4
3. Table of contents
1. Introduction .................................................................................................................................... 3
2. General points of attention .......................................................................................................... 3
3. Table of contents ........................................................................................................................... 4
4. Part List............................................................................................................................................. 8
5. Overview....................................................................................................................................... 30
6. Disassembly................................................................................................................................... 32
6.1. Disassembly of the interior....................................................................................................... 32
6.2. Disassembly of the exterior...................................................................................................... 33
6.3. Disassembly of the fuel tank –Diesel ..................................................................................... 34
6.4. Disassembly of the fuel tank –Petrol...................................................................................... 35
6.5. Disconnecting the ‘under body’ wiring loom....................................................................... 36
7. Preparing OEM body ................................................................................................................... 38
7.1. Cutting the floor without template set .................................................................................. 38
7.2. Cutting the floor with template set ........................................................................................ 39
7.3. Drilling holes for wheelchair seatbelt ..................................................................................... 40
7.4. Preparing body for 3rd seatrow consoles............................................................................... 42
7.5. Cutting OEM steel bumper ..................................................................................................... 45
7.6. Cutting OEM bumper without template ............................................................................... 46
7.7. Cutting OEM bumper with template set ............................................................................... 47
7.8. Cleaning underside of body................................................................................................... 48
8. Installing the rear beam (43.40.T.301) ........................................................................................ 50
9. Installing middle frame brackets (43.40.T.201) ......................................................................... 55
10. Installing the shock absorber brackets (43.40.T.202/2) ............................................................ 59
11. Installing the rear low floor (43.41.T.300).................................................................................... 64
11.1. Test fitting the rear low floor .................................................................................................... 65
11.2. Seal and protection instructions............................................................................................. 68
11.3. Installing the rear low floor ...................................................................................................... 70
12. Assemble rear bumper covers (43.54.T.301) ............................................................................. 77
13. Installing middle bumper assembly (43.54.2.300)..................................................................... 82
13.1. Preparing components ........................................................................................................... 83
13.2. Installing components.............................................................................................................. 84
14. Park distance control sensors (PDC).......................................................................................... 90
15. Installing the Diesel fuel tank (43.23.T.302) ................................................................................ 94
15.1. Preparing components ........................................................................................................... 96
15.1. Installing components.............................................................................................................. 99
16. Installing the Diesel exhaust system (43.20.T.300/1) ............................................................... 106
16.1. Cutting the exhaust ............................................................................................................... 107
16.2. Installing the exhaust ............................................................................................................. 108
17. Installing the Petrol fuel tank (43.23.T.303) .............................................................................. 113
17.1. Preparing components ......................................................................................................... 114
