nf
ercia

o
❑ Removing and installing

rm
m

⇒ page 149 .

atio
om

n in
c

7 - Seal
or

thi
te

sd
❑ For lock cylinder hous‐
iva

o
r

ing.
rp

cu
o

m
f

en
ng

8 - Guide
t.
yi Co
Cop py
❑ Removing and installing ht. rig
rig ht
⇒ page 144 py by
co Vo
by lksw
cted agen
9 - Door lock Prote AG.

❑ Removing ⇒ page 132

10 - Bearing bracket
❑ Removing and installing
⇒ page 150 .
11 - Door lower hinge
❑ Removing and installing ⇒ page 141
12 - Door arrester
❑ Removing and installing ⇒ page 142
13 - Door upper hinge
❑ Removing and installing ⇒ page 141
14 - Door upper lock
❑ Removing and installing ⇒ page 144

4. Right rear wing door 127

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

4.2 Assembly overview – door hinge

Note

♦ The right side is shown. The left side is similar.

♦ Only the lower door hinge is shown. The upper door hinge is identical to the lower hinge.

1 - Rear wing door

❑ Removing and installing
⇒ page 133 .
❑ Adjusting ⇒ page 135
2 - Bolt
❑ 3 each at top and bottom
❑ 23 Nm
3 - Door lower hinge
❑ The upper door hinge is
identical to the lower
hinge.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by

128
cted agen
Prote AG.
Rep. gr.58 - Rear doors, door components
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

4.3 Assembly overview – door arrester

Note

The right side is shown. The left side is similar.

1 - Door arrester
❑ Removing and installing
⇒ page 142
2 - Bolt
AG. Volkswagen AG d
❑ Qty. 3. lksw
agen oes
not
o
❑ 9.0 Nm byV gu
ara
ed
ris nte
o eo
3 - Bolt aut
h
ra
s c
❑ Qty. 4. s

ce
e
nl

pt
❑ 9.0 Nm
du

an
itte

y li
erm

4 - Detent bracket

ab
ility
ot p

❑ Removing and installing

wit
, is n

⇒ page 142

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4. Right rear wing door 129

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

4.4 Assembly overview - upper door lock and lower guide

Note

The right side is shown. The left side is similar.

1 - Right rear wing door

❑ Removing and installing
⇒ page 133 .
❑ Adjusting ⇒ page 135
2 - Door upper lock
❑ Removing and installing
⇒ page 144
3 - Bolt AG. Volkswagen AG d
agen
❑ Qty. 3. Volksw
oes
not
gu
by ara
❑ 10 Nm rise
d
nte
tho eo
4 - Bowden cable ss au ra
c
❑ To door lock

ce
le
un

pt
an
d
itte

5 - Lower guide

y li
erm

ab
❑ Removing and installing

ility
ot p

⇒ page 144

wit
is n

h re
6 - Bolt
ole,

spec
urposes, in part or in wh

❑ Qty. 2.

t to the co
❑ 10 Nm

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

130 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

4.5 Assembly overview - interior operating mechanism

1 - Interior opening mechanism

❑ Removing and installing
⇒ page 146
2 - Bolt
❑ Qty. 8.
❑ 2.0 Nm
3 - Bowden cable
❑ To door lock (unlock)
4 - Bowden cable
❑ To door lock (lock)

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4. Right rear wing door 131

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
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4.6 Assembly overview - door lock by
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2 - Bowden cable

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3 - Bowden cable
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t to the co
4 - Bowden cable
❑ To door interior actua‐

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tion
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5 - Connector
6 - Bowden cable retainer

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❑ For door upper lock

Bowden cable
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8 - Bolt

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❑ Qty. 3.
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❑ 10 Nm
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4.7 Removing and installing wing door inner

seal
During series production, a sealant is applied to the wing door
inner seal, which is then placed onto the door flange and rolled
on.

Note

♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, sealing and firm seating are no longer guaran‐
teed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.

Removing

132 Rep. gr.58 - Rear doors, door components

 AG. Volkswagen AG d
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Crafter 2006 ➤
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General r abody
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s

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atio
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co lksw
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Prote AG.

– Remove lock carrier cover ⇒ General body repairs, interior;

Rep. gr. 70 ; Luggage/load compartment trim .
– Pull wing door inner seal -1- off body flange.
Installing
– Push wing door inner seal -1- onto body flange.

Note

♦ The vulcanised point -arrow- on the rear wing door inner seal -1- must be positioned on the body flange
above the upper hinge of the left rear wing door.
♦ After installing, check that beading of hinged door inner seal -1- reaches completely over adjoining trim.

4.8 Removing and installing rear right wing

door
Special tools and workshop equipment required

4. Right rear wing door 133

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

Note

Removal and installation are described for the right side. The left
side is similar.

Removing

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– Pull off bellows from retaining ring on D-pillar and disconnect Cop py
multi-pin connectors -3- for installed electrical components
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134
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Rep. gr.58 - Rear doors, door components
AG.
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Vol body repairs, exterior -
not
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db ran
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and washer system hose (if fitted) ⇒ Electrical system; Rep. eo
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gr. 92 ; Rear window wipe and wash system
ss . c

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pt
– Unhook door arrester -4- from detent bracket.

du

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– Loosen upper and lower bolts -2- (Qty 3).

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Further dismantling requires the help of a second mechanic.

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– Now remove bolts -2- and remove rear wing door -1-.

hole

spec
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Installing

t to the co
Install in reverse order, but note the following:
Specified torques

rrectness of i
Component Specified torques
l purpos

Rear wing door 23 Nm

nform
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4.9 Adjusting rear wing door

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justment of the left rear wing door.
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♦ Basic adjustment of the rear wing door is performed by ad‐
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justing the upper and lower hinges.
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♦ The rear wing doors are adjusted via the upper and lower locks
and the upper U-shaped striker and lower U-shaped striker
with centring pin.
♦ Rear wing door adjustment is described in several steps as
follows.

⇒ “4.9.1 Basic adjustment of rear wing door”, page 135 .

⇒ “4.9.2 Adjusting lower door lock”, page 137 .
⇒ “4.9.3 Adjusting upper door lock”, page 138 .
⇒ “4.9.4 Adjusting striker”, page 139 .
⇒ “4.9.6 Synchronisation of door locks”, page 140 .

4.9.1 Basic adjustment of rear wing door

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

4. Right rear wing door 135

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

♦ Adjustment work should be performed on the right rear wing door first and then on the left. The aid of a
second mechanic is required. The description refers to the rear wing door on the left.
AG. Volkswagen AG d
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♦ Basic adjustment is described forVthe
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w oe
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is similar. g
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♦ The vehicle must be stoodau on its wheels
th for basic adjustment of the rearowing
ra door.
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♦ The rear wing door is correctly adjusted if, when closed, it is not sagging or protruding, the gap is uniform

ce
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pt
all around and the contours align.
du

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♦ To adjust or check gap dimensions ⇒ Body Repairs; Rep. gr. 00 ; Body gap dimensions; Body, rear

ab
ility
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♦ After installing or adjusting, carry out corrosion protection measures to hinge and bolts.

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Upper hinge
– Loosen bolts -5- with left rear wing door -1- open.
– Loosen bolt -4- with left rear wing door closed -1- through hole
in hinge -3-.
– Adjust left rear wing door -1- and tighten bolt -4-.

136 Rep. gr.58 - Rear doors, door components

 AG. Volkswagen AG d
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Crafter 2006 ➤
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ed ran
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– Open left rear wing door -1- and tightenau bolts -5-.
t or
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Lower hinge

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The procedure for adjusting the upper hinge -3- can be derived from the procedure for adjusting the lower hinge

hole
-2-.

spec
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Specified torques
Component Specified torques

rrectness of i
Hinge 20 Nm
l purpos

4.9.2 Adjusting lower door lock

nform
ercia

Special tools and workshop equipment required

m

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♦ Torque wrench - V.A.G 1331-

on
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ate

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– Loosen bolts -2- on lower door lock -1-.

– Align centring pin centrally to guide, and secure it in outer po‐
sition.
– Close left rear wing door.
– Tighten bolts on rear left wing door lock.

4. Right rear wing door 137

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Unclip cap -4- from lock carrier cover.

olkswagen AG
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– Loosen bolts -3- of left lower U-shaped striker
olks with centring pin
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A second person is required to check alignment of the left rear
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wing door to the edge of the roof.

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– Tighten bolts -3- of left lower U-shaped striker with centring pin

h re
hole

-2-.

spec
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Specified torques

t to the co
Component Specified torques

rrectness of i
Door lock centring pin 20 Nm
l purpos

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4.9.3 Adjusting upper door lock

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Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1331-
te

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– Loosen bolts -2- on upper door lock -1-.

• Align centring pin centrally to guide, and secure it in outer po‐
sition.
– Close left rear wing door.
– Tighten bolts -2- of upper door lock -1-.

138 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Loosen bolts -2- of upper U-shaped striker with centring pin

-1-, and adjust door alignment.
– Tighten bolts -2- of upper striker with centring pin -1-.
Specified torques
Component Specified torques
Door lock centring pin 20 Nm

4.9.4 Adjusting striker

Special tools and workshop equipment required
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♦ Torque wrench
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– Loosen striker -1- by loosening bolts -2-.

rrectness of i

– After loosening bolts -2- the striker -1- can be moved horizon‐
l purpos

tally and vertically.

– Adjust right rear wing door with U-shaped striker -1- so that
nform
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recess of door lock with rotary latch is positioned centrally in

m

relation to U-shaped striker and right rear wing door aligns with
at
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left rear wing door when closed.

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Striker 20 Nm
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4.9.5 Adjusting striker with centring pin
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Prote AG.

Special tools and workshop equipment required

4. Right rear wing door 139

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

– Unclip cap -4- from lock carrier cover.

– Loosen bolts -3- of lower striker with centring pin -1-.

AG. Volkswagen AG d
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– Loosen bolts -2- on striker plate -1- on rear wing door.

– Close rear wing door and check adjustment.
nform
ercia

– Tighten bolts of striker with centring pin and of closure plate.

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Specified torques
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Striker with centring pin 20 Nm

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4.9.6 Synchronisation of door locks

Special tools and workshop equipment required

140 Rep. gr.58 - Rear doors, door components

 AG. Volkswagen AG d
lksw
agen Crafter
oes 2006 ➤
not
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General d by body repairs, exterior - Edition 10.2014
V gu
ara
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♦ Torque wrench - V.A.G 1783- aut ra
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d
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ab
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wit
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spec
urposes, in part or in wh

t to the co
rrectnes
– Open left rear wing door and close upper and lower door locks

s o
using a screwdriver. cial p

f inform
mer

– Loosen bolts -2- on interior door mechanism of left rear wing

atio
door.
om

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or

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– Slowly operate door opener -1- until lower (or upper) door lock

thi
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opens.
t

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– Hold door opener -1- in this position.
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fo

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t.
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– Turn adjustment bolt -3- so that upper (or lower door) locks Cop py
open synchronously.
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– Tighten bolts -2- for interior release to specified torque of by c lksw
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8 Nm.
Prote AG.

Specified torques
Component Specified torques
Interior lock 8.0 Nm

4.10 Removing and installing door hinge

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Note

♦ The removal and installation procedure is for the right side.

The left side is similar.
♦ The removal and installation sequence is only for the lower
door hinge. The upper door hinge is similar.

Removing
– Remove rear wing door ⇒ page 133 .

4. Right rear wing door 141

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Unscrew bolts -2- and remove door hinge -3- from rear wing
door.

AG. Volkswagen AG d
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Installing
m

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Install in reverse order, but note the following:
n in
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te o

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Specified torques
s
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4.11 Removing and installing door arrester

fo

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Special tools and workshop equipment required C py
t. rig
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by c lksw
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Prote AG.

142 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
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Note s

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The removal and installation procedure is for the left side. The
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right side is similar.

ab
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Removing

h re
hole

spec
Removing door arrester
es, in part or in w

t to the co
– Release door arrester -1- from detent bracket -4-.
– Unscrew bolts -2- from rear wing door and remove door ar‐
rester.

rrectness of i
l purpos

nf
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gh ht
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Prote AG.

4. Right rear wing door 143

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
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byV gu
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ab
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spec
urposes, in part or in wh

t to the co
Removing detent bracket
– Remove bolts -3- and remove detent bracket.
rrectne

Installing
Install in reverse order, but note the following:
ss o
cial p

Specified torques
f inform
mer

♦ ⇒ “4.3 Assembly overview – door arrester”, page 129

atio
m

4.12 Removing and installing - door upper

o

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lock and lower guide

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Special tools and workshop equipment required

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t.
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Cop py
ht. rig
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by lksw
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Prote AG.

144 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
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Note

ility
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♦ The removal and installation procedure is for the right door

h re
hole

upper lock and lower guide.

spec
es, in part or in w

♦ The procedure for the door upper lock on the left rear wing

t to the co
door can be derived from this.

rrectness of i
Removing
Removing upper door lock
l purpos

– Unscrew bolt -3- and remove door upper lock -2- from rear
nf
ercia

wing door -1-. orm

m

– Unclip Bowden cable -4- from door upper lock -2- using a
atio
m

screwdriver.
o

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Prote AG.

4. Right rear wing door 145

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
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spec
es, in part or in w

t to the co
rrectness of i
Removing lower guide
l purpos

– Unscrew bolts -6- and remove lower guide -5- from rear wing
door -1-.

nform
ercia

Installing
m

Install in reverse order, but note the following:

com

tion in

Specified torques
r
te o

thi
s
iva

do

4.13 Removing and installing interior operat‐

r
rp

cum
fo

ing mechanism
en
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t.
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op py
Special tools and workshop equipment required
t. C rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

146 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

AG. Volkswagen AG d
agen oes
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Removing
yi Co
Cop py
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– Remove rear wing door trim ⇒ General body repairs, interior;
gh ht
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Rep. gr. 70 ; Trim, insulation; Door trims .
cop Vo
by lksw
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Prote AG.
– Unscrew bolts -2- and remove interior actuation -1- from inte‐
rior of door.
– Unclip Bowden cables -3- and -4- out of inner actuation -1-.

4. Right rear wing door 147

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Installing
Install in reverse order, but note the following:
Specified torques

4.14 Removing and installing door lock

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

Removing

AG. Volkswagen AG d
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wit
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orm
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

148 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove rear wing door trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Trim, insulation; Door trims .
– Remove upper door upper ⇒ page 144 .
– Unclip operating rod from lock cylinder housing ⇒ page 149 .
– Remove bolts -8- (Qty. 3).
– Remove door lock -1- from inner part of door.
– Separate electrical connector -5-.
– Unclip Bowden cables -2-, -3- and -4- from door lock -1-.
– Release catch -arrow- using a screwdriver.
– Pull Bowden cable retainer -6- off door lock -1-.
– Detach Bowden cable -7- from door lock -1-.
Installing
Install in reverse order, but note the following:

Note

If a door lock is renewed, the Bowden cables must be readjusted.

Specified torques
♦ ⇒ “4.6 Assembly overview - door lock”, page 132

4.15 Removing and installing lock cylinder

housing agen
AG. Volkswagen AG d
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4. Right rear wing door 149

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Remove front door trim panel ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Door trim panels .
– Lever cap -5- out of opening in front wing door.
– Remove bolt -4-.
– Unclip operating rod -3- from lock cylinder housing -2-.

Note

Operating rod -3- must be secured to prevent it falling into door.

– Carefully pull lock cylinder housing -2- at right angles relative

to wing door -1- out of door handle bracket.
– Carefully pull out lock cylinder housing -2- at right angles rel‐
ative to wing door -1-.
Installing
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Lock cylinder housing 3 Nm

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4.16 Removing and installing door handle

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– Remove lock cylinder housing ⇒ page 149 .

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– Pull door handle to rear and swivel handle out of door.
Installing

rrectne
Install in reverse order of removal.

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Prote AG.

150 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

Note

The removal and installation procedure is for the left side. The
right side is similar.

Removing
– Remove door handle ⇒ page 150 .
– Remove bolts -1- along with seal -2- from outer side of door.

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– Remove bearing bracket -1- from inside of door and unclip

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h re
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Specified torques
spec
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Component Specified torques

Mounting bracket 2.0 Nm
rrectness of i
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4.18 Removing and installing upper striker

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Special tools and workshop equipment required

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4. Right rear wing door 151

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

Note

Removal and installation are described for the right side. The left
side is similar.

Removing
– Unscrew bolts -2- and remove striker -1-.
Installing
Install in reverse order, but note the following:
– Adjust striker -1- ⇒ page 138 .
Specified torques
Component Specified torques
Striker 20 Nm

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4.19 Removing and installing centring pin

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spec

♦ Torque wrench - V.A.G 1331-

es, in part or in w

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152
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Rep. gr.58 - Rear doors, door components
agen
Prote AG.
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

The removal and installation procedure is described for the right

centring pin -1-. Removal and installation for the left striker with
centring pin -2- is similar.

Removing
– Unclip cap -4- from lock carrier cover.
– Unscrew bolts -3-, and remove striker pin -1-.
Installing
Install in reverse order, but note the following:
– Adjust centring pins -1- and -2- ⇒ page 137 .
Specified torques
Component Specified torques
Striker centring pin 20 Nm

AG. Volkswagen AG d
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4. Right rear wing door 153

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

5 Left rear wing door

⇒ “5.1 Assembly overview - left rear wing door”, page 154
⇒ “5.2 Assembly overview - interior lock”, page 156
⇒ “5.3 Assembly overview - door arrester with opening angle of
250°”, page 157
⇒ “5.4 Removing and installing upper door lock”, page 157
⇒ “5.5 Removing and installing lower door lock”, page 158
⇒ “5.6 Removing and installing striker”, page 159
⇒ “5.7 Removing and installing door opener”, page 159
⇒ “5.8 Removing and installing interior lock”, page 159
⇒ “5.9 Removing and installing door arrester with opening angle
of 250°”, page 161
⇒ “4.9 Adjusting rear wing door”, page 135

5.1 Assembly overview - left rear wing door

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154 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Left rear wing door

❑ Removing and installing
⇒ page 133 .
❑ Adjusting ⇒ page 135
2 - Door upper lock
❑ Removing and installing
⇒ page 157 .
3 - Door upper hinge
❑ Removing and installing
⇒ page 141
4 - Door arrester
❑ Removing and installing agen
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❑ Removing and installing ss a c
⇒ page 159 .

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6 - Door lower hinge

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❑ Removing and installing
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⇒ page 141
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7 - Door lower lock
hole

spec
❑ Removing and installing
es, in part or in w

⇒ page 158 .

t to the co
8 - Inner seal
❑ Pushed onto left wing

rrectness of i
door flange
l purpos

9 - Striker
❑ Removing and installing

nform
ercia

⇒ page 159 .
m

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10 - Door opener
com

tion in
❑ Removing and installing
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⇒ page 159 .

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11 - Number plate light trim

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❑ Removing and installing ⇒ page 255 .
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❑ Removing and installing ⇒ page 286 .
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5. Left rear wing door 155

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

5.2 Assembly overview - interior lock

1 - Right rear wing door n AG. Volkswagen AG do

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❑ Removing and installing byV
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⇒ page 133 . ir se
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❑ Adjusting ⇒ page 135 aut or
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2 - Interior lock

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❑ Removing and installing

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⇒ page 159 .

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3 - Bowden cable

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❑ To door upper lock ole,

spec
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4 - Bowden cable

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❑ To door lower lock
5 - Door opener

rrectne
❑ Removing and installing
⇒ page 159 .

ss
6 - Bolt

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f in
❑ Qty. 2.

form
mer

❑ 8.0 Nm

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156 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

5.3 Assembly overview - door arrester with opening angle of 250°

Note

Only the left side is shown. The right side is similar.

1 - Rubber seal
2 - Door arrester magnet
❑ Secured to side panel at
retainer -4-
❑ Specified torque: 20 Nm
❑ Removing and installing
⇒ page 161 .
3 - Bolt
❑ Qty. 3.
❑ Specified torque: 20 Nm
4 - Bracket
❑ For door arrester mag‐
net
❑ Removing and installing
⇒ page 161 .
5 - Door arrester stop swage
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⇒ page 161 s.s au ac
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6 - Washer
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❑ On inside of rear wing

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7 - Hexagon nut
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❑ 20 Nm
hole

spec

❑ On inside of rear wing

es, in part or in w

t to the co

door
rrectness of i
l purpos

nform
ercia

5.4 Removing and installing upper door lock

m

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tion in

Special tools and workshop equipment required

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5. Left rear wing door 157

 AG. Volkswagen AG d
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Crafter 2006 ➤ aut ra
c
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General body repairs, exterior - Edition 10.2014 s

ce
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♦ Torque wrench - V.A.G 1331-

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nf
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Removing
m

atio
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n in
– Unscrew bolt -2- and remove door upper lock -1- from rear
or c

thi
wing door.
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– Unclip Bowden cable from upper door lock -1- using a screw‐
rp

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Install in reverse order, noting the following.
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– Adjust upper door lock ⇒ page 138 .
AG.

Specified torques
Component Specified torques
Door lock 10 Nm

5.5 Removing and installing lower door lock

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

158 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Unscrew bolt -2- and remove door lower lock -1- from rear wing
door.
– Unclip Bowden cable from lower door lock -1- using a screw‐
driver.
Installing
Install in reverse order, noting the following.
– Adjust lower door lock ⇒ page 137 .
Specified torques
Component Specified torques
Door lock 10 Nm

5.6 Removing and installing striker

Removing
– Unscrew bolts -2-.
– Remove striker -1-.
Installing
Install in reverse order, noting the following.
– Adjust striker -1- ⇒ page 139 .
Specified torques
Component Specified torques
Striker agen20 Nm
AG. Volkswagen AG d
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5.7 Removing and installing door opener
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– Release locking lug -arrow-.

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– Pull door opener -1- from interior lock.

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Installing
h re
hole

spec

Press door opener -1- onto inner door mechanism until locking
es, in part or in w

tab -arrow- engages.

t to the co
rrectness of i
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nform
ercia

5.8 Removing and installing interior lock

m

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Prote AG.

5. Left rear wing door 159

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl

pt
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itte

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ab
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ot p

wit

Removing
, is n

h re
hole

– Remove rear wing door trim ⇒ General body repairs, interior;

spec

Rep. gr. 70 ; Trims/insulation; Door trims .

es, in part or in w

t to the co

– Remove door opener -5- ⇒ page 159 .

– Remove upper and lower door locks ⇒ page 144 .
rrectness of i

– Unscrew bolt -6- from left rear wing door -1-.

l purpos

– Remove interior lock -2- with Bowden cables -3- and -4- from
inner part of door.
nf
ercia

or

Installing
m
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Install in reverse order, noting the following.

n in
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– Specified torque of bolts ⇒ page 156 .

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Specified torques
o

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f

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t.
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♦ Bolts ⇒ Item 6 (page 156)
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Prote AG.

160 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

5.9 Removing and installing door arrester with opening angle of 250°

Note

The removal and installation procedure is for the left side. The right side is similar.

AG. Volkswagen AG d
agen oes
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V gu
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Removing
Door arrester stop
– Remove rear wing door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Door trims .
– Unscrew hexagon nuts -7- from inner side of rear wing door
and remove door arrester stop -5- from exterior.
Door arrester magnet
– Pull rubber seal -1- forwards off side panel using removal
wedge - 3409- .
– Using pliers, release magnet -2- from door arrester.
– Unscrew door arrester magnet -2- from bracket -4-.

5. Left rear wing door 161

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Bracket
– Unscrew bolts -3- (from inside vehicle) and remove bracket
-4- (door arrester magnet already removed).
Installing
Install in reverse order, noting the following.
Specified torques

AG. Volkswagen AG d
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es, in part or in w

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or

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Prote AG.

162 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

6 Cab door
⇒ “6.1 Assembly overview - cab door”, page 163
⇒ “6.2 Assembly overview - hinges and hinge brackets”,
page 165
⇒ “6.3 Removing and installing cab door seal”, page 165
⇒ “6.4 Removing and installing cab door”, page 167
⇒ “6.5 Adjusting cab door”, page 169
⇒ “6.6 Removing and installing hinges and hinge brackets”, page
171
⇒ “6.7 Removing and installing door arrester”, page 172
⇒ “6.8 Removing and installing housing”, page 173
⇒ “6.9 Removing and installing door handle”, page 174
⇒ “6.10 Removing and installing mounting bracket”, page 174
⇒ “6.11 Removing and installing door lock”, page 175
⇒ “6.12 Removing and installing interior operating mechanism”,
page 177
⇒ “6.13 Removing and installing striker”, page 178

6.1 Assembly overview - cab door

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♦ The right side is shown. The left side is similar.

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6. Cab door 163

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Cab door
❑ Removing and installing
⇒ page 167 .
❑ Adjusting ⇒ page 169
2 - Door handle
❑ Removing and installing
⇒ page 174 .
3 - Housing
❑ Removing and installing
⇒ page 173 .
4 - Seal
❑ For housing -3-.
5 - Seal
❑ For door handle -2-
6 - Bearing bracket
AG. Volkswagen AG d
❑ Removing and installing lksw
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⇒ page 174 . d by Vo gu
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7 - Door lock utho eo
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❑ Removing and installing ss c

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⇒ page 175 .
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8 - Bolt

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❑ Qty. 3.

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❑ 10 Nm
, is n

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hole

9 - Bolt

spec
es, in part or in w

❑ Qty. 2.

t to the co
❑ 20 Nm
10 - Striker

rrectness of i
❑ Removing and installing
l purpos

⇒ page 178 .
❑ Adjusting ⇒ page 170

nform
ercia

11 - Door hinge
m

at
❑ Upper and lower
om

ion
c

❑ Removing and installing ⇒ page 167 .

in t
or

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❑ Adjusting ⇒ page 169

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12 - Door arrester
f

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❑ Removing and installing ⇒ page 172 .
Co
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13 - Bolt
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❑ Qty. 2. Prote
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agen

❑ 23 Nm
14 - Bolt
❑ Qty. 2.
❑ 23 Nm
15 - Cab door inner seal
❑ Removing and installing ⇒ page 165 .
16 - Trim
❑ For interior release mechanism -17-.
17 - Interior opening mechanism
❑ Removing and installing ⇒ page 177 .

164 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

18 - Bolt
AG. Volkswagen AG d
❑ Qty. 8. lksw
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6.2 Assembly overview - hinges and hinge brackets

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1 - Cab door

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❑ Removing and installing

h re
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⇒ page 167 .

spec
urposes, in part or in wh
2 - Bolt

t to the co
❑ Qty. 2.
❑ 23 Nm

rrectne
3 - Clamping screw
❑ 18 ± 2.0 Nm

ss o
cial p

f
4 - Hinge

inform
❑ On lower B-pillar
mer

atio
m

❑ Removing and installing

o

n
c

⇒ page 171

i
or

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sd
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5 - Bolt
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❑ Qty. 2.
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t.
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❑ 23 Nm
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6 - Hinge bracket
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❑ On lower part of side
lksw
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wing door
AG.

❑ Removing and installing

⇒ page 171
7 - Bolt
❑ Qty. 2.
❑ 23 Nm
8 - Hinge
❑ On upper B-pillar
❑ Removing and installing
⇒ page 171
9 - Hinge bracket
❑ On upper part of side
wing door
❑ Removing and installing ⇒ page 171
10 - Bolt
❑ Qty. 2.
❑ 23 Nm
11 - Clamping screw
❑ 18 ± 2.0 Nm

6.3 Removing and installing cab door seal

During production, a sealant is applied to the door inner seals,
which are then placed on the door flange and rolled on.

6. Cab door 165

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

♦ The removal and installation sequence is only for the right door
inner seal. The removal and installation of the left door inner
seal is similar.
♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, sealing and firm seating are no longer guaran‐
teed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.

Removing

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es, in part or in w

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at
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ion
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or

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ate

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priv

cum
or

– Detach step insert -2- ⇒ General body repairs, interior; Rep.

f

en
g

gr. 68 ; Step inserts; Front step insert .

n

t.
yi Co
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– Pull door inner seal -1- off body flange.
t. rig
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Prote AG.

166 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Installing

Note

The vulcanised point -arrow- on the door inner seal -1- must be
positioned centrally on the body flange to entry step.

– Push door inner seal -1- onto body flange.

– Install step insert -2- ⇒ General body n Arepairs,
G. Volkswinterior;
agen AG Rep.
gr. 68 ; Step inserts; Front step wage
olks insert .
does
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Note s au ra
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After installing, check beading of door inner seal -1- reaches

pt
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d

completely over adjoining trim.

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6.4 Removing and installing cab door

wit
, is n

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hole

Special tools and workshop equipment required

spec
es, in part or in w

♦ Torque wrench - V.A.G 1331-

t to the co
rrectness of i
l purpos

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mercia

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te o

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rig
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cted
Removal and installation are described for the right side. The left
agen
Prote AG.
side is similar.

Removing:
– Remove bellows -4- from B-pillar and separate connector.
– Loosen clamping screw -2- from upper hinge and clamping
screw -5- from lower hinge.
– Unscrew bolt -3- for door arrester.
– Further dismantling requires the help of a second mechanic.
– Lift cab door -1- upwards out of hinge brackets.

6. Cab door 167

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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urposes, in part or in wh

t to the co
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cial p

f inform

Installing:
mer

atio

Install in reverse order, but note the following:

om

n
c

i
or

Specified torques
thi
te

sd
va

♦ ⇒ “6.2 Assembly overview - hinges and hinge brackets”, page

i

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pr

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165
fo

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pyri by
Vo
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cted agen
Prote AG.

168 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

6.5 Adjusting cab door

⇒ “6.5.1 Adjusting cab door at hinge and hinge bracket”,
page 169
⇒ “6.5.2 Adjusting striker”, page 170 AG. Volkswagen AG d
agen oes
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Note horis nte
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♦ To enable adjustment of the cab door, vehicle must be stand‐
s

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nl
ing on its wheels.

pt
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♦ The cab door is adjusted correctly if the gaps/shut lines are
erm

ab
even all around, the door is not too deep or does not protrude

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and all contours align when the is door closed

wit
, is n

h re
♦ To check or adjust the gaps/shut lines ⇒ Body Repairs; Rep.
hole

spec
gr. 00 ; Technical data; Body gaps/shut lines; Body - centre,
es, in part or in w

cab door .

t to the co
♦ After installing or adjusting, carry out corrosion protection
measures to hinges and bolts.

rrectness of i
♦ To ensure correct door adjustment the door hinge must be
l purpos

loosened on the cab door. Other measures such as raising the

door have no effect. Subsequent pressure from above will
cause the door to sack again.

nf
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m

atio
6.5.1 Adjusting cab door at hinge and hinge
om

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bracket
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Special tools and workshop equipment required

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ng

♦ Torque wrench - V.A.G 1331-

t.
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Cop py
t. rig
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pyri by
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cted agen
Prote AG.

6. Cab door 169

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
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nl

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es, in part or in w

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Prote AG.

– After loosening bolts -2- and -5-, cab door -1- can be adjusted
horizontally to B-pillar.
– After loosening bolts -3- and -4-, cab door -1- can be adjusted
vertically.
– Adjust striker ⇒ page 170 .

6.5.2 Adjusting striker

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

170 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

♦ Only the adjustment for the right cab door is described. The
adjustment of the left cab door is similar.
♦ The cab door must lock fully when closing without any addi‐
tional force being required and must not have any play.
♦ The cab door must not be pushed up or down due to striker
adjustment. AG. Volkswagen AG d
agen oes
olksw not
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The following can be adjusted
ise
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at the striker: ara
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or eo
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• If cab door doessnot
au align with C-pillar. ra
c
s

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– Loosen striker -1- by loosening bolts -2- on C-pillar.
le
un

pt
an
d
itte

– After loosening bolts -2-, striker -1- can be moved horizontally

y li
erm

ab
and vertically -arrows-.

ility
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wit
– Adjust cab door with U-shaped striker -1- so that recess of door
is n

h re
lock with rotary latch is positioned centrally in relation to U-
ole,

shaped striker and cab door aligns with C-pillar when closed.

spec
urposes, in part or in wh

t to the co
– Tighten bolts -2-.
Specified torques

rrectne
Component Specified torques
Interior operating mechanism 23 Nm

ss o
cial p

f inform
6.6 Removing and installing hinges and
mer

atio
hinge brackets
om

n
c

i
or

Special tools and workshop equipment required

thi
te

sd
iva

o
r

♦ Torque wrench - V.A.G 1331-

p

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove cab door -1- ⇒ page 167 .
Upper hinge and hinge bracket
– Remove bolt -7- and remove hinge -8- from B-pillar.
– Unscrew bolt -10- and remove upper hinge bracket -9- from
cab door -1-.

6. Cab door 171

 n AG. Volkswagen AG do
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Crafter 2006 ➤ ho
ir se tee
t or
General body repairs, exterior - Edition 10.2014s au ac
s

ce
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un

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an
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ility
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urposes, in part or in wh

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rrectness o
cial p

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mer

atio
om

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or

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fo

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ng

t.
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t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Lower hinge and hinge bracket

– Remove bolt -5- and remove hinge -4- from B-pillar.
– Unscrew bolt -2- and remove lower hinge bracket -6- from cab
door -1-.
Installing
Install in reverse order, but note the following:
Specified torques

6.7 Removing and installing door arrester

Special tools and workshop equipment required

172 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

Note

Removal and installation are described for the right side. The left
side is similar.

Removing
– Remove B-pillar trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Pillars and side trims .
– Remove bolts -2- from door.
– Remove bolt -3- from B-pillar. AG. Volkswagen AG d
agen oes
lksw not
– Remove door arrester -1- from B-pillar. d by
Vo gu
ara
ise nte
r
Installing ut
ho eo
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s a c
Install in reverse order, but note the following: s

ce
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un

pt
Specified torques

an
d
itte

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rm

ab
♦ ⇒ “6.1 Assembly overview - cab door”, page 163
pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i

6.8 Removing and installing housing

l purpos

Special tools and workshop equipment required

nform
ercia

♦ Torque wrench - V.A.G 1783-

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

6. Cab door 173

 AG. Volkswagen AG d
agen oes
olksw not
V
Crafter 2006 ➤ d by gu
ara
ise nte
General body repairs, exterior - Edition 10.2014thor eo
au ra
ss c

ce
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nl

pt
du
Note

an
itte

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erm

ab
ility
Removal and installation are described for the right side. The left

ot p
side is similar.

wit
, is n

h re
hole

spec
Removing

es, in part or in w

t to the co
– Lever cap -3- out of opening in cab door -1-.
– Remove bolt -4- located below.

rrectness of i
– Carefully pull housing -2- out at right angles to cab door -1-.

l purpos
Installing
Install in reverse order of removal, noting the following:

nf
ercia

orm
Specified torques
m

atio
om

n in
c

Component Specified torques

or

thi
te

sd
a

Housing 3.0 Nm
iv

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f

en
ng

t.
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t. rig
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pyri by
Vo
co lksw
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Prote AG.

6.9 Removing and installing door handle

Note

Removal and installation are described for the right side. The left
side is similar.

Removing
– Remove housing ⇒ page 173 .
– Pull door handle to rear and swivel handle out of door.
Installing
Install in reverse order of removal.

6.10 Removing and installing mounting

bracket
Special tools and workshop equipment required

174 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

Note

Removal and installation are described for the right side. The left
side is similar.

Removing:
– Remove door handle ⇒ page 174 .
. Volkswage n AG n AG d
wage oe
– Remove cab door yV
olkstrim ⇒ General body repairs,
s no interior; Rep.
t gu
gr. 70 ; Trims/insulation;
ise
d b Door trims . ara
n
r tee
ho
– Unscrew
sa
ut bolts -1- and remove seal -2-. or
ac
s
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un

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d
itte

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pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co

– Remove bearing bracket -2- from cab door -1-.

– Unclip Bowden cable -3- from bearing bracket -2-.
rrectness of i

Installing
l purpos

Install in reverse order of removal. The following should be ob‐

served:
nform
ercia

Specified torques
m

a
com

tion in

Component Specified torques

r
te o

thi

Mounting bracket 2.0 Nm

s
iva

do
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fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

6.11 Removing and installing door lock

Special tools and workshop equipment required

6. Cab door 175

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1783- ksw
agen oes
not
Vol
by gu
d ara
rise nte
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au ra
ss c

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un

pt
an
d
itte

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erm

ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
Note

ss
Removal and installation are described for the right side. The left

o
cial p

f
side is similar.

inform
mer

atio
Removing
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
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fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

176 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove cab door trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Trims/insulation; Door trims .
– Unscrew bolts -1- for door lock -2-.
– Remove door lock -2- from cab door.
. Volkswagen AG
does gen AG
– Unhook Bowden cable -3- from bearing
Vol
ksw
a bracket and discon‐ not
nect electrical connector -4-
ed from door lock -2-.
by gu
ara
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Installing ho eo
aut ra
ss c
Install in reverse order of removal. The following should be ob‐

ce
e
nl

pt
served:
du

an
itte

y li
Specified torques
erm

ab
ility
ot p

Component Specified torques

wit
, is n

h re
hole

Door lock 10 Nm

spec
es, in part or in w

6.12 Removing and installing interior operat‐

t to the co
ing mechanism

rrectness of i
Special tools and workshop equipment required
l purpos

♦ Torque wrench - V.A.G 1783-

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing

6. Cab door 177

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

– Remove cab door trim ⇒ General body repairs, interior; Rep.

t.
yi Co
op
gr. 70 ; Trims/insulation; Door trims . C py
ht. rig
rig ht
by
– Unscrew bolts -2- (Qty. 8) and remove interior actuation mech‐ copy Vo
by lksw
anism -1- from cab door. cted agen
Prote AG.

– Unclip Bowden cables -3- and -4- out of inner actuation -1-.
Installing
Install in reverse order of removal. The following should be ob‐
served:
Specified torques
Component Specified torques
Interior operating mechanism 2.0 Nm

6.13 Removing and installing striker

Special tools and workshop equipment required

178 Rep. gr.58 - Rear doors, door components

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331- . Volkswage

n AG n AG d
wage oes
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
ss

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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Removing
– Unscrew bolts -2-.

rrectne
– Remove striker -1-.

ss
Installing

o
cial p

f inform
– Adjust striker -1- ⇒ page 170 .
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6. Cab door 179

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

60 – Sunroof
1 Sunroof with glass panel
⇒ “1.1 Function”, page 180
⇒ “1.2 Assembly overview - sliding/tilting sunroof with glass pan‐
el”, page 181
⇒ “1.3 Removing and installing sliding/tilting sunroof with glass
panel”, page 181
⇒ “1.4 Removing and installing sliding glass roof”, page 183
AG. Volkswagen
⇒ “1.5 Removing and installing
lksw
agentilting arm”, page 184
AG do
es n
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⇒ “1.6 Removing rand
ise installing sliding sunroof motor”,
db ran
tee
page 185 ut
ho
or
sa ac
⇒ “1.7 Removing
s
and installing trim”, page 187

ce
e
nl

pt
du

1.1 Function

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itte

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When the ignition is switched off, the sliding/tilting sunroof can still

ility
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be opened or closed until the driver door or passenger door is

wit
, is n

h re
opened.
hole

spec
Manual control
es, in part or in w

t to the co
anheben - Manual sliding/tilting sunroof lifting via button
öffnen - Manual sliding/tilting sunroof opening via button
rrectness of i

schließen - Manual sliding/tilting sunroof closing via button

l purpos

senken - Manual sliding/tilting sunroof closing via button

These functions are activated by pressing the button to the 1st
nform
ercia

detent.
m

at
om

The sliding/tilting sunroof is immediately switched off on releasing

on
c

in t

the button.
or

his
ate

do
riv

Automatic function
p

cum
for

tippenanheben - Automatic sliding/tilting sunroof lifting to vent

en
ng

t.
yi
position via button
Co
Cop py
t. rig
gh
tippenöffnen - Automatic sliding/tilting sunroof opening via button
ht
pyri by
Vo
co lksw
by
cted
tippenschließen - Automatic sliding/tilting sunroof closing to vent
agen
Prote AG.
position via button
tippensenken - Automatic sliding/tilting sunroof closing via button
is not possible
These functions are activated by pressing the button to the 2nd
detent.
The sliding/tilting sunroof runs to the corresponding target posi‐
tion on releasing the button.
The automatic functions only become active on releasing the but‐
ton. As long as the button is held in the first or second detent by
the operator, the sliding/tilting sunroof carries out a manual func‐
tion.
Overload protection and blocking detection
The sunroof is equipped with a force limitation (anti-trap) mech‐
anism for the sliding function. If the sunroof encounters an ob‐
struction while closing, it will open automatically.
The sliding/tilting sunroof drive is protected against overheating
by a thermo switch. The protective mechanism activates when the

180 Rep. gr.60 - Sunroof

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

sunroof is operated continuously for approx. 2 minutes. It is func‐

tional again after a cooling-off phase.
If the power or the Hall sensors fail, the sliding/tilting sunroof is
closed either gradually or with the emergency crank on the drive
motor.

1.2 Assembly overview - sliding/tilting sunroof with glass panel

olkswagen AG
en AG. V
1 - Glass sliding roof olks
wag does
not
yV gu
❑ Removing and installing
ise
d b ara
nte
⇒ page 183 u.thor eo
ra
sa c
2 - Retaining clips

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nl

pt
❑ Left and right.
du

an
itte

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❑ For retaining screw -3-.
erm

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ility
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3 - Retaining screw

wit
, is n

❑ Left and right.

h re
hole

spec
❑ For glass sliding roof
es, in part or in w

-1-.

t to the co
4 - Wind deflector
5 - Frame

rrectness of i
❑ For glass sliding roof
l purpos

-1-.
❑ Removing and installing

nf
ercia

⇒ page 181 .

orm
m

6 - Retaining frame atio

om

n in
c

❑ For sliding/tilting sun‐

or

thi

roof with glass panel.

te

sd
iva

❑ Removing and installing

r
rp

cu
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⇒ page 181 .
f

en
ng

t.
yi Co
op
7 - Trim C py
t. rig
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❑ With roller sunblind. yri
p by
co Vo
by lksw
❑ Removing and installing cted agen
Prote AG.
⇒ page 187 .
8 - Sliding sunroof motor
❑ Removing and installing
⇒ page 185 .
9 - Tilting arm
❑ Left and right.
❑ Removing and installing ⇒ page 184 .

1.3 Removing and installing sliding/tilting

sunroof with glass panel
Special tools and workshop equipment required

1. Sunroof with glass panel 181

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench 210 Nm - V.A.G 1783-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Removing
nform
ercia

– Remove trim panel ⇒ page 187 .

m

at
om

– Remove sliding roof motor -3- ⇒ page 185 .

on
c

in t
or

– Remove bolts -2- (Qty 22).

his
ate

do
riv

– Guide retaining frame -1- downwards out of moulded headlin‐

p

cum
or

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182
c by lksw
cted agen
Rep. gr.60 - Sunroof Prote AG.
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove glass sliding roof -4- from roof cut-out from above.
Installing
Specified torques
Component Specified torques
Retaining frame 2.0 Nm

1.4 Removing and installing sliding glass

roof

Note

Installation is described only for the left side. The right side is
similar.

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Cop py
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Prote AG.

Removing
– Press in the detent -arrow b- with a screwdriver and pull out
retaining clip -4- in -direction of arrow c-.

1. Sunroof with glass panel 183

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Turn retaining screw -3- in -direction of arrow a- (notched po‐

sition downwards) and pull retaining screw -3- out from sliding
glass roof -1-.
– Pull sliding glass roof -1- parallel from frame -2- (left and right
tilting arms).
Installing
Install in reverse order of removal.

1.5 Removing and installing tilting arm

Special tools and workshop equipment required
♦ Torque wrench 210 Nm - V.A.G 1783-

Note

The removal and installation procedure is for the left side. The
right side is similar. swa
gen AG
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es, in part or in w

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rrectness of i
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at
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c

in t
or

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ate

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priv

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for

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Prote AG.

184 Rep. gr.60 - Sunroof

 n AG. Volkswagen AG do
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ua Crafter 2006 ➤
ran
ho
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tee exterior - Edition 10.2014
ut or
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ce
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nl

pt
du

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itte

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Prote AG.

Removing
– Remove sliding glass roof ⇒ page 183 .
– Unscrew bolts -5- and remove cover -6- upwards.
– Remove cable -8- upwards out of worm housing -7-.
– Unscrew bolts -3- and press spring -4- to side using a screw‐
driver in -direction of arrow-.
– Guide tilting arm -1- out of frame -2-.
Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torques
Tilting arm 3.5 Nm

1.6 Removing and installing sliding sunroof

motor
Special tools and workshop equipment required

1. Sunroof with glass panel 185

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench 210 Nm - V.A.G 1783-

n AG. Volkswagen AG do
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t to the co
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cial p

f inform
mer

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om

n
c

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te

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pr

cum
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.

Removing
– Remove trim panel ⇒ page 187 .
– Pull wiring harness out from moulded headliner and discon‐
nect connector -3-.
– Remove bolts -2- and remove sliding roof motor -1-.

186 Rep. gr.60 - Sunroof

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
agen oes
Installing olksw not
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Install in reverse order, but note the thofollowing:
ri
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Specified torques ss c

ce
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un

pt
Component Specified torques

an
d
itte

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erm

ab
Sliding sunroof motor 3.5 Nm

ility
ot p

wit
is n
1.7 Removing and installing trim

h re
ole,

spec
Special tools and workshop equipment required
urposes, in part or in wh

t to the co
♦ Release lever - T10039-

rrectness o
cial p

f inform
mer

atio
om

n
c

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te

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Removing Cop py
t. rig
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– Using wedge - T10039/1- , lever out trim -1- from mountings p by
co Vo
in retaining frame.
by lksw
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Prote AG.
Installing
– Press trim -1- into retaining frame mountings.

Note

Ensure that trim -1- is positioned correctly to moulded headliner.

1. Sunroof with glass panel 187

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

61 – Convertible roof, hardtop, canopy

1 Three-way tipper
For technical reasons, instructions for this repair group could not
be completed in time for publication in this workshop manual. The
repair procedures will be published in a later revision.

AG. Volkswagen AG d
agen oes
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es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
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or

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do
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cum
for

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Cop py
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Prote AG.

188 Rep. gr.61 - Convertible roof, hardtop, canopy

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

63 – Bumpers
1 Front bumper
⇒ “1.1 Assembly overview - front bumper cover”, page 189
⇒ “1.2 Assembly overview - add-on parts”, page 191
⇒ “1.3 Removing and installing front bumper cover, vehicles up
to 2012”, page 191
⇒ “1.4 Removing and installing front bumper cover, vehicles as of
2012”, page 193
⇒ “1.5 Removing and installing front bumper carrier, vehicles up
to 2012”, page 195
⇒ “1.6 Removing and installing front bumper carrier, vehicles as
of 2012”, page 196
⇒ “1.7 Repairing front bumper cover”, page 198

1.1 Assembly overview - front bumper wagcover

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Depending on model slight differences are possible when referring to assembly overview.

pt
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es, in part or in w

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Prote AG.

1. Front bumper 189

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Front bumper carrier

❑ ⇒ “1.5 Removing and in‐ . Volkswage
AG
stalling front bumper ksw
agen
n AG d
oes
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carrier, vehicles by V up to
o gu
ara
2012”, page rise 195
d
nte
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❑ ⇒ “1.6 s a Removing and in‐
ut ra
c
stalling
s front bumper

ce
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carrier, vehicles as of
nl

pt
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2012”, page 196
itte

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2 - Bolt

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❑ Qty. 2.
, is n

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❑ 20 Nm
hole

spec
es, in part or in w

3 - Lateral guide

t to the co
❑ Secured with bolts -2-
on left.

rrectness of i
4 - Front bumper cover
l purpos

❑ ⇒ “1.3 Removing and in‐

stalling front bumper
cover, vehicles up to

nf
ercia

2012”, page 191

orm
m

❑ ⇒ “1.4 Removing and in‐

atio
m

stalling front bumper

o

n in
or c

cover, vehicles as of
thi
te

2012”, page 193

sd
iva

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5 - Left fog light trim

o

m
f

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ng

t.
yi
❑ Pull forwards out of de‐
Co
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6 - Centre air duct
co lksw
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cted agen
Prote
❑ Engages in bumper cov‐
AG.

er.
❑ Can be removed only
with radiator grille re‐
moved ⇒ page 243 .
7 - Trim
❑ Engages in bumper cover.
❑ Can be removed only with radiator grille removed ⇒ page 243 .
8 - Step
❑ Only remove when centre air duct -1- is removed
9 - Bolt
❑ Qty. 2.
❑ 20 Nm
10 - Bolt
❑ Qty. 2.
❑ 20 Nm
11 - Spacer ring
❑ Qty. 2.
12 - Right fog light trim
❑ Pull forwards out of detent.
13 - Lateral guide
❑ Secured with bolts -2- on right.

190 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.2 Assembly overview - add-on parts

Note

Depending on model slight differences are possible concerning add-on parts.

1 - Front bumper cover

❑ ⇒ “1.3 Removing and in‐
stalling front bumper
cover, vehicles up to
2012”, page 191 .
❑ ⇒ “1.4 Removing and in‐
stalling front bumper
cover, vehicles as of
2012”, page 193
2 - Left fog light trim
❑ Pull forwards out of de‐
tent.
3 - Centre air duct
❑ Engaged in bumper
cover.
❑ Can only be removed
with front bumper cover
removed -1-.
4 - Step
❑ Can only be removed
with centre air inlet re‐
moved -1-.
5 - Right fog light trim
❑ Pull forwards out of de‐
tent. AG. Volkswagen AG d
agen oes
6 - Towing eye cap olksw not
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❑ Engaged in front bump‐ orise nte
eo
er cover -1- auth
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is n

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spec
urposes, in part or in wh

1.3 Removing and installing front bumper

t to the co

cover, vehicles up to 2012

Special tools and workshop equipment required
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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o
pr

cum
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fo

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t.
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Cop py
t. rig
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yri by

191
cop Vo
by lksw
Prote
cted AG. 1. Front bumper
agen
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

Note

The removal and installation procedures may have to be revised

slightly depending on model.

AG. Volkswagen AG d
agen oes
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tion in
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te o

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t.
Removing
yi Co
Cop py
t. rig
– Remove radiator grille ⇒ page 244 . gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

192 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove trim on left and right headlight ⇒ page 251 .

– Lever out spreader rivets -3-, -4-, -5- and -6- using a screw‐
driver.
– Unscrew bolts -2- and -7-.
– With help of a second mechanic, remove front bumper cover
-1-.
– Detach connectors from electrical components (if fitted) ⇒
Electrical system; Rep. gr. 94 ; Lights, bulbs, switches - ex‐
terior; Fog lights .
Installing
Install in reverse order of removal. The following should be ob‐
served:

Note

When positioning front bumper cover, ensure it is parallel to wing.

– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
pairs; Rep. gr. 00 ; Body gaps/shut lines; Body, front .
Specified torques

1.4 Removing and installing front bumper

AG. Volkswagen AG d
cover, vehicles as of 2012 Volksw
agen oes
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tho or
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♦ Torque wrench - V.A.G 1331- ss
ac

ce
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nl

pt
du

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itte

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

Note
orm
m

atio
m

The removal and installation procedures may have to be revised

o

n in
c

slightly depending on model.

or

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

1. Front bumper 193

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

n AG. Volkswagen AG do
lkswage es n
o ot g
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tho
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ss

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nl

pt
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an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

Removing
at
om

ion
c

– Remove radiator grille ⇒ page 245 .

in t
or

his
ate

– Remove trim on left and right headlight ⇒ page 251 .

do
priv

cum
or

– Lever out spreader rivets -4-, -5- and -6- using a screwdriver.
f

en
ng

t.
yi Co
op
– Pull clip -8- on right and left on wing upwards in C py
t. rig
-direction of arrow-.
gh ht
pyri by
Vo
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by
– Lever out spreader rivets -3- on left and right using a screw‐ cted agen
Prote AG.
driver.
– Unscrew bolts -2- and -7-.
– With help of a second mechanic, remove front bumper cover
-1-.
– Detach connectors from electrical components (if fitted) ⇒
Electrical system; Rep. gr. 94 ; Lights, bulbs, switches - ex‐
terior; Fog lights .
Installing
Install in reverse order of removal. The following should be ob‐
served:

194 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

When positioning front bumper cover, ensure it is parallel to wing.

– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
pairs; Rep. gr. 00 ; Body gaps/shut lines; Body, front .
Specified torques

1.5 Removing and installing front bumper

carrier, vehicles up to 2012
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
ut
♦ Hot air blower - V.A.G
ss a 1416- ra
c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Front bumper 195

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
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d
itte

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rm

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pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r

Removing
te o

thi
s
iva

do

– Remove front bumper cover ⇒ page 191 .

r
rp

cum
fo

en
g

– Remove bolts -2- on left and right (qty. 4).

n

t.
yi Co
op py
– Heat seal in area of front bumper carrier -1- and longitudinal
t. C rig
gh ht
yri
member with hot air blower - V.A.G 1416- . p by
co Vo
by lksw
cted agen
– Loosen front bumper carrier -1- from left and right longitudinal Prote AG.
members with a large screwdriver.
Installing
– Fit front bumper carrier -1- and tighten bolts -2-.
Specified torques
Component Specified torques
Front bumper carrier 23 Nm

1.6 Removing and installing front bumper

carrier, vehicles as of 2012
Special tools and workshop equipment required

196 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331- n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove front bumper cover ⇒ page 191 .
– Undo bolts -2- on left and right (qty. 4) and remove front bump‐
er carrier -1-.
Installing
– Fit front bumper carrier -1- and tighten bolts -2-.

1. Front bumper 197

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques
Component Specified torques
Front bumper carrier 23 Nm

1.7 Repairing front bumper cover

Note

If bumper cover is damaged, determine whether plastic can be

repaired before renewing bumper ⇒ General Information; Body
Repairs, General Body Repairs ; Plastic repair process .

n AG. Volkswagen AG do
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o ot g
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ss

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nl

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

198 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2 Rear bumper
⇒ “2.1 Assembly overview - rear bumper cover”, page 199
⇒ “2.2 Assembly overview - rear bumper cover, add-on parts”,
page 200
⇒ “2.3 Assembly overview - steps”, page 201
⇒ “2.4 Removing and installing rear bumper cover”, page 201
⇒ “2.5 Removing and installing rear step”, page 203
⇒ “2.6 Repairing rear bumper cover”, page 205
AG. Volkswagen AG d
agen oes
2.1 Assembly overview - rear bumper cover by
Volksw not
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ara
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is nte
Bumper cover with step ut
hor eo
a ra
ss c

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e
nl

pt
Note
du

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itte

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erm

ab
Depending on model slight differences are possible when refer‐

ility
ot p

ring to assembly overview.

wit
, is n

h re
hole

spec
es, in part or in w

1 - Rear bumper cover

t to the co
❑ For vehicles with park‐
ing aid.

rrectness of i
2 - Right cover
l purpos

❑ Secured with expansion

rivet -10-.

nform
ercia

3 - Right bumper corner sec‐

tion
m

at
om

i
❑ Inserted into rear bump‐

on
c

in t
er cover.
or

his
ate

do
riv

4 - Bumper cover with step

p

cum
or

❑ For vehicles with towing

f

en
ng

t.
bracket.
yi Co
Cop py
❑ Removing and installing
t. rig
gh ht
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⇒ page 201 .
p by
o Vo
by c lksw
cted agen
5 - Spreader rivet
Prote AG.

❑ Qty. 3.
6 - Spreader rivet
❑ For vehicles with park‐
ing aid and towing
bracket.
❑ Qty. 3.
7 - Cover
❑ For vehicles with towing
bracket.
8 - Left bumper corner section
❑ Inserted into rear bump‐
er cover.
9 - Left cover
❑ Secured with expansion
rivet -10-.

2. Rear bumper 199

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

10 - Spreader rivet
❑ Left and right.

2.2 Assembly overview - rear

agen
bumper
AG. Volkswagencover,
AG do add-on parts
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1 - Bumper cover with step thoris tee
or
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❑ Removing and installing
ss
ac
⇒ page 201 .

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2 - Rear carriers
itte

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❑ Engaged in rear bumper
pe

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cover on inside
ot

wit
, is n

h re
❑ Only remove when rear
hole

bumper cover -1- is re‐

spec
moved
es, in part or in w

t to the co
3 - Right bumper corner sec‐
tion

rrectness of i
❑ Inserted into rear bump‐
er cover -1-.
l purpos

4 - Rear right reflector

❑ Engaged in rear bumper

nform
ercia

cover.
m

a
com

ti
5 - Rear left reflector

on in
r
te o

❑ Engaged in rear bumper

thi
s
iva

cover. do
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rp

cum
fo

6 - Left bumper corner section

en
ng

t.
yi Co
❑ Inserted into rear bump‐ Cop py
er cover -1-.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

200 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
2.3 Assembly overview - steps Volkswagen oes
not
y gu
db ara
rise nte
1 - Rear step tho eo
au ra
c
ss
❑ For models with wheel‐

ce
le
un
base: 3665 mm and

pt
an
d
itte
4325 mm

y li
erm

ab
❑ For vehicles with per‐

ility
ot p
missible GVW: 5000 kg.

wit
is n

h re
2 - Bolt ole,

spec
urposes, in part or in wh

❑ Left and right.

t to the co
❑ Qty. 3, depending on
step version.
❑ 90 Nm

rrectne
3 - Rear step

ss
❑ For vehicles without

o
cial p

f
towing bracket.

inform
mer

4 - Retaining plate

atio
m

❑ Qty. 2.
o

n
c

i
or

n
❑ Depending on step ver‐

thi
te

sd
sion.
iva

o
pr

cum
r

5 - Rear step
fo

en
ng

t.
yi
❑ For vehicles with towing
Co
Cop py
bracket.
t. rig
gh ht
pyri by
Vo
o
6 - Upper bracket by c lksw
cted agen
Prote AG.
❑ For step -8-.
7 - Lower bracket
❑ For step -8-.
8 - Rear step

2.4 Removing and installing rear bumper

cover
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

2. Rear bumper 201

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
d by ara
e nte
ris
ho eo
Note au
t ra
c
ss

ce
e
nl
The removal and installation procedures may have to be revised

pt
du

an
slightly depending on model.

itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing
– Remove D-pillar protective side moulding
⇒ Item 7 (page 258) .
– Detach rear protective side moulding in rear area
⇒ Item 6 (page 258) .
– Lever out spreader rivets -3- on left and right using a screw‐
driver.
– Lever out spreader rivets -6- from above using a screwdriver.
– Remove bolt -4- (Qty. 7).
– Detach connectors from electrical components (if fitted) ⇒
Electrical system; Rep. gr. 94 ; Exterior lights, bulbs, switches;
Parking aid .

202 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
agen oes
lksw not
– With the bhelpy V of a second mechanic, pull rear
o gu bumper cover
ar
-1- along
ris with bumper cover corner sections -2-aand
ed
nte -5- parallel
outaut of guides.
ho eo
ra
ss c
Installing

ce
le
un

pt
an
d

Install in reverse order, noting the following.

itte

y li
erm

ab
– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐

ility
ot p

pairs; Rep. gr. 00 ; Body gaps; Body, rear .

wit
is n

h re
Specified torques
ole,

spec
urposes, in part or in wh

Component Specified torques

t to the co
Rear bumper cover 9.0 Nm

rrectne
2.5 Removing and installing rear step
Special tools and workshop equipment required

ss o
cial p

f
♦ Torque wrench - V.A.G 1331-

inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note

The removal and installation procedures may have to be revised

slightly depending on model.

2. Rear bumper 203

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove rear bumper cover ⇒ page 201 .
– Remove hexagonal nuts -3-.

Note

Have rear step -1- held with help of second mechanic.

– Remove bolts -2- from mountings and remove rear step -1-
with a second mechanic.
Installing
Install in reverse order, noting the following.

204 Rep. gr.63 - Bumpers

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques

2.6 Repairing rear bumper cover

Note

If bumper cover is damaged, determine whether plastic can be

repaired before renewing bumper ⇒ General Information; Body
Repairs, General Body Repairs ; Plastic repair process .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Rear bumper 205

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

64 – Glazing
1 Repair instructions
⇒ “1.1 Minimum curing period”, page 206
⇒ “1.2 Repairing windscreen”, page 207
⇒ “1.3 Installation instructions for bonded windows”, page 207
⇒ “1.4 Preparing old undamaged window for glazing”, page 208
⇒ “1.5 Preparing new windows for installing”, page 209
⇒ “1.6 Preparing body flange for glazing”, page 210
⇒ “1.7 Touching up paint damage”, page 210
⇒ “1.8 Cleaning off excess adhesive sealing material”,
page 211

1.1 Minimum curing period

WARNING agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
Special standards must be adheredrise to when replacing bonded
d
nte
windows. One of these standards
o
auth is, for example, that a freshly eo
ra
bonded windscreen must comply
ss with the safety requirements, c
even in an accident, following the minimum prescribed curing
ce
le
un

period. pt
an
d
itte

y li
rm

ab
pe

ility
ot

2-component adhesive wit

, is n

h re
The minimum curing time for the 2-component adhesive is 2 hours
hole

spec

for all windows.

es, in part or in w

t to the co

The operational safety of the vehicle is restored completely after

2 hours.
rrectness of i

1-component adhesive
l purpos

The minimum curing time for the 1-component adhesive is 16

hours for all windows.
nform
ercia

The vehicle is definitely safe to operate again after 16 hours if the

1-component adhesive is used.
m

a
com

tio

For 2-component adhesive and 1-component adhesive

n in
r
te o

thi

Irrespective of which adhesive is used, the vehicle can be moved

s
iva

do

again half an hour after the window has been installed.

r
rp

cum
fo

en

Minimum curing period is the time from bonding the window until
ng

t.
yi Co
vehicle may be used (operational safety). During this time, the t. Cop py
vehicle must stand on a level surface at room temperature (at
rig
gh ht
yri by
least 15 °C). cop Vo
by lksw
cted agen
Prote AG.

WARNING

Vehicle is safe to use only after curing period is completed.

206 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.2 Repairing windscreen

Note

♦ If windscreen is damaged, determine whether glass can be

repaired before replacing.
♦ Damaged windscreens can be repaired with the window repair
kit - VAS 6092- .
♦ This damage must not exceed a certain size or position.
♦ Each window repair kit comes with a set of instructions.

Special tools and workshop equipment required

♦ Window repair kit - VAS 6092-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab

1.3 Installation instructions for bonded win‐

ility
ot p

dows
wit
, is n

h re
hole

spec
es, in part or in w

1.3.1 Installation instructions

t to the co

– Apply adhesive sealing material -1- in continuous bead, hold‐

ing applicator at right angle to window -2-.
rrectness of i
l purpos

WARNING
nform
ercia

Window must be installed within 10 minutes, or adhesive prop‐

erties of glass adhesive will be impaired.
m

at
om

io

Adhesive bead should not be applied too thick and windows

n
c

in t
or

should not be pressed too forcibly on body flange. Windows no

his
ate

longer have sealing lips and therefore excessive adhesive will

do
priv

be visible in the joint area.

cum
for

en
ng

t.
yi Co
Cop py
t. rig
♦ Using 2 suction lifters - V.A.G 1344- , install glass pane in win‐
yri
gh by
ht
dow aperture, align to centre and press in onto spacing lip.
op Vo
by c lksw
cted agen
Prote
♦ Replace stickers (e.g. for airbag) if there were any.
AG.

1. Repair instructions 207

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.3.2 Materials

Note

The part numbers of the materials can be found in the ⇒ Elec‐

tronic Parts Catalogue .

♦ 2K glass adhesive 1) 2) 3) 6)

♦ 1K glass adhesive 1) 2) 4) 5) 6)

♦ Activator 1) 6)

♦ Glass primer/paint 1) 6)
primer

♦ Cleaning solution 1) 6)

♦ Primer applicator 1) 6)
n AG. Volkswagen AG do
lkswage es n
o ot g
♦ Adhesive remover 1) 6)
d byV ua
ran
ir se tee
ho
♦ Cutting cord 1) 6) aut or
ac
ss

ce
e

♦ Mixing nozzle 1) 6)
nl

pt
du

an
itte

y li
erm

ab
1)Observe instructions for use on the information sheet provided

ility
ot p

by the manufacturer.

wit
, is n

h re
2) Minimum curing period ⇒ page 206
hole

spec
es, in part or in w

3)
Double cartridge gun - VAS 5237- must be used to apply these

t to the co
materials.
4)Heat according to manufacturer's instructions, using cartridge
heater - V.A.G 1939- . rrectness of i
l purpos

5)Small cartridge, 180 ml, for sealing and/or when a 400 ml dou‐
ble cartridge alone is not sufficient.
nform
ercia

6 The part numbers of the materials can be found in the ⇒ Elec‐

m

tronic Parts Catalogue (ETKA) .

at
om

ion
c

1.4 Preparing old undamaged window for

in t
or

his
ate

glazing
do
priv

cum
for

Cutting back adhesive bead

en
ng

t.
yi Co
Cop py
t. rig
gh ht
WARNING yri
p by
co Vo
by lksw
cted agen
Prote AG.
Keep bonding surface free of dirt and grease.
Do not treat bonding surface with activator immediately after
cutting back. Do not prime. Do not treat with cleaning solution.

208 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

♦ If an undamaged window is being re-used, cut back the resid‐

ual adhesive sealant to 1 to 2 mm shortly before bonding it
back in. Do not damage primer and ceramic coating when do‐
ing this.
♦ The remaining material is required as a base for the new ad‐
hesive sealing material.

WARNING

Exception: if bonding is performed later than one day after cut‐

ting back adhesive bead, the remaining residual material must
be activated with activator .
Apply activator evenly in one stroke using applicator .
Activator must not come in contact with paint, or the paintwork
will be damaged.
Drying time approx. 10 minutes

Exception: if bonding is not performed immediately after cutting

back, the remaining residual material must be activated with ac‐
tivator.

1.5 Preparing new windows for installing

Preparing new glass with inspection window for vehicle identifi‐
cation number ⇒ page 211 .
AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
♦ The area on which the adhesive bead is appliedut is not pre‐
ho eo
ra
coated or primed. ss a c
ce
e
nl

♦ The sealing lip is included with a new windscreen. pt

du

an
itte

y li
♦ None of the windows are precoated.
erm

ab
ility
ot p

wit
, is n

– Clean all round edge of window over a width of 20 mm with

h re

cleaning solution.
hole

spec
es, in part or in w

– Then rub edge of window dry using a lint-free cloth.

t to the co

WARNING
rrectness of i

The ceramic coating on the window is not glass/paint primer!

l purpos

The ceramic coating must be primed before application of ad‐

hesive sealing compound! Use only glass/paint primer
D 009 200 02!
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Repair instructions 209

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Using applicator -1-, apply glass and paint primer -2- evenly
in one pass.
♦ Drying time approx. 10 minutes

1.6 Preparing body flange for glazing

– Cut back remaining material on body flange with electric cutter
- V.A.G 1561 A- and U-shaped blade - V.A.G 1561/3- , but do
not remove completely under any circumstances.

Note

Remaining material serves as adhesion base for newly applied . Volkswagen AG

gen AG
adhesive sealing compound. Keep dirt and grease off ofolkbonding
swa does
not
surfaces. ed
byV gu
ara
ris nte
ho eo
aut ra
ss c
WARNING
ce
e
nl

pt
du

an
itte

Activator must not have contact with paint or the paintwork will
y li
erm

ab

be damaged.
ility
ot p

wit
, is n

h re
hole

Exception:
spec
es, in part or in w

If bonding is not performed immediately after cutting back, the

t to the co

remaining residual material must be activated with activator - D

181 801 A1- .
rrectness of i

♦ If the window flange has been repaired or partially renewed,

the area concerned must be cleaned and primed again after
l purpos

painting.
nform
ercia

1.7 Touching up paint damage

m

at
om

For paintwork damage in non-visible areas and large areas of

on
c

damage in the non-visible area when the window is installed, the

in t
or

his
e

paint structure must be restored according to the specifications in

at

do
riv

the ⇒ “Paint” manual .

p

cum
for

en
g

The following repair method is suitable for minor paintwork dam‐

n

t.
yi Co
age in the non-visible area when the window is installed: Coat . Cop py
twice in opposite directions (wet-on-wet) with glass/paint primer -
ht rig
rig ht
by
D 009 200 02- . copy Vo
by lksw
cted agen
Prote
Coat the damaged area once and wait 10 minutes to flash-off.
AG.

Coat a second time, but this time in the opposite direction.

210 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.8 Cleaning off excess adhesive sealing

material
– Use adhesive remover - D 002 000 10- as a cleaning solution.
Observe the appropriate safety precautions when performing
this work. Volkswa
AG. gen AG
agen does
olksw not
yV gu
WARNING db ara
rise nte
tho eo
When cleaning freshly installed glass from
s au the inside in the ve‐ ra
c
s
hicle, do not press glass outwards.

ce
le
un

pt
an
d
itte

y li
erm

ab
– First clean painted surface as well as possible using a dry

ility
ot p

cloth. Remove residue using adhesive remover - D 002 000

wit
is n

10- .

h re
ole,

spec
– Clean plastic trim: Allow adhesive sealant to cure (approx. 1
urposes, in part or in wh

hour) and then peel off.

t to the co
1.9 Preparing windscreen with inspection
window for vehicles without vehicle

rrectne
identification number

ss o
In future all windscreens will be fitted with a viewing or inspection
cial p

f in
window for the vehicle identification number

form
mer

For vehicles without vehicle identification number the viewing

atio
m

window in the windscreen must be blackened out from inside

o

n
c

i
or

n
(primed).

thi
te

sd
va

– Clean viewing window -arrow- of windscreen -1- from inside

i

o
pr

cum
using cleaning solution - 009 401 04- .
r
fo

en
ng

t.
yi Co
– Blacken the viewing window -arrow- from inside using glass/ Cop py
paint primer - D 009 200 02- .
t. rig
gh ht
pyri by
Vo
o
– Apply glass/paint primer - D 009 500 25- using applicator - D
c by lksw
cted agen
009 200 02- evenly and in one stroke to previously cleaned
Prote AG.

area of windscreen.
– After a flash-off time of about 10 minutes, prime the inspection
window a second time.
– The new windscreen can then be fitted ⇒ page 217 .

1. Repair instructions 211

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2 Windscreen
⇒ “2.1 Assembly overview - windscreen”, page 212
⇒ “2.2 Assembly overview - heated windscreen and rain sensor”,
page 213
⇒ “2.3 Removing and installing windscreen”, page 213

2.1 Assembly overview - windscreen

1 - Windscreen
❑ Removing windscreen
⇒ page 213 .
❑ With rain and light sen‐
sor - G397-
2 - Window surround (one- AG. Volkswagen AG d
piece) agen oes
olksw not
y V gu
❑ Fit on window before ap‐ rised b ara
nte
plying adhesive bead utho eo
r
sa ac
3 - PUR adhesive sealant s

ce
e
nl

pt
❑ Cross section of bead:
du

an
itte

width = 7 mm, height =

y li
erm

ab
11 mm (including pre‐

ility
ot p

coating, residual materi‐

wit
, is n

al on window glass and

h re
window flange)
hole

spec
es, in part or in w

4 - Window flange

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

212 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.2 Assembly overview - heated windscreen and rain sensor

1 - Heated windscreen and rain

sensor
❑ Removing and installing
⇒ page 213
. Volkswagen AG
gen AG does
2 - Connector Vol
ksw
a
not
by gu
❑ For heated
ris
e windscreen
d ara
nte
tho eo
3 - Interiors amirror
u ra
c
s

ce
e

4 - Upper cap
nl

pt
du

an
itte

5 - Lower cap

y li
erm

ab
ility
6 - Connector
ot p

wit
, is n

❑ For rain sensor.

h re
hole

spec
7 - Retaining plate
es, in part or in w

❑ For rain sensor.

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.3 Removing and installing windscreen

Note

The removal of a bonded window is described using the Removal

kit for flush bonded windows - V.A.G 1474 A- . The respective
tools from Removal kit for flush bonded windows - VAS 6452- may
also be used.

2. Windscreen 213
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Special tools and workshop

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
♦ Windscreen removal kit - n AG. Volkswagen AG do
V.A.G 1755- lkswage es n
o ot g
byV ua
d ran
♦ Cartridge gun - o
ir se tee
V.A.G 1628- auth or
ac
ss
♦ Cartridge heater -

ce
e
nl

pt
V.A.G 1939-
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

214 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Electric cutter -
V.A.G 1561 A-
♦ Cutting blade -
V.A.G 1561/2-
♦ Cutting blade -
V.A.G 1561/8- AG. Volkswagen AG d
agen oes
olksw not
♦ Setting gauge - 3371- d by V gu
ara
rise nte
♦ Cutting blade - utho eo
ra
V.A.G 1561/19- ss a c

ce
le
♦ Double cartridge gun - un

pt
an
d

VAS 5237-
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Window
wash/wipe system; Windscreen wiper system; Removing and
installing windscreen wiper system; Removing wiper arms .
– Remove A-pillar trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Pillar and side panel trim; Removing A-pillar trim .
– Remove interior mirror -3- ⇒ General body repairs, interior;
Rep. gr. 68 ; Interior mirror .
– Remove rain sensor (if fitted) ⇒ Electrical system; Rep. gr.
92 ; Windscreen wiper system; Removing and installing rain
sensor .
– Separate electrical wiring connector of heated windscreen
-1- (if fitted) ⇒ Item 2 (page 213) .

2. Windscreen 215
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Pull off windscreen surround -2- from around windscreen -1-.

nform
ercia

– Insert cover for Audi A4 dash panel - V.A.G 1474/13- between

m

a
com

windscreen and dash panel.

ion in
r
te o

thi
s
iva

do

Note
r
rp

cum
fo

en
ng

t.
If the cover is not pushed in far enough, the dash panel may become damaged.
yi Co
Cop py
t. rig
gh ht
yri by
– Place cutting cord around window. cop Vo
by lksw
cted agen
Prote
• Ensure that cutting cord lies under windscreen in corners.
AG.

– Pull end of cutting cord through adhesive sealing material into

inside of vehicle using awl - 1474 A- .

216 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– On inside, prevent end of cutting cord from being pulled out by

attaching pull handle - V.A.G 1351/1-- .
– Attach other end of cord to reel device - V.A.G 1654- .
– Apply the reel device - V.A.G 1654- to “position I”.
– Turn reel device - V.A.G 1654- accordingly and cut windscreen
free.
– Use wedge - V.A.G 1474/5- to press cutting cord against wind‐
screen while cutting in order to gain clearance at window
flange and dash panel.
– Lift out windscreen from aperture using 2 suction lifters - V.A.G
1344- and with aid of second person.
– Use vacuum cleaner to remove any glass splinters and dirt.
Installing
Preparing old undamaged window for glazing ⇒ page 208 .
Preparing new window for glazing ⇒ page 209 .
Preparing body flange for glazing ⇒ page 210 .
Installation instructions ⇒ page 207 .
Minimum curing period ⇒ page 206 .

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Windscreen 217
 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Crafter 2006 ➤ orise nte
eo
h
General body repairs,
s aut
exterior - Edition 10.2014 ra
c
s

ce
e
nl

pt
du

an
3 Side windows

itte

y li
erm

ab
ility
⇒ “3.1 Assembly overview - side window”, page 218 ot p

wit
, is n

⇒ “3.2 Removing and installing side window”, page 218

h re
hole

spec
3.1 Assembly overview - side window
es, in part or in w

t to the co
1 - Side window

rrectness of i
❑ Removing undamaged
side window
l purpos

⇒ page 218 .
❑ Removing broken side

nform
ercia

window ⇒ page 220 .

m

at
❑ Installing side window
om

io
⇒ page 220 .

n
c

in t
or

his
e

2 - PUR adhesive sealant

at

do
priv

c
❑ Cross section of bead:

um
for

width = 7 mm, height =

en
ng

t.
yi
11 mm (including pre‐
Co
Cop py
coating, residual materi‐
t. rig
gh ht
yri
al on window glass and p by
co Vo
lksw
window flange)
by
cted agen
Prote AG.
3 - Window flange

3.2 Removing and installing side window

Note

The removal of a bonded window is described using the Removal

kit for flush bonded windows - V.A.G 1474 A- . The respective
tools from Removal kit for flush bonded windows - VAS 6452- may
also be used.

218 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Special tools and workshop

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
♦ Windscreen removal kit -
V.A.G 1755-
♦ Cartridge gun -
V.A.G 1628-
♦ Cartridge heater -
V.A.G 1939-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

⇒ “3.2.1 Removing and installing undamaged side window”, page

219 h re
hole

spec
es, in part or in w

⇒ “3.2.2 Removing broken side window”, page 220

t to the co

3.2.1 Removing and installing undamaged

side window
rrectness of i

Removing
l purpos

– Remove adjoining trim (if fitted) ⇒ General body repairs, in‐

nf

terior; Rep. gr. 70 ; Pillar and side panel trim .

ercia

orm
m

– Take trimming needle -2- from windscreen removal kit - V.A.G

atio
m

1755- and use handle -1- to force it through adhesive bead.

o

n in
or c

thi

• Look for a place where the gap is the largest. Protect the
te

sd
iva

paintwork at this place from damage.

o
r
rp

cu
o

m
f

– Unscrew handle -1- and feed cutting cord through eye of nee‐
en
ng

t.
yi
dle.
Co
Cop py
t. rig
gh
– Pull in trimming needle with end of cutting cord. Use pliers and
ht
pyri by
Vo
o
gloves.
c by lksw
cted agen
Prote AG.
Undamaged side window on sliding door side

3. Side windows 219

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Pull end of cutting cord through adhesive sealing material into

inside of vehicle using awl - V.A.G 1474 A-- .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
– On inside, prevent
aut end of cutting cord -2- from being pulled out or a
h
by attaching sit to pull handle - V.A.G 1351/1- -1-.
s c

ce
le
un

pt
– Lay cutting cord -2- around side window and guide second end

an
d
itte

of cord inwards.

y li
rm

ab
pe

ility
• Ensure that cutting cord lies under side window in corners.
ot

wit
, is n

• Have second person hold side window using 2 suction lifters

h re
hole

- V.A.G 1344- .

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Secure other end of cutting cord to reel device - V.A.G 1654

A- and cut side window free, repositioning reel device -
V.A.G 1654 A- as necessary.
nform
ercia

– Use wedge - V.A.G 1474/5- to press cutting cord against side

m

a
com

window while cutting in order to obtain clearance at window

tion in

flange.
r
te o

thi
s

– Lift out side window from window aperture.

iva

do
r
rp

cum
fo

– Use vacuum cleaner to remove any glass splinters and dirt.

en
ng

t.
yi Co
Installing Cop py
t. rig
gh ht
yri
Preparing old undamaged window for glazing ⇒ page 208 . p by
o Vo
by c lksw
cted agen
Preparing new window for glazing ⇒ page 209 . Prote AG.

Preparing body flange for glazing ⇒ page 210 .

Installation instructions ⇒ page 207 .
Minimum curing period ⇒ page 206 .

3.2.2 Removing broken side window

A broken side window is removed in a similar way to the descrip‐
tion of the “broken rear window” ⇒ page 227 .

220 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

4 Movable section of sliding window

⇒ “4.1 Assembly overview – control mechanism for sliding win‐
dow”, page 221
⇒ “4.2 Removal and installation of sliding window”, page 221

4.1 Assembly overview – control mechanism for sliding window

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Note ir se
d ran
tee
tho
u or
a ac
Only the left sliding window is described. The right sliding window
ss is similar.

ce
le
un

pt
an
d
itte

y li
erm

ab
1 - Sliding window

ility
ot p

❑ Removing and installing

wit
is n

⇒ page 221

h re
ole,

spec
2 - Button
urposes, in part or in wh

t to the co
❑ Secured with an axis.
3 - Lower cover

rrectne
❑ Clipped into sliding win‐
dow -1-.

ss
4 - Upper cover

o
cial p

f i
❑ Clipped into sliding win‐
nform
dow -1-.
mer

atio
m

5 - Lower linkage
o

n
c

i
or

❑ For latch in sliding win‐

thi
te

sd

dow -1-.
iva

o
pr

cum
r

6 - Star wheel
fo

en
ng

t.
yi
❑ Upper and lower
Co
Cop py
t. rig
❑ For actuation of upper
gh ht
yri by
linkage -6- and lower
cop Vo
by lksw
cted
linkage -4-.
agen
Prote AG.

7 - Upper linkage
❑ For upper latch in sliding
window -1-.

4.2 Removal and installation of sliding win‐

dow

Note

Only the removal of the left sliding window is described. Removal

of the right sliding window is similar.

4. Movable section of sliding window 221

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Special tools and workshop equipment required

♦ Removal wedge - 3409-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Removing ut
ho eo
ra
s a c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Use a small screwdriver to lever out end caps -3- from lower
guide rail -2- and end cap -4- from upper guide rail -5-.
– Open sliding window -1-.

222 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Carefully push guide rail upwards using removal wedge -

3409- .
– Lift out sliding window -1- from guide rails at top and bottom.
Installing

AG. Volkswagen AG d
agen oes
o lksw not
The installation of the sliding window ed by-1-
V
is basically carried out gu
ara
in reverse order of removal. horis nte
eo
aut ra
ss c

ce
le

Note
un

pt
an
d
itte

y li
erm

Make sure that relay levers -2- are inserted evenly into upper and

ab
ility
lower guide rails.
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4. Movable section of sliding window 223

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

5 Rear window
⇒ “5.1 Assembly overview – rear wing door window”, page 224
⇒ “5.2 Removing and installing rear wing door window”,
page 224

5.1 Assembly overview – rear wing door window

1 - Left rear window

❑ Removing and installing
rear window
⇒ page 225
2 - PUR adhesive sealant
❑ Cross section of bead:
width = 7 mm, height =
11 mm (including pre‐
coating, residual materi‐
al on window glass and
window flange)
3 - Window flange
4 - Right rear window

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

5.2 Removing and installing rear wing door

window
rrectness of i
l purpos

Note
nform
ercia

The removal of a bonded window is described using the Removal

kit for flush bonded windows - V.A.G 1474 A- . The respective
m

at

tools from Removal kit for flush bonded windows - VAS 6452- may
om

ion

also be used.
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

224
co Vo
by lksw
Rep. gr.64 - Glazing cted agen
Prote AG.
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Special tools and workshop

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
♦ Windscreen removal kit -
V.A.G 1755-
♦ Cartridge gun -
V.A.G 1628-
♦ Cartridge heater -
V.A.G 1939-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

⇒ “5.2.1 Removing and installing undamaged rear wing door win‐

inform

dow”, page 225

mer

atio
m

⇒ “5.2.2 Removing broken rear wing door window”, page 227

o

n
c

i
or

5.2.1 Removing and installing undamaged

thi
te

sd
va

rear wing door window

i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
co lksw
by
Removal is described for the undamaged left rear wing door win‐ cted agen
Prote AG.
dow only. Removal of the undamaged right rear wing door window
is similar.

Removing
– Remove wiper arm (if fitted) ⇒ Electrical system; Rep. gr. 92 ;
Rear window wash/wipe system .
– Remove emblem trim ⇒ page 286 .
– Pull off connections for heated rear window and press con‐
necting tab onto window.

5. Rear window 225

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
Crafter 2006 ➤ rise
d b ara
nte
General body repairs, exterior - Edition 10.2014
autho eo
ra
ss c

ce
e
– Use awl - V.A.G 1474/2- -2- to poke through adhesive sealant

nl

pt
du
outwards.

an
itte

y li
erm

ab
– Pull cutting cord -1- through adhesive sealant into vehicle in‐

ility
ot p
terior using awl - V.A.G 1474/2- .

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– On inside, pull out end of cutting cord -2- using the pull handle

nform
ercia

- V.A.G 1351/1- -1-.

m

at
– Lay cutting cord -2- around rear window in rear hinged wing
om

ion
door and take second end of cord towards the inside of vehicle.
c

in t
or

his
te

• Ensure that cutting cord lies under rear wing door window in
a

do
riv

corners.
p

cum
for

en
ng

• Have second person hold rear wing door window using suction
t.
yi Co
op
lifter - V.A.G 1344- .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Secure other end of cutting cord to reel device - V.A.G 1654

A- and cut rear wing door window free, repositioning reel de‐
vice - V.A.G 1654 A- as necessary.
– Use wedge - V.A.G 1474/5- to press cutting cord against rear
wing door window while cutting in order to obtain clearance at
window flange.
– Lift out rear window from window aperture.
– Use vacuum cleaner to remove any glass splinters and dirt.
Installing
Preparing old undamaged window for glazing ⇒ page 208 .
Preparing new window for glazing ⇒ page 209 .
Preparing body flange for glazing ⇒ page 210 .
Installation instructions ⇒ page 207 .
Minimum curing period ⇒ page 206 .

226 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

5.2.2 Removing broken rear wing door win‐

dow
– Protect body and interior from glass splinters.
– Remove fragments of glass -1- up to adhesive sealant.
– Remove connections to window heater unit.
– Apply textile reinforced adhesive tape all around flange.
– Cut through adhesive sealing material (with remainders of
glass) in window aperture using electric cutter -
V.A.G 1561/18- and blade -V.A.G 1561/10- (with stop roller).

WARNING

Always wear safety goggles and leather gloves.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Rear window 227

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

6 Rear sliding window

⇒ “6.1 Removing and installing rear sliding window”, page 228

6.1 Removing and installing rear sliding win‐

dow
⇒ “6.1.1 Rear window and sliding window for partition”,
page 228
⇒ “6.1.2 Rear window for double cab and dropside models”, page
229

6.1.1 Rear window and sliding window for partition n AG. Volkswagen A
G do
wage es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Detach seal -2- from inside out over window flange using re‐
moval wedge - 3409- .
– Press rear window -1- or sliding window -2- with seal -3- out
of window aperture from inside.
Installing
– Spray seal -3- with soapy water.

228 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Insert thread inserting tool - V.A.G 1818- around seal -2-.

Further installation is possible only with the help of a second me‐
chanic.
– Place rear window -1- or sliding window -2- into window aper‐
ture using 2 suction lifters - V.A.G 1344- .
– Pull out thread inserting tool - V.A.G 1818- all the way around
from inside and thereby pull sealing lip over window flange.

6.1.2 Rear window for double cab and dropside models

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
Removing
yi Co
Cop py
t. rig
– Detach seal -2- from inside out over window flange using re‐
gh ht
pyri by
moval wedge - 3409- .
co Vo
by lksw
cted agen
Prote AG.
– Press rear window -1- with seal -2- out of window aperture
from inside.
Installing
– Spray seal -2- with soapy water.
– Insert thread inserting tool - V.A.G 1818- around seal -2-.

6. Rear sliding window 229

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Further installation is possible only with the help of a second me‐

chanic.
– Place rear window -1- into window aperture using 2 suction
lifters - V.A.G 1344- .
– Pull out thread inserting tool - V.A.G 1818- all the way around
from inside and thereby pull sealing lip over window flange.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

230 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
agen oes
7 Roof window d by
Volksw not
gu
ara
ise nte
r
⇒ “7.1 Assembly overview - roof
ut window”, page 231
ho eo
ra
s a c
s
⇒ “7.2 Removing and installing roof window”, page 231

ce
le
un

pt
an
d
7.1 Assembly overview - roof window
itte

y li
erm

ab
ility
ot p

wit
1 - Front roof window
is n

h re
ole,

❑ Removing and installing

spec
urposes, in part or in wh

⇒ page 231

t to the co
2 - Rear roof window
❑ Removing and installing
⇒ page 231

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

7.2 Removing and installing roof window

Note

The removal of a bonded window is described using the Removal

kit for flush bonded windows - V.A.G 1474 A- . The respective
tools from Removal kit for flush bonded windows - VAS 6452- may
also be used.

7. Roof window 231

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Special tools and workshop

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
♦ Windscreen removal kit -
V.A.G 1755-
♦ Cartridge gun - AG. Volkswagen AG d
agen oes
ksw
V.A.G 1628- byV
ol not
gu
ara
ed
is nte
♦ Cartridge heater - hor eo
ut
V.A.G 1939- ss a ra
c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
– Protect surrounding parts from damage opy
rig by
Vo
ht
by c lksw
– Lay cutting cord around roof window. Prote
cted AG.
agen

– Ensure that cutting cord lies under windscreen in corners.

– Pull end of cutting cord through adhesive sealant into inside
of vehicle using awl - V.A.G 1474/2- .
– Attach one end of cord to reel device - V.A.G 1654 A- .
– Cut out roof window using reel device - V.A.G 1654 A- .
Installing
Preparing old undamaged window for glazing ⇒ page 208 .
Preparing new window for glazing ⇒ page 209 .
Preparing body flange for glazing ⇒ page 210 .
Installation instructions ⇒ page 207 .
Minimum curing period ⇒ page 206 .

232 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r

– Apply adhesive sealant -4- with double cartridge gun - VAS

rp

cu
o

5237- all around primed area -3- perpendicular to roof window

f

en
ng

t.
yi
-1-.
Co
Cop py
ht. rig
– Place roof window -1- in window aperture using 2 suction lifters rig ht
py by
- V.A.G 1344- -2-, align to centre and press in onto spacing lip.
co Vo
by lksw
cted agen
Prote AG.

WARNING

Window must be installed within 10 minutes, or adhesive prop‐

erties of glass adhesive will be impaired.
Adhesive bead should not be applied too thick and windows
should not be pressed too forcibly on body flange. Windows no
longer have sealing lips and therefore excessive adhesive will
be visible in the joint area.

Note

If the adhesive bead is too thick and the adhesive expands onto the area of the window heater the excess
adhesive must be removed.

7. Roof window 233

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

8 Front door window

⇒ “8.1 Assembly overview - front door window”, page 234
⇒ “8.2 Removing and installing door window”, page 234
⇒ “8.3 Adjusting door window”, page 235
⇒ “8.4 Removing and installing quarter light window”, page 236

8.1 Assembly overview - front door window

1 - Front door
2 - Window channel
❑ Pushed all round onto
door flange
3 - Clip
❑ For window channel -2-
4 - Wind deflector seal
❑ Secure to door frame
with clips -5-
5 - Clip
❑ For wind deflector seal
-4-
6 - Window seal
❑ For quarter light window
-7-. AG. Volkswagen AG d
agen oes
lksw not
7 - Quarter light window byV
o gu
ara
ed
❑ Removing and installing horis nte
eo
⇒ page 236 . s aut ra
c
s
8 - Door window
ce
le
un

pt
an
d

❑ Removing and installing

itte

y li

⇒ page 234 .
erm

ab
ility
ot p

9 - Window regulator motor

wit
is n

h re

❑ Removing and installing

ole,

spec

⇒ page 43 .
urposes, in part or in wh

t to the co

10 - Window regulator
❑ Removing and installing
⇒ page 41
rrectness o
cial p

f inform
mer

8.2 Removing and installing door window

atio
om

n
c

i
or

Special tools and workshop equipment required

thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

234 Rep. gr.64 - Glazing

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Crafter 2006 ➤
ise nte
r
tho General body repairs, exteriore o - Edition 10.2014
au ra
c
ss
♦ Torque wrench - V.A.G 1783-

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Note
m

at
om

ion
c

in t
Removal and installation are described for the right side. The left
or

his
e

side is similar.
at

do
priv

cum
for

Removing

en
ng

t.
yi Co
op
– Remove front door trim ⇒ General body repairs, interior; Rep.
C py
t. rig
gh
gr. 70 ; Trims/insulation; Door trims .
ht
pyri by
Vo
o
by c lksw
cted
– Remove electrical components (if fitted) from front door ⇒
agen
Prote AG.
Electrical system; Rep. gr. 96 ; Lights, bulbs, switches - inte‐
rior .
– Carefully pull off sealing film from front door.
– Lower door window -1- until clamping bolts -2- are accessible.
– Loosen clamping bolts -2- (do not remove) and prise apart
clamping jaws.
– Push door window upwards completely and secure with ad‐
hesive tape to prevent it from slipping.
– Remove window regulators ⇒ page 41 .
– Guide door window downwards out of front door.
Installing
Install in reverse order, but note the following:
– Operate window regulator once in each direction to upper and
lower stops. This initialises the window regulator motor and it
is now ready for operation.
• Carry out functional test before fitting door trim.
Specified torques
Component Specified torques
Door window 6.0 Nm

8.3 Adjusting door window

Special tools and workshop equipment required

8. Front door window 235

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

– Lower door window -1- until clamping bolts -2- are accessible
⇒ page 234 .
– Loosen clamping bolts -2- (do not unscrew completely).
– Slide door window -1- without additional force into clamping
jaws and align door window to rear window channel.
– Tighten clamping bolts -2-.
Specified torques
Component Specified torques
Door window 6.0 Nm

AG. Volkswagen AG d
agen oes
olksw not
V gu
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ise nte
or eo
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un

pt
an
d
itte

8.4 Removing and installing quarter light

y li
rm

ab
window
pe

ility
ot

wit
, is n

Special tools and workshop equipment required

h re
hole

spec
♦ Removal wedge - 3409-
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

Removing
en
ng

t.
yi Co
op
– Remove exterior mirror ⇒ page 277 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

236 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Detach window rubber -2- from inside out over door flange
using removal wedge - 3409- .
– Push quarter light window -1- together with window rubber
-2- out of door -arrow- from inside of vehicle.
Installing AG. Volkswagen AG d
agen oes
lksw not
– Spray window rubber with soapy d bywater.
Vo gu
ara
rise nte
– Insert thread inserting toolut-hoV.A.G 1818- around window rub‐ eo
ra
ber. ss a c

ce
e
nl

Further installation is possible only with the help of a second me‐

pt
du

an
chanic.
itte

y li
erm

ab
– Place quarter light window in aperture

ility
ot p

wit
, is n

– Pull out thread inserting tool - V.A.G 1818- all the way around

h re
from inside and thereby pull sealing lip over door flange.
hole

spec
es, in part or in w

– Install exterior mirror ⇒ page 277 .

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

8. Front door window 237

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed
9 Windows having threaded connec‐ ris nte
tho eo
au ra
tions ss c

ce
le
un

pt
⇒ “9.1 Assembly overview - rear vent window”, page 238

an
d
itte

y li
rm

ab
⇒ “9.2 Assembly overview - cab rear door vent window”, pe

ility
page 239
ot

wit
, is n

h re
⇒ “9.3 Removing and installing rear vent window”, page 239
hole

spec
⇒ “9.4 Removing and installing cab rear door vent window”, page
es, in part or in w

t to the co
241

9.1 Assembly overview - rear vent window

rrectness of i
l purpos

Note

nform
ercia

Only the left side is shown. The right side is similar.

m

a
com

tion in
r

1 - Rear vent window

te o

thi
s
iva

❑ Removing and installing

do
r
rp

c
⇒ page 239 .

um
fo

en
ng

t.
yi
2 - Tilting arm
Co
Cop py
t. rig
gh
3 - Bolt
ht
pyri by
Vo
co lksw
❑ Qty. 2.
by
cted agen
Prote AG.
❑ For fastening vent win‐
dow.
4 - Bolt
❑ Qty. 4.
❑ For fastening tilting arm.
5 - Bolt
❑ Qty. 2.
❑ For fastening drive.
6 - Cover
❑ Qty. 2.
7 - Hexagon nut
❑ Qty. 2.
❑ 8.0 Nm

238 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

9.2 Assembly overview - cab rear door vent window

Note

Only the left side is shown. The right side is similar.

1 - Vent window, cab door

❑ Removing and installing
⇒ page 241 .
2 - Bolt
❑ Qty. 2.
❑ 8.0 Nm
3 - Lock
4 - Bolt
❑ 8.0 Nm
5 - Cap
❑ Qty. 2.
6 - Hexagon nut
❑ Qty. 2.
❑ 8.0 Nm

n AG. Volkswagen AG do
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ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f in

9.3 Removing and installing rear vent win‐

form
mer

dow
atio
om

n
c

i
or

Special tools and workshop equipment required

thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Windows having threaded connections 239

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1783-

Note

The removal and installation sequence is only for the left side.
The removal and installation of the right side is similar.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

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om

n in
or c

thi
te

sd
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r
rp

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o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Open vent window -1-.

240 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Unscrew bolts -4- inside vehicle on vent window actuator.

Note

Have second person hold vent window -1- with suction lifter - V.A.G 1344- .

– Pull off caps -3-.

– Unscrew hexagon nuts -2- from openings inside vehicle.
– Remove vent window -1- from exterior.
Installing
Install in reverse order, noting the following.
Specified torques

9.4 Removing and installing cab rear door

vent window
Special tools and workshop
swa
gen AG equipment required
. Volkswagen AG
does
k not
Vol gu
♦ Torque wrench
ed
by - V.A.G 1783- ara
nte
ris
utho eo
ra
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ss
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pt
an
d
itte

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ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

Note
ss o
cial p

f in

The removal and installation procedure is for the right side. The
form
mer

removal and installation of the left side is similar.

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Windows having threaded connections 241

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Removing
m

– Open vent window -1-.

at
om

ion
c

in t

– Remove bolts -2- on cabin door.

or

his
ate

– Remove bolts -4- between latch -3-

do
priv

cum
for

en
ng

t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Have second person hold vent window -1- with suction lifter - V.A.G 1344- .
co Vo
by lksw
cted agen
Prote AG.

– Pull off caps -5-.

– Unscrew hexagon nuts -6- from cab door.
– Remove vent window -1- from exterior.
Installing
Install in reverse order, noting the following.
Specified torques

242 Rep. gr.64 - Glazing

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

66 – Exterior equipment
1 Radiator grille/front trim
⇒ “1.1 Assembly overview - radiator grille and emblem, vehicles
up to 2012”, page 243
⇒ “1.2 Assembly overview - radiator grille, vehicles as of 2012”,
page 244
⇒ “1.3 Removing and installing radiator grille and emblem, vehi‐
cles up to 2012”, page 244
⇒ “1.4 Removing and installing radiator grille and emblem, vehi‐
cles as of 2012”, page 245

1.1 Assembly overview - radiator grille and emblem, vehicles up to 2012

AG. Volkswagen AG d
agen oes
lksw not
1 - Radiator grille by Vo gu
ara
d
❑ Removing rise and installing nte
ho eo
⇒
s a page 244
ut ra
c
s
2 - Bolt
ce
e
nl

pt
du

an
❑ Qty. 4.
itte

y li
erm

ab

❑ Specified torque: 3.0

ility
ot p

Nm
wit
, is n

h re

3 - Emblem
hole

spec

❑ Removing and installing

es, in part or in w

⇒ page 245
t to the co

❑ Engaged in radiator
grille
rrectness of i

❑ Can be removed only

with radiator grille re‐
l purpos

moved.
4 - Locking lug
nform
ercia

❑ Qty. 6.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Radiator grille/front trim 243

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1.2 Assembly overview - radiator grille, vehicles as of 2012

1 - Radiator grille
❑ Removing and installing
⇒ page 244
2 - Bolt
❑ Qty. 4.
❑ 2.5 Nm
3 - Bolt AG. Volkswagen AG d
agen oes
❑ Qty. 2. olksw not
byV gu
ara
d
❑ 7.0 Nm orise nte
eo
h
ut ra
4 - Bolt ss a c

ce
e

❑ Qty. 2.
nl

pt
du

an
itte

❑ 2.5 Nm

y li
erm

ab
5 - Clip

ility
ot p

wit
, is n

❑ Clipped onto wing on left

h re
and right
hole

spec
es, in part or in w

6 - Radiator grille trim

t to the co
❑ Removing and installing
⇒ page 244

rrectness of i
7 - Spreader rivet
l purpos

❑ Qty. 4.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.3 Removing and installing radiator grille

and emblem, vehicles up to 2012
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

Removing
– Undo top bolts -2-.

244 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove radiator grille -1- upwards.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

Removing and installing emblem

en
ng

t.
yi Co
op
– Using a screwdriver, press locking lugs -4- inwards and pull
C py
t. rig
emblem -3- out of radiator grille -1-.
gh ht
pyri by
Vo
o
by c lksw
Installing
Prote
cted AG.
agen

– Insert emblem -3- in radiator grille -1-.

– Press emblem -3- downwards until locking lugs -4- engage.
Install in reverse order, but note the following:
Specified torques

1.4 Removing and installing radiator grille

and emblem, vehicles as of 2012
Special tools and workshop equipment required

1. Radiator grille/front trim 245

 AG. Volkswagen AG d
agen oes
olksw not
Crafter 2006 ➤ d by
V gu
ara
e nte
General body repairs, exterior - Edition
horis
10.2014 eo
aut ra
ss c
♦ Torque wrench - V.A.G 1783-

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Front end hook - 3370-

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

246 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r

Removing
te o

thi
s
iva

do

– Remove cap for headlight washer system (if fitted) ⇒ Electrical

r
rp

cum

system; Rep. gr. 92 ; Headlight washer system; Removing

fo

en
g

and installing spray jet retainer .

n

t.
yi Co
Cop py
– Undo and remove bolts -4- at top from radiator grille -1-.
t. rig
gh ht
pyri by
Vo
co
– Lever out spreader rivets -3- (Qty: 4) from below using a
by lksw
cted agen
Prote
screwdriver.
AG.

– Push feeler gauge -6- with thickest feeler (1 mm) into space
between radiator grille trim -2- and clip -5-.

Note

This releases locking device -arrow-.

– Using front end hook - 3370- -7-, pull radiator grille trim -2- out
of clip -5- “carefully” forwards in -direction of arrow-.
Fit on the right-hand side.
– With help of a second mechanic, pull radiator grille trim -2-
parallel out of clips -5-.

1. Radiator grille/front trim 247

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– While doing so, release 8 clips of radiator grille -1- and radiator
grille trim -2- with a flat plastic wedge.

Caution

Radiator grille trim -2- is seated very tightly in clips -5-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Unscrew bolts -2- and -3- on left and right.

l purpos

– Remove radiator grille -1- upwards.

Installing
nf
ercia

orm

Install in reverse order, but note the following:

m

atio
om

n in
or c

thi
e

Note
t

sd
iva

o
r
rp

cu
o

♦ Before installing radiator grille trim -2-, check securing parts

f

en
ng

t.
and renew if necessary.
yi Co
Cop py
ht. rig
♦ If radiator grille trim -2- is damaged, anti-corrosion measures rig ht
py by
must be taken.
co Vo
by lksw
cted agen
Prote AG.

248 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques
Volkswagen AG
♦ ⇒ “1.2 Assembly overview - radiator grille, vehicles as of agen
AG. does
ksw
2012”, page 244 by
Vol not
gu
ara
ed nte
ris
tho eo
au ra
c
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Radiator grille/front trim 249

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2 Mouldings / trims / extensions

⇒ “2.1 Tools”, page 250
⇒ “2.2 Assembly overview - headlight trim”, page 250
⇒ “2.3 Removing and installing headlight trim”, page 251
⇒ “2.4 Removing and installing air intake grille”, page 252
⇒ “2.5 Removing and installing wing cover ”, page 254
⇒ “2.6 Removing and installing side panel trim”, page 254
⇒ “2.7 Removing and installing number plate light trim”,
page 255
⇒ “2.8 Assembly overview - protective side strip”, page 258

2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

♦ Hot air blower - V.A.G 1416-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi

2.2 Assembly overview - headlight trim

te

sd
iva

o
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rp

cu
o

m
f

en
ng

t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Only the left side is shown. The right side is similar.
p by
co Vo
by lksw
cted agen
Prote AG.

250 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Left headlight trim panel

❑ Removing and installing
⇒ page 251
2 - Bolt
❑ Specified torque: 7 ± 0.5
Nm
3 - Bolt
❑ Qty. 2.
❑ Specified torque: 7 ± 0.5
Nm
4 - Bracket
❑ Clipped into wing.

AG. Volkswagen AG d
agen oes
olksw not
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un

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pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

2.3 Removing and installing headlight trim

nform

Special tools and workshop equipment required

mercia

♦ Torque wrench - V.A.G 1783-

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note

The removal and installation procedure is for the left side. The right side is similar.

2. Mouldings / trims / extensions 251

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove radiator grille ⇒ page 244 .
– Remove bolts -2- and -3-.
– Pull headlight trim -1- out of retainer -4-.
Installing:
Install in reverse order, but note the following:

Note

Before installing headlight trim -1-, check retainer -4- and renew if necessary.

Specified torques

2.4 Removing and installing air intake grille

Special tools and workshop equipment required

252 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Removal wedge - 3409-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing
– Lever left inlet grille -2- and right inlet grille -3- upwards out of
fasteners -4- and out of bonnet -1- using wedge - 3409- .

2. Mouldings / trims / extensions 253

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Installing

Note

♦ Before installing left grille -2- and right grille -3-,

en AG. V
olkcheck
swagenlocking
AG lugs -4-.
ag does
lksw
♦ Renew air grille if locking lugs -4-
by are damaged.
not
Vo gu
ara
ed nte
oris eo
th
– Insert left air grille -2- andau right air grille -3- in bonnet -1-. ra
c
ss

ce
– Push left air grille -2- and right air grille -3- downwards until
le
un

pt
locking lugs -4- engage.

an
d
itte

y li
erm

ab
2.5 Removing and installing wing cover

ility
ot p

wit
is n

Special tools and workshop equipment required

h re
ole,

spec
♦ Removal wedge - 3409-
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
The removal and installation procedure is for the left side. The op Vo
by c lksw
right side is similar. cted agen
Prote AG.

Removing
– Lever off wing cover cap -1- from A-pillar forwards using
wedge - 3409- .
Installing
Install in reverse order, but note the following:

Note

Before installing wing cover cap -1-, check clips -2- and -3- and
renew as necessary.

– Place wing cover cap -1- on clips -2- and press on forcefully.

2.6 Removing and installing side panel trim

Special tools and workshop equipment required

254 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Removal wedge - 3409-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
Note
d
itte

y li
rm

ab
pe

ility
The removal and installation procedure is for the right side. The
ot

wit
left side is similar.
, is n

h re
hole

spec
Removing
es, in part or in w

t to the co
– Lever off side panel trim -1- from side panel forwards using
wedge - 3409- .

rrectness of i
Clips -2- remain on vehicle.
l purpos

Installing
nform
ercia

Note
m

a
com

tio

Before installing side panel trim -1-, check clips -2- and renew as
n in
r

necessary.
te o

thi
s
iva

do
r
rp

– Insert side panel trim -1- onto clips -2- and press on by exerting
um
fo

en
g

strong pressure.
n

t.
yi Co
Cop py
ht. rig

2.7 Removing and installing number plate

rig ht
py by
co Vo
by lksw
light trim
cted agen
Prote AG.

2.7.1 Removing

2. Mouldings / trims / extensions 255

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove rear wing door trim ⇒ General body repairs, interior;

Rep. gr. 70; ; Trims and insulation; Rear hinged door trim .
– Remove hexagon nuts -2- (qty. 2) from inside of left rear wing
door.
– Release clips -3- (Qty. 3) from inside and remove number plate
light trim -1- from outside.
– Detach connector -4- for number plate lights.

256 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.7.2 Installing

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Number plate light trim -1- installation is carried out in reverse

order of removal. When doing this, observe the following:

Note

Before installing number plate light trim -1-, check clips -3- (qty. 3) and renew as necessary.

– Specified torque for hexagon nuts -2- 5 Nm.

2. Mouldings / trims / extensions 257

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

2.8 Assembly overview - protective side strip

AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise nte
♦ Only the left side is shown. The right side is similar.
uthor eo
ra
s a c
♦ Depending on model slight differences are possible
s when referring to assembly overview.

ce
e
nl

pt
du

an
itte

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erm

ab
1 - Wing protective side mould‐

ility
ing ot p

wit
, is n

h re
❑ Secured with clips -8-
hole

spec
2 - Front door protective side
es, in part or in w

strip

t to the co
❑ Protective side mould‐
ing secured with clips

rrectness of i
-8- and screws -9-
l purpos

3 - B-pillar protective side

moulding
❑ Secured with clips -8-

nform
ercia

❑ Remove side lights ⇒

m

at
om

Electrical system; Rep.

ion
c

gr. 94 ; Removing and

in t
or

installing side lights .

his
ate

do
priv

c
4 - Middle protective side

um
for

moulding

en
ng

t.
yi Co
op
❑ Secured with clips -8- C py
t. rig
gh ht
❑ Sliding door protective yri
p by
co Vo
side moulding secured
by lksw
cted agen
with clips -8- and screws
Prote AG.

-9-
5 - Rear forward part of protec‐
tive side moulding
❑ Secured with clips -8-
and screws -9-
❑ Remove side lights ⇒
Electrical system; Rep.
gr. 94 ; Removing and
installing side lights .
6 - Rear rearward part of pro‐
tective side moulding
❑ Secured with clips -8-
and screws -9-
❑ Remove side lights ⇒ Electrical system; Rep. gr. 94 ; Removing and installing side lights .
7 - D-pillar protective side moulding
❑ Secured with clips -8-
❑ Secured in addition under back of rear part of protective side moulding -6- with expanding clip
8 - Clip

Note

Before installing protective side

moulding, check securing clips and
renew as necessary.

258 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

9 - Bolt
❑ Specified torque: 1.5 Nm

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Mouldings / trims / extensions 259

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3 Noise insulation
⇒ “3.1 Assembly overview - noise insulation”, page 260
⇒ “3.2 Removing and installing noise insulation”, page 261

3.1 Assembly overview - noise insulation

1 - Front noise insulation

❑ Upper and lower part
❑ Removing and installing
⇒ page 261
2 - Centre noise insulation
❑ Removing and installing
⇒ page 262
3 - Rear noise insulation
❑ Removing and installing
⇒ page 263

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

260 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3.2 Removing and installing noise insulation

⇒ “3.2.1 Removing and installing front noise insulation”,
page 261
⇒ “3.2.2 Removing and installing centre noise insulation”,
page 262
⇒ “3.2.3 Removing and installing rear noise insulation”,
page 263

3.2.1 Removing and installing front noise insulation

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

io

Removing
n
c

in t
or

his

Upper part with lower part

ate

do
priv

– Unscrew hexagon nuts -2- and -3- on left and right.

um
for

en
ng

t.
– Unscrew bolts -6- (qty. 3) and remove noise insulation -1- with
yi Co
op py
upper part -4-. t. C rig
gh ht
pyri by
Lower part
o Vo
by c lksw
cted agen
Prote AG.
– Unscrew bolts -5- (qty. 4 each side) and remove noise insu‐
lation -1- lower section.

3. Noise insulation 261

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Crafter 2006 ➤ thor eo
u ra
General body repairs,
ss a exterior - Edition 10.2014 c

ce
e
nl

pt
du
Installing

an
itte

y li
erm

ab
Install in reverse order, but note the following:

ility
ot p
Specified torques

wit
, is n

h re
hole

Noise insulation Specified torques

spec
es, in part or in w

Bolts 3.0 Nm

t to the co
Hexagon nut 5.0 Nm

rrectness of i
3.2.2 Removing and installing centre noise insulation
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove bolts -2- and -3- (qty. 3 at front and rear) and remove
centre noise insulation -1-.
Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torques
Noise insulation 3.0 Nm

262 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

3.2.3 Removing and installing rear noise insulation

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Unscrew hexagon nuts -3- on left and right.
– Unscrew bolts -2- (qty. 3) and remove rear noise insulation
-1-.
Installing
Install in reverse order, but note the following:
Specified torques
Noise insulation Specified torques
Bolts 3.0 Nm
Hexagon nut 5.0 Nm

3. Noise insulation 263

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Crafter 2006 ➤ orise nte
eo
h
General body repairs, exterior - Edition
s aut
10.2014 ra
c
s

ce
le
un

pt
an
d
4 Drive assembly guard - Crafter 4MO‐

itte

y li
rm

ab
TION with Achleitner all-wheel drive

pe

ility
ot

wit
, is n
⇒ “4.1.1 Assembly overview - drive assembly guard”, page 264

h re
hole

spec
⇒ “4.1.2 Removing and installing drive assembly guard”,

es, in part or in w
page 264

t to the co
4.1 Drive assembly guard

rrectness of i
l purpos

4.1.1 Assembly overview - drive assembly guard

nform
ercia

1 - Drive assembly guard

m

a
com

t
❑ Removing and installing

ion in
⇒ page 264 .
r
te o

thi
s
iva

2 - Bolt

do
r
rp

cum
❑ Qty. 3.
fo

en
ng

t.
yi
❑ 42 Nm
Co
Cop py
t. rig
gh
3 - Bolt
ht
pyri by
Vo
co lksw
❑ Left and right with wash‐
by
cted agen
Prote
er -4-.
AG.

❑ 42 Nm
4 - Washer
❑ With bolt -3-.
5 - Washer
❑ Qty. 3 between drive as‐
sembly guard -1- and
front axle assembly.

4.1.2 Removing and installing drive assembly

guard
Special tools and workshop equipment required

264 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
ht
Removing
rig by
copy Vo
by lksw
cted
– Undo bolts -2- and -3- and remove drive assembly guard -1-.
agen
Prote AG.

Installing
– Position drive assembly guard -1- with help of a second me‐
chanic.
– Slide washer -5- between drive assembly guard and front axle
assembly.

4. Drive assembly guard - Crafter 4MOTION with Achleitner all-wheel drive 265
 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Start bolts -2- and -3- and tighten to specified tightening torque
⇒ page 264 .

WARNING

Bolts -2- and -3- must be secured with locking fluid - D 000 600
A2- if reused.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

266 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

5 Exterior mirror
⇒ “5.1 Assembly overview - exterior mirror”, page 267
⇒ “5.2 Removing and installing mirror glass, up to 2010”,
page 271
⇒ “5.3 Removing and installing mirror glass, from 2010”,
page 272
⇒ “5.4 Removing and installing auxiliary panoramic mirror, up to
2010”, page 274
⇒ “5.5 Removing and installing auxiliary panoramic mirror, from
2010”, page 275
⇒ “5.6 Removing and installing mirror housing”, page 276
⇒ “5.7 Removing and installing exterior mirror (electrically adjust‐
able)”, page 277 wagen AG. Volkswagen AG does
ks not
Vol gu
5.1 ris
ed by
Assembly overview - exterior mirror ara
nte
utho eo
⇒ “5.1.1
ss
a Assembly
overview - exterior mirror with turn signal
ra
c re‐
peater”, page 267 ce
e
nl

pt
du

an
⇒ “5.1.2 Assembly overview - exterior mirror for vehicles with turn
itte

y li
signal repeater in wing”, page 268
erm

ab
ility
ot p

⇒ “5.1.3 Assembly overview - extended exterior mirror with turn

wit
, is n

signal repeater”, page 269

h re
hole

spec

⇒ “5.1.4 Assembly overview - extended exterior mirror for vehicles

es, in part or in w

with turn signal repeater in wing”, page 270

t to the co

5.1.1 Assembly overview - exterior mirror with

turn signal repeater
rrectness of i
l purpos

Note
nform
ercia

Only the left side is shown. The right side is analogous.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Exterior mirror 267

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Mirror housing
❑ Removing and installing
⇒ page 276 .
2 - Mirror carrier
❑ Removing and installing
⇒ page 277
3 - Mirror frame
❑ Removing and installing
⇒ page 276
4 - Bolts
❑ Qty. 4
❑ 2 Nm
5 - Adjuster unit
❑ With motor for exterior
mirror
6 - Mirror glass
❑ Removing and installing
⇒ page 271 .
7 - Auxiliary panoramic mirror
❑ Removing and installing
⇒ page 274 .
8 - Bolts agen
AG. Volkswagen AG d
oes
lksw not
❑ Qty. 4 d byV
o gu
ara
e nte
❑ 2 Nm horis
eo
aut ra
9 - Plastic nut ss c

ce
e
nl

pt
10 - Adjuster unit
du

an
itte

y li
❑ For auxiliary panoramic
erm

ab
mirror.

ility
ot p

wit
, is n

11 - Spacer washer

h re
hole

spec
12 - Display unit
es, in part or in w

t to the co
13 - Bolts
❑ Qty. 2
❑ 2 Nm rrectness of i

14 - Electrical wiring harness

l purpos

15 - Bulb holder
nform
ercia

❑ For additional turn signal

m

❑ ⇒ Electrical system; Rep. gr. 94 ; Removing and installing mirror turn signal bulb .
at
om

ion
c

16 - Turn signal repeater

in t
or

his
te

❑ Removing and installing ⇒ page 276 .

a

do
priv

cum
for

en
ng

t.
yi Co
op
5.1.2 Assembly overview - exterior mirror for
C py
ht. rig
rig ht
vehicles with turn signal repeater in wing
py by
co Vo
by lksw
cted agen
Prote AG.

Note

Only the left side is shown. The right side is analogous.

268 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Mirror carrier
❑ Removing and installing
⇒ page 277
2 - Bolts
❑ Qty. 3
❑ 8 Nm
3 - Plugs
4 - Mirror frame
❑ Removing and installing
⇒ page 276
5 - Bolt
❑ Qty. 4
❑ 2 Nm
6 - Mirror glass
❑ Removing and installing
⇒ page 272 .
7 - Auxiliary panoramic mirror
❑ Removing and installing
⇒ page 275 .
8 - Display unit
9 - Bolts
❑ Qty. 2
❑ 2 Nm
10 - Bolts
❑ Qty. 2
❑ 2 Nm
AG. Volkswagen AG d
agen
11 - Adjuster unit Volksw
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not
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❑ With motor for exterior rised
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12 - Mirror housing
ce
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nl

pt
du

❑ Removing and installing ⇒ page 276 .

an
itte

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erm

ab

13 - Wing cover cap

ility
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❑ Removing and installing ⇒ page 254 .

wit
, is n

h re
hole

spec
es, in part or in w

5.1.3 Assembly overview - extended exterior

t to the co

mirror with turn signal repeater

rrectness of i

Note
l purpos

Only the left side is shown. The right side is analogous.

nf
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orm
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Prote AG.

5. Exterior mirror 269

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Extended exterior mirror

❑ Removing and installing
⇒ page 277
2 - Plugs
3 - Bolts
❑ Qty. 3
❑ 8 Nm
4 - Mirror frame
❑ Removing and installing
⇒ page 276
5 - Bolts
❑ Qty. 4
❑ 2 Nm
6 - Mirror glass
❑ Removing and installing
⇒ page 271 .
7 - Auxiliary panoramic mirror
❑ Removing and installing
⇒ page 274 .
8 - Display unit
9 - Bolts
❑ Qty. 2
❑ 2 Nm
10 - Adjuster unit
❑ For auxiliary panoramic agen
AG. Volkswagen AG d
oes
mirror. olksw not
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11 - Adjuster unit horis
eo
ut ra
❑ With motor for exterior
ss a c
mirror
ce
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nl

pt
du

an

12 - Turn signal repeater

itte

y li
erm

ab

❑ Removing and installing ⇒ page 276 .

ility
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wit

13 - Mirror housing
, is n

h re
hole

❑ Removing and installing ⇒ page 276 .

spec
es, in part or in w

t to the co

5.1.4 Assembly overview - extended exterior

rrectness of i

mirror for vehicles with turn signal re‐

peater in wing
l purpos

nform
ercia

Note
m

at
om

io

Only the left side is shown. The right side is analogous.

n
c

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or

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ate

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cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

270 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Mirror carrier
❑ Removing and installing
⇒ page 277
2 - Bolts
❑ Qty. 3
❑ 8 Nm
3 - Plugs
4 - Mirror frame
❑ Removing and installing
⇒ page 276
5 - Bolts
❑ Qty. 4
❑ 2 Nm
6 - Mirror glass
❑ Removing and installing
⇒ page 272 .
7 - Auxiliary panoramic mirror
❑ Removing and installing
⇒ page 275 .
8 - Bolts
❑ Qty. 2
❑ 2 Nm
9 - Adjuster unit
❑ With motor for exterior
mirror
10 - Mirror housing
❑ Removing and installing
AG. Volkswagen AG d
⇒ page 276 . ksw
agen oes
not
Vol
by gu
11 - Wing cover cap ised ara
nte
or
❑ Removing and installing
aut
h ⇒ page 254 . eo
ra
ss c
ce
le
un

pt
an
d
itte

5.2 Removing and installing mirror glass, up

y li
erm

ab

to 2010
ility
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wit
is n

h re
ole,

spec

Note
urposes, in part or in wh

t to the co

The removal and installation procedure is for the left side. The
right side is similar.
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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o
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cum
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fo

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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5. Exterior mirror 271

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing
– Push in mirror glass -1- at bottom.
– Pull mirror glass -1- upwards -arrow b-. n AG. Volkswagen AG do
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ab
ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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ercia

– Remove mirror glass -1- out of guides -arrows-.

m

– Pull off connector for exterior mirror heating -2-.

at
om

ion
c

– Unscrew bolts -3- for display unit -4- on left and right.

in t
or

his
ate

– Remove mirror glass -1-.

do
priv

cum
or

Installing
f

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op
Install in reverse order of removal. C py
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gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.

5.3 Removing and installing mirror glass,

from 2010
Special tools and workshop equipment required
♦ Removal lever - 80 - 200-

272 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Removing

Note

The removal and installation sequence is only for the left mirror
glass. The removal and installation of the right mirror glass is
similar.

WARNING

When doing this repair work, always wear safety goggles and
leather gloves!

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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d
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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

– Press side of mirror glass -1- into mirror housing.

– Using removal lever - 80 - 200- -2-, carefully press mirror glass
-1- in -direction of arrow- and out of adjustment unit.
– Swing mirror glass -1- towards side.
– If fitted, disconnect connector for anti-dazzle function and mir‐
ror heating on back of mirror glass.

5. Exterior mirror 273

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Installing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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ce
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nl

pt
du

an
itte

y li
erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

Install in reverse order, but note the following: t to the co

– If present, connect connector to mirror glass -1-.
rrectness of i

– Push mirror glass -2- centrally onto adjustment unit -1- in

l purpos

housing.
nf

– Mirror glass -2- clicks audibly into clip -arrows-.

ercia

orm
m

5.4 Removing and installing auxiliary pan‐

atio
om

n in

oramic mirror, up to 2010

or c

thi
te

sd
iva

Special tools and workshop equipment required

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

274 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Removal wedge - 3409-

Note

The removal and installation procedure is for the left side. The
right side is analogous.

Removing agen
AG. Volkswagen AG d
oes
olksw not
V
– Remove mirror glass ⇒ page 271 . d by gu
ara
rise nte
o eo
– Push in auxiliary panoramic mirror -1- as afar
ut as possible
h
ra
-arrow A-. ss c

ce
e
nl

pt
– Push auxiliary panoramic mirror -1- out of guide -arrow B- us‐
du

an
itte

ing removal wedge - 3409- .

y li
erm

ab
ility
Installing
ot p

wit
, is n

Install in reverse order, but note the following:

h re
hole

spec
es, in part or in w

t to the co
Note

In vehicles as of 10.2010, the wiring for the panoramic mirror

rrectness of i
heater (if there is one) is to be taken out of service.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

5.5 Removing and installing auxiliary pan‐

do
priv

cum
or

oramic mirror, from 2010

f

en
ng

t.
yi Co
op
Special tools and workshop equipment required
C py
t. rig
gh ht
yri by
♦ Removal wedge - 3409- cop Vo
by lksw
cted agen
Prote AG.

5. Exterior mirror 275

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

Removing t to the co
rrectness of i
– Push in mirror glass -1- at bottom.
l purpos

– “Carefully” press auxiliary panoramic mirror -2- forwards off

ball head with the help of a removal wedge - 3409- .
nform
ercia

– If fitted, disconnect connector for panoramic mirror heater.

m

Installing
a
com

tion in

Install in reverse order, but note the following:

r
te o

thi
s
iva

– Press auxiliary panoramic mirror -2- “carefully” onto ball head.

do
r
rp

cum
fo

5.6 Removing and installing mirror housing

en
ng

t.
yi Co
Cop py
Special tools and workshop equipment required
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

276 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Torque screwdriver - V.A.G 1624-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
Note
pe

ility
ot

wit
, is n

h re
The removal and installation procedure is for the left side. The
hole

right side is analogous.

spec
es, in part or in w

t to the co
Removing
– Removing mirror glass, up to 2010 ⇒ page 271 .

rrectness of i
– Remove mirror glass, as of 2010 ⇒ page 272 .
l purpos

– Remove auxiliary panoramic mirror, up to 2010 ⇒ page 274 .

nform
ercia

– Remove auxiliary panoramic mirror, as of 2010 ⇒ page 275 .

m

– Unscrew bolts -arrows- and remove mirror housing and mirror

a
com

tio
frame.
n in
r
te o

thi
Installing
s
iva

do
r
rp

Install in reverse order, but note the following:

um
fo

en
ng

t.
yi
Specified torques
Co
Cop py
t. rig
♦ ⇒ “5.1 Assembly overview - exterior mirror”, page 267
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5.7 Removing and installing exterior mirror

(electrically adjustable)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

5. Exterior mirror 277

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

The removal and installation procedure is for the left side. The
right side is analogous.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Removing
nform
ercia

Connectors on exterior mirror

m

at
om

io

– Lever cap -4- out of opening on inside of front door.

n
c

in t
or

his
e

– Unscrew bolts -3- from inside of front door and remove exterior
at

do
riv

mirror -1- from front door.

p

cum
for

en
g

– Separate electrical connector -2-.

n

t.
yi Co
Cop py
Connectors on door shell ht. rig
rig ht
py by
o Vo
– Remove front door trim ⇒ General body repairs, interior; Rep. by c lksw
cted agen
gr. 70 ; Trims/insulation; Door trims .
Prote AG.

– Disconnect connector for exterior mirror on door shell.

– Lever cap -4- out of opening on inside of front door.

278 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Unscrew bolts -3- from inside of front door and remove exterior
mirror from front door.
– Pull out cable through hole in door.
Connectors on A-pillar
– Remove front door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims/insulation; Door trims .
– Pull bellows off retaining ring on A-pillar, and disconnect con‐
nector.
– Lever cap -4- out of opening on inside of front door.
– Unscrew bolts -3- from inside of front door and remove exterior
mirror from front door.
– Pull out cable through hole in door.
Installing
AG. Volkswagen AG d
Install in reverse order, but note the following: agen oes
olksw not
byV gu
ara
Specified torques rised
nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5. Exterior mirror 279

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

6 Wheel housing liner

⇒ “6.1 Tools”, page 280
⇒ “6.2 Assembly overview - front wheel housing liner”,
page 280
⇒ “6.3 Removing and installing front wheel housing liner”,
page 282

6.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

6.2 Assembly overview - front wheel housing liner

Note
AG. Volkswagen AG d
agen oes
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♦ Only the left side is shown. The right side by
V is similar.
o l not
gu
ara
ed
is nte
♦ Depending on model slight differenceshor are possible when referring to assembly e ooverview.
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

280 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Wheel housing liner rear

part
❑ Removing and installing
⇒ page 282 .
2 - Bolt
❑ Qty. 2.
❑ Specified torque 3 Nm
3 - Spreader rivet
❑ Qty. 5.
4 - Hexagon nut
❑ Qty. 6.
❑ Specified torque 3 Nm
5 - Wheel housing liner front
part
❑ Removing and installing
⇒ page 282 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6. Wheel housing liner 281

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
AG. Volkswagen AG d
agen oes
6.3 Removing and installing front wheel housing liner
d byV
olksw not
gu
ara
ise nte
r
Removing ut
ho eo
ra
s a c
s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Wheel housing liner rear part

– Remove bolts -2-.
– Undo hexagon nut -4- and pull rear part of wheel housing liner
-4- out of wheel housing.
Wheel housing liner front part
– Lever out spreader rivet -3- in front area using a screwdriver.
– Undo hexagon nut -4- and pull front part of wheel housing liner
-5- out of wheel housing.
Installing:
Installation is basically carried out in the reverse sequence; note
the following when doing this:
Specified tightening torque for bolts -2- ⇒ page 280 .

282 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

7 Lettering and emblems

⇒ “7.1 Assembly overview - rear emblem and trim panel”,
page 283
⇒ “7.2 Dimensions, lettering on rear”, page 283
⇒ “7.3 Removing and installing rear emblem and trim panel”, page
286

7.1 Assembly overview - rear emblem and trim panel

1 - Right trim
❑ Removing and installing
⇒ page 286
2 - Rear emblem
❑ Removing and installing
⇒ page 286
3 - Left trim
❑ Removing and installing
⇒ page 286
4 - Bolt
❑ 4.0 Nm
5 - Bolt
❑ Qty. 2. n AG. Volkswagen AG do
wage
❑ 4.0 Nm olks es n
ot g
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ss
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

7.2 Dimensions, lettering on rear

his
ate

do
priv

cum
or

⇒ “7.2.1 Rear lettering - dimensions”, page 284

f

en
ng

t.
yi Co
⇒ “7.2.2 Replacing lettering”, page 286 t. Cop py
rig
gh ht
Special tools and workshop equipment required pyri by
Vo
co lksw
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cted agen
Prote AG.

7. Lettering and emblems 283

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Hot air blower - V.A.G 1416-

♦ Adhesive strip remover - VAS 6349-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

Note

spec
es, in part or in w

t to the co
♦ The illustrated lettering »Crafter TDI« is just an example.
♦ Various forms of lettering are used.

rrectness of i
♦ The dimensions for all lettering are identical.
l purpos

Fitting notes

nform
ercia

♦ Before removing the lettering, heat it with a hot air blower -

V.A.G 1416- .
m

a
com

tio
♦ If lettering is fitted for the first time on a new vehicle or on newly n in
r
te o

painted surfaces, the procedure in ⇒ Workshop manual

thi
s
iva

"Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings ⇒

do
r

Film should be observed.

rp

cum
fo

en
ng

t.
♦ If lettering is removed and reinstalled, only use adhesive re‐
yi Co
op
mover - D 002 000 10- to remove the adhesive remains.
C py
t. rig
gh ht
yri by
♦ Remove existing adhesive residue of adhesive tape using ad‐ cop Vo
by lksw
hesive strip remover - VAS 6349- .
cted agen
Prote AG.

♦ Ensure that the adhesive surfaces are free of dust and grease.
♦ The lettering must be bonded in place immediately after clean‐
ing.
♦ Remove protective film immediately before installation.
♦ Working temperature is approx. 21°C.
♦ Lettering cannot be removed without damage.

7.2.1 Rear lettering - dimensions

284 Rep. gr.66 - Exterior equipment

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Crafter 2006 ➤
ris
tho General body repairs, exterior e-o Edition 10.2014
au ra
c
ss
1 - Dimension a = 55 mm

ce
e
nl

pt
du

an
❑ Edge of rear wing door

itte

y li
to lower edge of letter‐

erm

ab
ing.

ility
ot p

wit
, is n
2 - Dimension b = 90 mm

h re
hole
❑ Outer edge of rear wing

spec
es, in part or in w
door to start/end of let‐

t to the co
tering.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
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cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

7. Lettering and emblems 285

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

7.2.2 Replacing lettering

Note AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
♦ Lettering cannot be removed without damage. orise nte
eo
h
ut ra
♦ When fitting the lettering, observe the fitting notes ⇒ page
ss a
284 . c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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rp

cu
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m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Follow installation instructions ⇒ page 284 .

Apply lettering as per specified dimensions ⇒ page 284 .

7.3 Removing and installing rear emblem and trim panel

Removing
Right trim
– Unscrew screws -5- and remove emblem -2-.

286 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Pull right trim panel -1- off in -direction of arrow-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Left trim
– Remove rear wing door trim ⇒ General body repairs, interior;
Rep. gr. 70; ; Trims and insulation; Rear hinged door trim .
– Unscrew screws -4- and remove left trim -2- in
-direction of arrow-.
Installing
Install in reverse order, but note the following:

7. Lettering and emblems 287

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Specified torques

7.4 Wing lettering - Crafter 4MOTION with Achleitner all-wheel drive

Note

Only the left side is shown. The right side is similar.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Heat wing lettering using hot air blower - V.A.G 1416- and pull
it off wing.
Installing
Follow installation instructions ⇒ page 284 .
– Position wing lettering on reference point and press it smooth
using a plastic blade wrapped in a soft paper towel.

288 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

8 Special add-on parts

⇒ “8.1 Wheel housing extensions - Crafter 4MOTION with Achleit‐
ner all-wheel drive”, page 289

8.1 Wheel housing extensions - Crafter

4MOTION with Achleitner all-wheel
drive
⇒ “8.2 Repair instructions”, page 289
⇒ “8.3 Assembly overview - wheel housing extensions”,
page 290
⇒ “8.4 Removing and installing front bumper cover extension”,
page 291
⇒ “8.5 Removing and installing wing extension”, page 293
. Volkswagen AG
a gen AG d
⇒ “8.6 RemovingVoand
lksw installing wing protective
oes
noside
t gu moulding ex‐
tension”, page
ed b296
y ara
n
ris tee
tho
8.2 ss
au Repair instructions or
ac
ce
e

⇒ “8.2.1 Materials”, page 289

nl

pt
du

an
itte

y li
⇒ “8.2.2 Notes for extensions”, page 289
erm

ab
ility
ot p

⇒ “8.2.3 Preparing extension for bonding”, page 289

wit
, is n

h re

⇒ “8.2.4 Preparing body kit component for bonding”, page 290

hole

spec

8.2.1 Materials
es, in part or in w

t to the co

♦ Double-sided adhesive tape 1) 2)

rrectness of i

♦ Cleaning solution 1) 2)
l purpos

♦ Adhesive remover 1) 2)
nform
ercia

1)Observe instructions for use on the information sheet provided

m

at

by the manufacturer.
om

ion
c

in t

2
r

The part numbers of the materials can be found in the ⇒ Elec‐

o

his
e

tronic Parts Catalogue (ETKA) .

at

do
priv

cum
or

8.2.2 Notes for extensions

f

en
ng

t.
yi Co
op
♦ The extensions have been developed to fulfil the technical re‐
C py
t. rig
gh
quirements of the respective models. These extensions
ht
pyri by
Vo
should always be replaced with the corresponding genuine
co lksw
by
cted agen
parts. Prote AG.

♦ The trim is bonded using double-sided adhesive tape at the

factory.
♦ The extensions are supplied with double-sided tape.

8.2.3 Preparing extension for bonding

– Clean bonding surface for double-sided adhesive tape thor‐
oughly with adhesive remover.
– Apply double-sided adhesive tape along defined bonding sur‐
faces without stretching and without creating wrinkles.

8. Special add-on parts 289

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

Note

The part numbers of the materials can be found in the ⇒ Elec‐

tronic Parts Catalogue .

WARNING

Apply double-sided adhesive tape cleanly and cut to size pre‐

cisely without raising or loosening protective film on adhesive
tape, as adhesive effect of adhesive tape will otherwise be re‐
duced.

8.2.4 Preparing body kit component for bond‐

ing
If an extension is removed and reattached, only use adhesive re‐
mover to remove the adhesive residue.
Always use a clean, lint-free cloth for cleaning.
olkswagen AG
en AG. V
Remove existing adhesive residue
ksw
ag of adhesive tapedousing
es n adhe‐
Vol ot g
sive strip remover - VAS
d b6349- .
y ua
ra e nte
ris
Ensure that the adhesive
au
tho surfaces are free of dust and grease. eo
ra
ss c
Attach extension immediately after cleaning.
ce
le
un

pt
an
d

Remove protective foil immediately before installation.

itte

y li
rm

ab

Working temperature is approx. 21°C.

pe

ility
ot

wit
, is n

If a part of the body is fitted for the first time on a new vehicle or
h re

on newly painted surfaces, the procedure in ⇒ Workshop manual

hole

spec

"Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings ⇒ Film

es, in part or in w

should be observed.
t to the co

8.3 Assembly overview - wheel housing ex‐

tensions
rrectness of i
l purpos

Note
nform
ercia

The wheel housing extensions are only fitted on models of 3.5 t

m

and 5.0 t weight class which have offroad wheels fitted.

com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

290 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Front bumper cover

2 - Front bumper cover exten‐
sion
❑ Material PUR.
❑ Removing and installing
⇒ page 291 .
3 - Wing
4 - Wing extension
❑ Material PUR.
❑ Removing and installing
⇒ page 293 .
5 - Wing protective side mould‐
ing
6 - Wing protective side mould‐
ing extension
❑ Material PUR.
❑ Removing and installing
⇒ page 296 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

8.4 Removing and installing front bumper

cover extension
rrectne

Special tools and workshop equipment required

s

♦ Hot air blower - V.A.G 1416-

s o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

8. Special add-on parts 291

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Removal wedge - 3409-

Note

The removal and installation procedure is for the left side. The
right side is similar.

Removing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

292 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Warm front bumper cover extension -1- with hot air blower -
V.A.G 1416- before removing.
– Lift front bumper cover extension -1- at one corner using re‐
moval wedge - 3409- .
– Grasp under front bumper cover extension -1- and carefully
pull it off front bumper cover -2-.
Installing

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Observe repair instructions ⇒ page 289 .

– Pull protective foil -3- off double-sided adhesive tape.
– Press front bumper cover extension -1- onto front bumper
cover -2- forcefully over whole area of double-sided tape.

8.5 Removing and installing wing extension

Special tools and workshop equipment required

8. Special add-on parts 293

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Hot air blower - V.A.G 1416-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
♦ Removal wedge - 3409-

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm

Note
m

atio
om

n in
c

The removal and installation procedure is for the left side. The
or

thi
e

right side is similar.

t

sd
iva

o
r
rp

cu
o

m
f

Removing
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

294 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

– Warm wing extension -1- with hot air blower - V.A.G 1416- h re
hole

spec
before removing.
es, in part or in w

t to the co

– Lift wing extension -1- at one corner using removal wedge -

3409- .
– Grasp under wing extension -1- and carefully pull it off from
rrectness of i

wing -2-.
l purpos

Installing
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

8. Special add-on parts 295

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Observe repair instructions ⇒ page 289 .

– Pull protective foil -3- off double-sided adhesive tape.
– Press wing extension -1- onto wing -2- forcefully over whole
area of double-sided tape.

8.6 Removing and installing wing protective

side moulding extension
Special tools and workshop equipment required
♦ Hot air blower - V.A.G 1416-

296 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

♦ Removal wedge - 3409-

Note

The removal and installation procedure is for the left side. The
right side is similar.

Removing

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

8. Special add-on parts 297

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Warm wing protective side moulding extension -1- with hot air
blower - V.A.G 1416- before removing.
– Lift wing protective side moulding extension -1- at one corner
using removal wedge - 3409- .
– Grasp under wing protective side moulding extension -1- and
carefully pull it off from wing protective side moulding -2-.
Installing

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Observe repair instructions ⇒ page 289 .

nf
ercia

or

– Pull protective foil -3- off double-sided adhesive tape.

m
m

atio
m

– Press wing protective side moulding extension -1- onto wing

o

n in
or c

protective side moulding -2- forcefully over whole area of dou‐

thi
e

ble-sided tape.
t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

298 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
n AG. Volkswagen AG do
lkswage body repairs, exterior
General es n - Edition 10.2014
o ot gu
yV
db ara
ir se nte
ho eo
9 Towing bracket ss
aut ra
c

ce
e
nl
⇒ “9.1 Tools”, page 299

pt
du

an
itte

y li
⇒ “9.2 Installation instructions”, page 299

erm

ab
ility
ot p
⇒ “9.3 Assembly overview - towing brackets”, page 299

wit
, is n

h re
⇒ “9.4 Removing and installing rigid towing bracket”, page 302

hole

spec
⇒ “9.5 Installation notes”, page 303
es, in part or in w

t to the co
9.1 Tools
Special tools and workshop equipment required

rrectness of i
♦ Torque wrench - V.A.G 1332-
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9.2 Installation instructions

Note

♦ Depending on model slight differences are possible when re‐

ferring to assembly overview.
♦ Information on electrics can be found under ⇒ Towing mode
current flow diagram workshop manual .

WARNING

The towing bracket is a safety component that only qualified

personnel are allowed to attach to the vehicle.
All modifications and conversions of the towing bracket are
prohibited and lead to cancellation of the General Type Ap‐
proval.
The specified torques refer only to factory-installed towing
brackets.
Refer to manufacturer's assembly instructions for tightening
torques for other towing brackets.
Towing brackets or removable ball heads designed for models
with all-wheel drive must not be fitted to models with front-
wheel drive and vice versa.

9.3 Assembly overview - towing brackets

9. Towing bracket 299

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
n AG. Volkswagen AG do
lkswage es n
o ot g
1 - Towing bracket, removable d byV ua
ran
ir se
❑ For panel van and Kom‐ utho tee
or
bi. ss
a ac

ce
e
2 - Plate

nl

pt
du

an
itte
❑ Left and right.

y li
erm

ab
ility
3 - Bolt

ot p

wit
, is n
❑ Qty. 4.

h re
❑ Specified torque: 58 Nm hole

spec
es, in part or in w

4 - Ball coupling

t to the co
5 - Bolt
❑ Qty. 4.

rrectness of i
❑ Specified torque: 58 Nm
l purpos

6 - Hexagon nut
❑ Qty. 4.

nform
ercia

❑ Specified torque: 58 Nm
m

at
om

io
7 - Bolt

n
c

in t
or

his
e

❑ Qty. 4.
at

do
riv

❑ Specified torque: 58 Nm
p

cum
for

en
g

8 - Plate
n

t.
yi Co
op py
❑ Left and right.
t. C rig
gh ht
pyri by
Vo
9 - Towing bracket, removable
co lksw
by
cted agen
Prote
❑ For dropside and double
AG.

cab.
10 - Towing jaw
❑ For dropside, double
cab, panel van and
Kombi.
11 - Hexagon nut
❑ Qty. 4.
❑ Specified torque: 58 Nm
12 - Stud
❑ With collar.
❑ Specified torque: 58 Nm
13 - Bolt
❑ Qty. 3.
❑ Specified torque: 58 Nm
14 - Bolt
❑ Qty. 4.
❑ Specified torque: 58 Nm
15 - Plate
❑ Left and right.
16 - Towing bracket, rigid
❑ For panel van and Kombi.
❑ Removing and installing ⇒ page 302 .
17 - Ball coupling
❑ Removable and lockable.

300 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

18 - Hexagon nut
❑ Qty. 4.
❑ Specified torque: 58 Nm
19 - Protective cap
❑ Qty. 4.
20 - Cover
21 - Bolt
❑ Qty. 4.
❑ Specified torque: 58 Nm
22 - Bolt
❑ Qty. 4.
❑ Specified torque: 90 Nm
❑ Self-locking.
23 - Base plate
❑ For removable ball coupling -17-.
24 - Hexagon nut
❑ Qty. 2
n AG. Volkswagen AG do
❑ Specified torque:
olks
w90
ageNm es n
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yV t gu
db ara
rise nte
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c
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ce
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nl

pt
du

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itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

9. Towing bracket 301

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

9.4 Removing and installing rigid towing bracket

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at

Removing:
om

ion
c

in t
r

– Remove rear bumper cover -2- (if fitted) ⇒ page 201 .

o

his
ate

do
riv

– Remove bolts -6- on left and right of step -5-.

p

cum
for

en
ng

t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
Have a second mechanic hold towing bracket -1-.
by c lksw
cted agen
Prote AG.

– Remove hexagon nuts -7- on left and right.

– Remove bolts -4- with plate -3- from mountings and remove
towing bracket -1- with aid of a second mechanic.
Installing:
Installation is carried out in the reverse sequence, when doing this
note the following:
Follow installation instructions ⇒ page 303 .
Specified torque settings from assembly overview ⇒ page 299

302 Rep. gr.66 - Exterior equipment

 AG. Volkswagen AG d Crafter 2006 ➤
agen oes
Volksw General
not
gu
body repairs, exterior - Edition 10.2014
by ara
ed
ris ntee
9.5 Installation notes
aut
ho or
ac
ss

ce
le
un

pt
Caution

an
d
itte

y li
erm

ab
Undercoating (if fitted) in area of towing bracket contact surfa‐

ility
ot p

ces must be removed.

wit
is n

h re
ole,

Contact surfaces of towing bracket must be free of sealing

spec
compound and wax accumulation.
urposes, in part or in wh

t to the co
Corrosion protection measures must be carried out on bare
metal body areas.

rrectne
Adherence to the standard, approved fastening points is re‐
quired.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Towing bracket 303

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

AG. Volkswagen AG d
agen
10 Spare wheel carrier
oes
olksw not
y V gu
d b ara
ise nte
⇒ “10.1 Tools”, page 304 thor eo
au ra
c
⇒ “10.2 Assembly overview - spare wheel carrier”, page 304 ss

ce
le
un

pt
⇒ “10.3 Removing and installing spare wheel carrier”, page 305

an
d
itte

y li
erm

ab
10.1 Tools

ility
ot p

wit
is n
Special tools and workshop equipment required

h re
ole,

spec
♦ Torque wrench - V.A.G 1331-

urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r

10.2 Assembly overview - spare wheel carrier

fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

304 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Spare wheel carrier

❑ Removing and installing
⇒ page 305 .
2 - Spare wheel
❑ ⇒ Running gear, axles,
steering; Rep. gr. 44 ;
Wheels, tyres, vehicle
geometry
3 - Bracket
❑ Left and right.
4 - Hexagon nut
❑ Qty. 2 on each ageside.
n AG. Volkswagen AG do
es n
lksw
❑ Specified
d by V torque 6 Nm
o ot g
ua
e ran
ris tee
5 - Hook tho or
au ac
❑s Left and right.
s

ce
e
nl

pt
6 - Lock carrier cover
du

an
itte

y li
erm

7 - Bolt

ab
ility
ot p

❑ Left and right.

wit
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h re
❑ Specified torque 23 Nm
hole

8 - Cover spec
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❑ Left and right.
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– Prise cover caps -8- on right and left out of lock carrier cover
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– Only loosen bolts -7- until hooks -5- on left and right can be
pushed aside.
– Fold spare wheel carrier -1- downwards and pull spare wheel
-2- out to rear.
– Unscrew hexagon nuts -3- on left and right from spare wheel
carrier -3-.

10. Spare wheel carrier 305

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General body au repairs, exterior - Edition 10.2014
th or
ac
ss

ce
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– Remove spare wheel carrier -1- from underbody.

un

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Installing:
Install in reverse order, but note the following:
Specified torque of bolts ⇒ page 304 .

306 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General
olkswagen AG
body repairs, exterior - Edition 10.2014
ag en AG. V does
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11 Mudflaps
ara
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th
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⇒ “11.1 Tools”, page 307
ss c

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⇒ “11.2 Front mudflap”, page 307

an
d
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⇒ “11.3 Rear mudflap”, page 310
rm

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pe

ility
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11.1 Tools

wit
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hole

Special tools and workshop equipment required

spec
es, in part or in w

♦ Torque wrench - V.A.G 1783-

t to the co
rrectness of i
l purpos

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mercia

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tion in
r
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11.2 Front mudflap
Co
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Note
agen
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The removal and installation procedure is for the left side. The
right side is similar.

11.2.1 Assembly overview

Note

Only the left side is shown. The right side is similar.

11. Mudflaps 307

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Front mudflap
❑ Removing and installing
⇒ page 308 .
2 - Bolt
❑ Qty. 2.
❑ Specified torque: 2 Nm
3 - Wheel housing liner rear
part
4 - Bolt
❑ Specified torque: 2 Nm
5 - Bolt
❑ Specified torque: 2 Nm

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11.2.2 Removing and installing

du

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Removing
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– Remove bolts -2-.

h re
hole

– Loosen rear part of wheel housing liner -3- ⇒ page 282 .

spec
es, in part or in w

t to the co

– Fold rear part of wheel housing liner -3- to one side.

rrectness of i
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nf
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Prote AG.

308 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Undo bolts -4- and -5- and remove rear part of wheel housing
liner -3-.

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ab
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t.
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Cop py
ht. rig
rig ht
py by
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Installing
Install in reverse order, but note the following:
Specified torque of bolts ⇒ page 307 .

11. Mudflaps 309

 Crafter 2006 ➤ n AG. Volkswagen AG do
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General body repairs, exterior - Edition 10.2014
yV
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11.3 Rear mudflap tho
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11.3.1 Assembly overview

itte

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1 - Rear mudflap

h re
hole
❑ Removing and installing

spec
⇒ page 310 .
es, in part or in w

t to the co
2 - Bolt
❑ Qty. 2.

rrectness of i
❑ Specified torque: 2 Nm
l purpos

3 - Bolt
❑ Qty. 2.

nf
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❑ Specified torque: 6 Nm

rm
m

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Cop py
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Prote AG.

11.3.2 Removing and installing

Removing
– Remove bolts -3- from below.

310 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove bolts -2- from wheel arch and remove rear mud flap
-1-.
AG. Volkswagen AG d
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ab
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spec
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mercia

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c

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or

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priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Installing:
Install in reverse order, but note the following:
Specified torque of bolts ⇒ page 310 .

11. Mudflaps 311

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

12 Loading floor body

⇒ “12.1 Tools”, page 312
⇒ “12.2 Contact corrosion!”, page 313
⇒ “12.3 Assembly overview - dropside body”, page 313
⇒ “12.4 Assembly overview - load floor and side boards/tail AG. Volkswagen AG d
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⇒ “12.5 Side board”, page 316 hor eo
aut ra
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⇒ “12.6 Underride guard”, page 318 ss

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nl

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⇒ “12.7 Rear underride guard”, page 320

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itte

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⇒ “12.8 Rear wing”, page 321

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12.1 Tools

wit
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spec
Special tools and workshop equipment required
es, in part or in w

t to the co
♦ Torque wrench - V.A.G 1783-

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l purpos

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♦ Torque wrench - V.A.G 1331- . Cop py
rig
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rig by
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Prote AG.

♦ Special pop rivet pliers - V.A.G 1753A-

312 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

12.2 Contact corrosion! AG. Volkswagen AG d

agen oes
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The attaching parts and side boards/tail
by V boards in the dropside
o gu
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model are made from aluminium.rise d
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When these parts are installed,
ss a special care must be taken re‐ ra
c
garding contact corrosion.

ce
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nl

pt
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Contact corrosion can occur if unsuitable fastening elements
itte

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(bolts, nuts, washers and pop rivets) are used.
erm

ab
ility
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For this reason, only connecting elements with a special surface

wit
, is n

coating (Dacromet) have been fitted. These elements can be rec‐

h re
hole

ognised by their green colour.

spec
es, in part or in w

If unsure about the reusability of a specific part, always fit a new

t to the co
part.

rrectness of i
WARNING
l purpos

♦ Use only genuine part!

♦ Accessories must be approved by Volkswagen AG!

nf
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♦ Damage due to contact corrosion is not covered by the
m

atio
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warranty.
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12.3 Assembly overview - dropside body
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The right side is shown. The left side is similar.
agen
Prote AG.

12. Loading floor body 313

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

1 - Dropside body
2 - Bolt
❑ Qty. 6 on each side.
3 - Hexagon nut
❑ Qty. 6 on each side.
❑ Tightening torque: 95
Nm ± 10 Nm

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spec
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t to the co
rrectness of i
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mercia

a
com

tion in
r
te o

thi
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do
r
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cum
fo

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ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

314 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

12.4 Assembly overview - load floor and side boards/tail board

Note

Depending on model slight differences are possible when referring to assembly overview.

1 - Loading floor
❑ 4330 x 2130 mm, adapt
with workshop tools.
AG. Volkswagen AG d
2 - Latch agen oes
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❑ Rear left and front right. ised ara
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❑ Secured on inside and aut
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outside with 5 pop rivets ss c

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3 - Rear panel

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❑ Material: Aluminium

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4 - Latch

h re
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❑ Rear left and front right.

spec
es, in part or in w

❑ Secured on inside and

t to the co
outside with 5 pop rivets
-5-.

rrectness of i
5 - Pop rivet
❑ Insert with special pop
l purpos

rivet pliers - V.A.G

1753A-

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6 - Latch

rm
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❑ Rear left and front right.

o

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❑ Secured on inside and

or

thi
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outside with 5 pop rivets

t

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-5-.

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7 - Side board
t.
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op
❑ Removing and installing
C py
t. rig
gh
⇒ page 316 .
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❑ Material: Aluminium Prote
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agen

❑ Left.
8 - Latch
❑ Front left and rear right.
❑ Secured on inside and outside with 5 pop rivets -5-.
9 - Tie-down ring
❑ Qty. 4 on each side
❑ Bolted from below with 2 hexagon nuts each.
10 - Hinge bearing
❑ 4 each on left and right.
❑ 3 at rear.
11 - Safety cable
❑ Left and right.
12 - Plenum chamber bulkhead
13 - Side board
❑ Removing and installing ⇒ page 316 .

12. Loading floor body 315

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014
❑ Material: Aluminium
❑ Right.
14 - Underride guard
❑ Removing and installing ⇒ page 320 .
15 - Rear wing
❑ Removing and installing ⇒ page 322 .
❑ Left and right.

12.5 Side board

Note

The removal and installation procedure is for the right side. Re‐
moval and installation on the left can be derived from this. n AG. Volkswagen AG do
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12.5.1 Removing and installing d b ran
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Removing ss
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– Open side board -1- (vertically) and detach arrester cable.

pt
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itte

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– Tell a second mechanic to hold side board -1-.
erm

ab
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Note
hole

spec
es, in part or in w

Depending on model, a retainer is clipped into side boards at rear hinge positions on left and right side boards.

t to the co
– Press retainer (if fitted) out of side board with a screwdriver.

rrectness of i
– Push side board -1- with hinge bearings -3- out of hinges -4-
in -direction of arrow-.
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mercia

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c

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t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

316 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove side board -1- from loading floor -2- with a second
mechanic.

AG. Volkswagen AG d
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spec
es, in part or in w

t to the co
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mercia

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tion in
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cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Installing
Install in reverse order of removal.

12. Loading floor body 317

 Crafter 2006 ➤
n AG. Volkswagen AG do
General body repairs, exterior - Edition 10.2014 lkswage es n
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12.6 Underride guard autho tee
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ac
ss

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12.6.1 Assembly overview

an
d
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is n
Note

h re
ole,

spec
The right side is shown. The left side is similar.

urposes, in part or in wh

t to the co
1 - Underride guard

rrectne
❑ Removing and installing
⇒ page 318 .

ss o
2 - Bolt
cial p

f inform
❑ Qty. 4.
mer

atio
❑ Specified torque: 35 Nm
om

n
c

i
3 - Bolt
or

n thi
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❑ Qty. 4.
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❑ Specified torque: 35 Nm
fo

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t.
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Cop py
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Prote AG.

12.6.2 Removing and installing

Removing
– Remove bolts -2- and -3-.

318 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– With help of a second mechanic, remove underride guard

-1-.

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cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.

Installing:
Install in reverse order, but note the following:
Specified torque of bolts ⇒ page 318 .

12. Loading floor body 319

 . Volkswagen AG
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Crafter 2006 ➤ olks
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General body repairs, exterior - Edition
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b ara
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12.7 Rear underride guard
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ss

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pt
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12.7.1 Assembly overview

ab
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h re
ole,
Note

spec
urposes, in part or in wh

t to the co
Depending on model slight differences are possible when referring to assembly overview.

rrectne
1 - Rear underride guard
❑ Removing and installing

ss
⇒ page 320 .

o
cial p

f inform
2 - Connector
mer

atio
❑ For tail light.
om

n
c

❑ Left and right.

i
or

n thi
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sd
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3 - Hexagon nut
iv

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pr

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r

❑ Qty. 4 on each side.

fo

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ng

t.
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❑ Specified torque: 35 Nm
Co
Cop py
t. rig
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Prote AG.

12.7.2 Removing and installing

Removing
– Disconnect left and right connector -2- ⇒ Electrical system;
Rep. gr. 94 ; Tail light in vehicles with dropside body .

320 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Unscrew left and right hexagon nut -3- and remove rear un‐
derride guard -1- with the help of a second mechanic.

AG. Volkswagen AG d
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ab
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wit
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h re
ole,

spec
urposes, in part or in wh

Installing:
t to the co

Install in reverse order, but note the following:

rrectne

Specified torque of bolts ⇒ page 320 .

12.8 Rear wing

ss o
cial p

f inform

Note
mer

atio
om

The removal and installation procedure is for the right side. The
c

i
or

removal and installation of the left side is similar.

thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
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rig ht
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by lksw
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Prote AG.

12. Loading floor body 321

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

12.8.1 Assembly overview

Note

The right side is shown. The left side is similar.

1 - Rear wing
❑ Removing and installing
⇒ page 322 .
2 - Hexagon nut
❑ Qty. 6.
❑ Specified torque: 10.5
Nm
3 - Washer
❑ Qty. 6. agen
AG. Volkswagen AG d
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❑ Qty. 6.uthor eo
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spec
es, in part or in w

t to the co
rrectness of i
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Cop py
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12.8.2 Removing and installing
by c lksw
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Prote AG.

Removing
– Unscrew hexagon nuts -3- from bolts -4-.

322 Rep. gr.66 - Exterior equipment

 Crafter 2006 ➤
General body repairs, exterior - Edition 10.2014

– Remove washers -2- together with rear wing -1-.

AG. Volkswagen AG d
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t to the co
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mercia

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tion in
r
te o

thi
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cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installing
Install in reverse order, but note the following:
Specified torque of bolts ⇒ page 322 .

12. Loading floor body 323