Service: Crafter 2006

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Service Department. Technical Information

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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 © 2016 Volkswagen AG, Wolfsburg D4B8057952F

Crafter 2006 ➤
AG. Volkswagen AG d
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Contents
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pt
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Box body (Junge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Exterior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
h re
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1.3 Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
spec
es, in part or in w
1.4 Box body, exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.5 Box body, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Box body, interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2 Box body (Spier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
l purpos
2.2 Exterior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.4 Box body, exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.5 Box body, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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2.6 Box body, interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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3 Tail lift (Sörensen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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3.2 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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3.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.4 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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35
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3.5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
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38
4 Tail lift (BÄR - Cargolift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.4 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Contents i
Crafter 2006 ➤
Box bodies - Edition 12.2015
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ii Contents
Crafter 2006 ➤
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66 – Exterior equipment
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⇒ “1.1 Data”, page 1
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⇒ “1.2 Exterior lighting”, page 3
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⇒ “1.3 Interior lighting”, page 7
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⇒ “1.4 Box body, exterior”, page 8
⇒ “1.5 Box body, rear”, page 9
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⇒ “1.6 Box body, interior”, page 11
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1.1 Data
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⇒ “1.1.1 Identification plate”, page 1
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⇒ “1.1.2 Operating and maintenance instructions”, page 2

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1. Box body (Junge) 1

Crafter 2006 ➤
Type plate -arrow- is located on front right of box body behind co-
driver door.
1.1.2 Operating and maintenance instructions
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Operating and maintenance instructions -arrow- are located at

rear right on inside of box body.
2 Rep. gr.66 - Exterior equipment

Crafter 2006 ➤
1.2 Exterior lighting

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⇒ “1.2.1 Removing and installingd by V tail light cluster”, page 3
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⇒ “1.2.2 Removing and uth installing rear fog light”, page 4
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⇒ “1.2.3 Removing and installing number plate light”, page 4
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⇒ “1.2.4 Removing and installing high-level brake light”,
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⇒ “1.2.5 Removing and installing upper marker lights”,
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⇒ “1.2.6 Removing and installing side marker light with bracket”,
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⇒ “1.2.7 Removing and installing lower marker light”, page 6
1.2.1 Removing and installing tail light cluster
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The removal and installation procedure is described for the left-

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Removing
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– Turn light switch to “0” position.

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– Remove bolts -1-.
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– Remove trim.
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– Separate electrical connector -2-.
– Remove nut -3-.
– Remove tail light cluster -1- from box body.

Installing
Install in reverse order, but note the following:
Specified torques
Component Specified torque
Nut 5 Nm

Crafter 2006 ➤
1.2.2 Removing and installing rear fog light

Removing
– Remove trim.
– Detach cable tie.
– Remove nut -3-.
– Remove rear fog light -1- from box body.

Installing
Specified torques
Nut 5 Nm agen
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1.2.3 Removing and installing number plate
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Removing
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– Remove bolt -1-.

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– Remove cap -2-.

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Crafter 2006 ➤
– Separate electrical connectors -1- from connector contacts.

– Remove number plate light from box body.
Installing
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– Remove high-level brake light -2- from box body, separating
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electrical connector to do so.
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Installing
Installation is carried out in reverse order.
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1.2.5 Removing and installing upper marker Cop py
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Note

Removing
– Remove upper marker light -1- from box body, separating
electrical connector to do so.
Installing

Crafter 2006 ➤
1.2.6 Removing and installing side marker

light with bracket
Note
♦ The removal and installation procedure is described for the

right-hand side. The removal and installation procedure for the
left-hand side is basically the same.
♦ The box body has a total of 4 side marker lights.
Removing
– Remove side marker light -1- from box body.

Installing
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1.2.7 Removing and installing lower marker
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– Remove trim. pe
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– Detach cable tie.
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– Remove nut -2-.
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– Remove lower marker light -1- from box body.
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Installing
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Specified torques
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Nut 3 Nm
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1.3 Interior lighting

⇒ “1.3.1 Interior light switch”, page 7
⇒ “1.3.2 Removing and installing interior lighting”, page 8
1.3.1 Interior light switch

Interior light switch for box body -1- is located on right next to
steering wheel and is controlled from this point.
– Remove interior light switch for box body -1- ⇒ Electrical sys‐
tem; Rep. gr. 96 ; Lights and control elements in dash panel;
Removing and installing left and right switch unit next to steer‐
ing wheel .

Crafter 2006 ➤
1.3.2 Removing and installing interior lighting

Removing
– Switch off interior light switch for box body ⇒ page 7 .
– Remove interior light lens -2-.
– Separate electrical connector in interior light.
– Remove nut -3-.
– Remove interior light from box body.
Installing
Specified torques
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1.4 Box body, exterior
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♦ The roof corners are only fitted to the front of the body. nf
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Removing
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– Detach sealed and bonded joint -1- around circumference.

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– Detach bonded joint between roof corner -2- and box body.
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– Remove roof corner from box body.

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– Remove sealing and adhesive compound residue.

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Note
The part numbers of the materials of the box body can be found
in the ⇒ Electronic parts catalogue (ETKA) .
– Lightly sand down bonding surfaces and clean.

– Apply assembly adhesive.
– Fit roof corner and secure in position.
– Seal all around with sealing and adhesive compound.

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⇒ “1.5.1 Removing and installing gas strut”, page 9
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⇒ “1.5.2 Removing and installing tail flap”, page 10
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⇒ “1.5.3 Removing and installing tail flap seal”, page 10
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⇒ “1.5.4 Removing and installing box body seals”, page 10
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1.5.1 Removing and installing gas strut
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Gas struts are under extreme pressure. Only remove with the
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– Open tail lift.

– Prop up tail flap and secure.
– Detach both metal clips -1- at top and bottom with a screw‐
driver.

Crafter 2006 ➤
– Pull off gas strut from ball heads -2-.

Installing AG. Volkswagen AG d
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Installation is carried out in reverse order. by Vo gu
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1.5.2 Removing and installing tail flap or eo
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Removing
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– Open tail lift.
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– Remove gas struts of tail flap ⇒ page 9 .
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– Remove tail flap from box body.
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– Remove bolts -1- of seal.
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– Remove seal from tail flap.

Installing
1.5.4 Removing and installing box body seals
Note


Crafter 2006 ➤
Removing
– Unscrew bolts -1- of plastic block.
– Remove plastic block from box body.
– Unscrew all bolts in seal.
– Remove seal from box body.
Installing
1.6 Box body, interior

⇒ “1.6.1 Removing and installing securing strap rail”, page 11
⇒ “1.6.2 Removing and installing securing strap recesses”, page
12
⇒ “1.6.3 Removing and installing pull strap”, page 13
1.6.1 Removing and installing securing strap

rail
Note

♦ A total of 4 securing strap rails are fitted: 2 rails on each side.
Removing
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Crafter 2006 ➤
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– Drill out rivets -1- along whole of securing strap rail and re‐ rig ht
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– Unscrew bolts -2- at start and end of securing strap rail.
– Remove securing strap rail from box body.
Installing

recesses
Note
♦ The removal and installation process is described for one se‐

curing strap recess. For the other securing strap recesses, the
removal and installation process is basically the same.
♦ The securing strap recesses are bonded from underneath and
bolted on.
♦ A total of 8 securing strap recesses are fitted: 4 recesses on
each side.

Crafter 2006 ➤
Removing
– Remove nut -2-.
– Detach washer -1- and remove.
– Release bonded joint.
– Remove securing strap recess from inside.
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– Remove sealing and adhesive compound
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t to the co
– Apply sealing and adhesive compound.
– Fit securing strap recess from inside.
rrectness of i
– Fit washer -1-.
l purpos
– Tighten nut -2-.
nform
ercia
Specified torques
m
at
om
ion
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or
Nut 8 Nm
his
ate
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1.6.3 Removing and installing pull strap

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Prote AG.
The pull strap is secured to the inside of the tail flap on the right.
Removing
– Drill out rivets -1- and remove.
– Remove pull strap -2- from tail flap.
Installing

Crafter 2006 ➤
2 Box body (Spier)

⇒ “2.1 Data”, page 14
⇒ “2.2 Exterior lighting”, page 16
AG. Volkswagen AG d
⇒ “2.3 Interior lighting”, page 19 agen oes
olksw not
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⇒ “2.4 Box body, exterior”, page 20 orise nte
th eo
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⇒ “2.5 Box body, rear”, page 23 ss a c
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e
⇒ “2.6 Box body, interior”, page 26 nl
pt
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2.1 Data
erm
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⇒ “2.1.1 Identification plate”, page 14
wit
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⇒ “2.1.2 Operating and maintenance instructions”, page 15
spec
es, in part or in w
t to the co
rrectness of i
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nf
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The type plate -arrow- is located at the front right on the vehicle
frame.

Crafter 2006 ➤
2.1.2 Operating and maintenance instructions
AG. Volkswagen AG d
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Operating and maintenance instructions -arrow- are located at
es, in part or in w
rear right on inside of box body. t to the co

rrectness of i
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nform
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Cop py
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Prote AG.
2. Box body (Spier) 15

Crafter 2006 ➤
2.2 Exterior lighting

⇒ “2.2.1 Removing and installing tail light cluster”, page 16
⇒ “2.2.2 Removing and installing number plate light”, page 16
⇒ “2.2.3 Removing and installing high-level brake light”,
page 17
⇒ “2.2.4 Removing and installing upper marker lights”,
page 17
⇒ “2.2.5 Removing and installing side marker light”, page 18
AG. Volkswagen AG d
agen oes
2.2.1 Removing and installing tail light cluster byV
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♦ To avoid mistaken allocation of the electrical connectors, it is
h re
ole,
recommended that they are marked before separating.
spec
t to the co
Removing
rrectne
– Unscrew bolts from lens -1-.
– Remove lens -1- from tail light cluster.
ss o
cial p
f
– Separate electrical connector in tail light cluster and pull out.
inform
mer
atio
om
n
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or
n thi
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t.
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Cop py
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– Remove nut -1-. rig ht
py by
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– Remove tail light cluster from box body. cted agen
Prote AG.
Installing
Specified torques
Nut 1.5 Nm
Bolts securing lens 0.5 Nm
2.2.2 Removing and installing number plate

light
Note


Crafter 2006 ➤
Removing
– Remove cap -2-.
– Separate electrical connectors -1- from connector contacts.

AG. Volkswagen AG d
– Remove bolts -2-. agen oes
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– Remove number plate lightorisfrom
e box body. nte
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Installing ss a c
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Specified torques
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Bolts 0.8 Nm
hole
spec
es, in part or in w
t to the co
2.2.3 Removing and installing high-level
brake light
rrectness of i
Removing
l purpos
– Detach brake light -1- from box body by suitable means.

nform
ercia
– Remove brake light from box body, separating wiring harness

when doing so.
m
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io
Installing
n
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– Repair wiring harness ⇒ Electrical system, General informa‐

um
for
tion; Rep. gr. 97 ; Wiring; Repairing wiring harnesses and

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t.
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connectors . t. Cop py
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Prote AG.
2.2.4 Removing and installing upper marker

lights
Note
The removal and installation procedure is described for the right-

hand side. The removal and installation procedure for the left-

Crafter 2006 ➤
Removing
– Remove upper marker light -2- from box body, cutting through
wiring harness to do so.
Installing
connectors .
Specified torques
Bolts 0.3 Nm
2.2.5 Removing and installing side marker

light
Note

left-hand side is basically
swa
gthe same.
en AG. Volkswagen AG
does
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♦ The box body has
ed a total of 4 side marker lights.
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♦ Since there
au is no electrical connector on the
th marker light, thera
wiring harness
ss must be cut through for complete renewal of c
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the marker light with bulb holder.

nl
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erm
Removing without bracket

ab
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wit
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– Cut through wiring harness -1-.

hole
spec
es, in part or in w
– Detach marker light from bracket.

t to the co
Removing with bracket

rrectness of i
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nf
ercia
orm
m
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n in
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Cop py
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Prote AG.

AG. Volkswagen AG d Crafter 2006 ➤
agen oes Box bodies - Edition 12.2015
o lksw not
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– Turn light horswitch to “0” position. eo
aut ra
c
– Cut through
ss
wiring harness.
ce
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nl
pt
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erm
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– Remove side marker light -2- with bracket from box body.
ility
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Installing
wit
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spec
es, in part or in w
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connectors .
rrectness of i
Specified torques
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Bolts 1 Nm
nf
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orm
m
atio
2.3 Interior lighting
om
n in
or c
thi
⇒ “2.3.1 Interior light switch”, page 19
te
sd
iva
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⇒ “2.3.2 Removing and installing interior lighting”, page 19

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2.3.1 Interior light switch
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Interior light switch for box body -1- is located on right next to
py by
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steering wheel and is controlled from this point.
by c lksw
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Prote AG.
– Remove interior light switch for box body -1- ⇒ Electrical sys‐
tem; Rep. gr. 96 ; Lights and control elements in dash panel;
Removing and installing left and right switch unit next to steer‐
ing wheel .
2.3.2 Removing and installing interior lighting

Removing
– Switch off interior light switch for box body ⇒ page 19 .
– Loosen bolts -3-.
– Remove interior light lens -2-.
– Separate electrical connector in interior light.
– Remove nut -1-.
– Remove interior light from box body.
Installing
Specified torques
Nut 15 Nm
Bolt securing lens 0.6 Nm

Crafter 2006 ➤
2.4 Box body, exterior

⇒ “2.4.1 Removing and installing front roof corner”, page 20
⇒ “2.4.2 Removing and installing rear roof corner”, page 21
2.4.1 Removing and installing front roof cor‐

ner
Special tools and workshop equipment required . Volkswagen AG
gen AG does
swa
♦ Hot air blower - V.A.G 1416- or hot air blower - VAS 1978/14A- yV
olk not
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Note
l purpos
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Cop py
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by lksw
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Prote AG.

Crafter 2006 ➤
Removing
– Heat up bonded joint between roof corner -3- and box body
using hot air blower and carefully detach.
Installing
Note
♦ The rivet connection serves purely to secure the roof corner.

♦ The part numbers of the materials of the box body can be
found in the ⇒ Electronic parts catalogue (ETKA) .

– Apply SIKA activator - 100- to the bonding surface of the new
part and the sidewall.
– Observe flash-off period of at least 20 minutes.
– Apply SIKA adhesive - 552- to new part.
– Fit roof corner and restore original bond.
– Seal all around with SIKA adhesive - 552- .
Note
olkswagen AG
en AG. V
After bonding in, the vehicle must be parked ksw on a hard, level
ag does
not
Vol
standing for at least 24 hours at room
d b temperature (at 18°C) to
y gu
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allow the bonded componentshto orisharden.
e nte
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au ac
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nl
2.4.2 Removing and installing rear roof corner

pt
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Special tools and workshop equipment required

ab
ility
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♦ Hot air blower - V.A.G 1416- or hot air blower - VAS 1978/14A-
wit
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
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for
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Cop py
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Prote AG.

Crafter 2006 ➤
Note

Removing
– Heat up bonded joint between roof corner -3- and box body
using hot air blower and carefully detach.
Installing
lkswage es n
o ot g
byV ua
d ran
Note o
ir se tee
th or
au ac
ss
♦ The rivet connection serves purely to secure the roof corner.
ce
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erm
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ility
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wit
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– Apply SIKA activator - 100- to the bonding surface of the new
spec
part and the sidewall.
es, in part or in w
t to the co
rrectness of i
– Fit roof corner and restore original bond.
l purpos
– Seal all around with SIKA adhesive - 552- .

nf
ercia
orm
Note
m
atio
om
n in
or c
After bonding in, the vehicle must be parked on a hard, level

thi
te
standing for at least 24 hours at room temperature (at 18°C) to

sd
iva
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r
allow the bonded components to harden.

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Cop py
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co lksw
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Prote AG.

Crafter 2006 ➤
2.5 Box body, rear

⇒ “2.5.1 Removing and installing gas strut”, page 23
⇒ “2.5.2 Removing and installing tail flap”, page 24
⇒ “2.5.3 Removing and installing tail flap seals”, page 25
⇒ “2.5.4 Removing and installing rear box body seals”,
page 25
⇒ “2.5.5 Removing and installing reversing camera”, page 25
2.5.1 Removing and installing gas strut
Note
♦ Removal and installation is described for right side of vehicle.

Follow same instructions for left side as appropriate.
♦ Gas struts are under extreme pressure. Only remove with the
rams extended.
Removing
AG. Volkswagen AG d
agen oes
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ab
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Open tail lift.

– Remove split pin -3- with washer -4-.
– Unscrew nut -2-.
– Remove gas strut -1- from box body.
Installing
Note
The split pin must be renewed.
Specified torques
Nut 1 Nm
2.5.2 Removing and installing tail flap
Note
rams extended.
Removing agen
AG. Volkswagen AG d
oes
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– Open tail lift. d by V gu
ara
rise nte
o
– Prop up tail flap and secure. auth eo
ra
ss c
– Remove gas struts of tail flap ⇒ page 23 .
ce
e
nl
pt
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an
– Unscrew nuts -1- from all hinges.

itte
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erm
ab
– Remove tail flap from box body.

ility
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Installing
h re
hole

spec
es, in part or in w
t to the co
Specified torques
rrectness of i
Nut 15 Nm
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nf
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orm
m
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Cop py
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Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
2.5.3 Removing and installing tail flap seals
d byV
olksw not
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Removing ut
ho eo
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– Detach seal -1- from all around tail flap. s
ce
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un
pt
– Remove seal from tail flap.
an
d
itte
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ab
Installing
pe
ility
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hole
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es, in part or in w
t to the co
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2.5.4 Removing and installing rear box body
nform
ercia
seals
m
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com
tion in
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Note
thi
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hand side. The removal and installation procedure for the right
en
ng
t.
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seal and upper seal is basically the same. ht. Cop py
rig
rig ht
py by
Vo
Removing
co lksw
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Prote AG.
– Pull out seal from metal rail.
Installing
– Insert seal in metal rail using commercially available lubricant .
2.5.5 Removing and installing reversing cam‐

era
Removing
– Separate electrical connector on camera.
– Unscrew nut -3-.
– Remove reversing camera -1- from bracket -2-.
Installing

Crafter 2006 ➤
2.6 Box body, interior

⇒ “2.6.1 Removing and installing securing strap rail”, page 26
⇒ “2.6.2 Removing and installing securing strap recess”,
page 27
⇒ “2.6.3 Pull strap”, page 28

rail
Note

upper right-hand side. The removal and installation procedure
for the lower securing strap rail and left-hand side is basically
the same.
♦ A total of 4 securing strap rails are fitted: 2 rails on each side.
Removing
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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nl
pt
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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
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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
cted agen
Prote AG.

Crafter 2006 ➤
en AGrail -1- and . Volkswage
– Release bonded joint between securing
ksw
agstrap side‐
n AG d
oes
not
l
wall -3-. by Vo gu
a d ran
ise
– Remove securing strap rail
ut
hofrom sidewall.
r tee
or
sa ac
– Remove adhesive residue.
s
ce
le
un
pt
– Lightly sand down bonding surface and clean.
an
d
itte
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erm
ab
Installing
ility
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ole,
spec
Note
t to the co
♦ The bolts serve purely to attach the securing strap rail.
rrectne
ss o
cial p
– Clean bonding surface.
f inform
mer
– Apply SIKA activator to the bonding surface of the new part
atio
and the sidewall.
om
n
c
i
or
n
thi
te
sd
va

i
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pr
cum
r
fo
– Fit securing strap rail and secure with bolts -2-.
en
ng
t.
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op py
– Remove any excess adhesive after approx. 2 hours using a t. C rig
gh ht
commercially available scraper. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Note
After bonding in, the vehicle must be parked on a hard, level

standing for at least 48 hours at room temperature (at 18°C) to
allow the bonded components to harden.
Specified torques
Bolts 0.8 Nm

recess
Note
♦ The removal and installation process is described for one se‐

curing strap recess. For the other securing strap recesses, the
removal and installation process is basically the same.
♦ The securing strap recesses are bonded from underneath and
bolted on.
♦ A total of 8 securing strap recesses are fitted: 4 recesses on
each side.

Crafter 2006 ➤
Removing
– Remove nut -2-.
– Detach washer -1- and remove.
– Release bonded joint.
– Remove securing strap recess from inside.
Installing
Note
– Remove loose adhesive residue.

– Clean bonding surfaces.
Volkswa
– Apply SIKA-FLEX (brown) - 221- assemblyswadhesive
agen
AG. to new
gen AG
does
part. by Volk not
gu
a d ran
ise
– Adapt moulding from inside andthspread
or adhesive evenly by tee
or
turning. ss au ac
ce
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– Remove excess adhesive.

un
pt
an
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– Fit washer -1-.
rm
ab
pe
ility
– Tighten nut -2-.
ot
wit
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Specified torques
hole
spec
es, in part or in w
Nut 10 Nm t to the co
rrectness of i
2.6.3 Pull strap

l purpos
Removing
nform
ercia
– Remove holder -2- with pull strap -3- from tail flap.
m
a
com
tion in
Installing
r
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s

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Specified torques
fo
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ng
t.
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op
Component Specified torqueC py
t. rig
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Bolts 1.5 Nmop Vo
by c lksw
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Prote AG.

Crafter 2006 ➤
3 Tail lift (Sörensen)

⇒ “3.1 General notes”, page 29
⇒ “3.2 Data”, page 30
⇒ “3.3 Electrical system”, page 33
⇒ “3.4 Platform”, page 35
⇒ “3.5 Hydraulic system”, page 38
3.1 General notes
Note
♦ Before commencing with the repair measures, observe the

manufacturer's general notes.
♦ The tail lift may only be operated, serviced and repaired by
persons who have received relevant induction training on the
technology and, in particular, have been instructed about the
hazards associated with operation.
♦ The accident prevention regulations must be strictly adhered
to, especially BGR 500 lifting platforms (VBG 14) in this case.
The main regulations can be gleaned from the inspection
booklet of the tail lift.
♦ Modifications to the tail lift may not be carried out unless writ‐
ten approval from the manufacturer's engineering department
has been given. agen
AG. Volkswagen AG d
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byV ua
Safety precautions ir se
d ran
tee
tho
u or
Before commencing ss with
a repairs and maintenance measures, se‐ ac
cure the tail lift to prevent it from moving unintentionally.
ce
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un
pt
an
d
The tail lift must be observed at all times while functions are car‐
itte
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ried out using the controls.

erm
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ility
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The entire area of tail lift movement is to be kept clear of persons

wit
is n
and objects.
h re
ole,
spec
Pay particular attention to crushing and shearing areas between

the platform and body as well as between the platform and road
t to the co
surface.
Electric motor for hydraulic unit
rrectne
To prevent damage to the electric motor and power relay, a suf‐

ficient supply of voltage must be assured at all times for operation
ss
of the tail lift.

o
cial p
f in
If it becomes apparent that the electric motor is struggling, the

form
mer
lifting procedure must be stopped immediately and the batteries

atio
m
must be charged.
o
n
c
i
or
Foot switch
thi
te
sd
va
Using the foot switch on the platform, which is protected in a

i
o
pr
cum
r
pressure cast aluminium housing, the tail lift can be lowered down
fo
en
ng
to the ground and raised up to the height of the vehicle bed.

t.
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Cop py
t. rig
Tilting of the platform to the horizontal position from floor level is yri
gh by
ht
initiated automatically. cop Vo
by lksw
cted agen
Prote
The foot switch has priority over other commands. When the tail
AG.
lift is operated via the foot switch, any other means of controlling
it (operating panel, control box) are automatically blocked elec‐
trically.
3. Tail lift (Sörensen) 29

Crafter 2006 ➤
Hydraulic system
The hydraulic system is bled automatically during operation of the
tail lift.
Damaged hydraulic hoses are to be replaced without delay.
Replacement of the hydraulic hoses must be recorded in the in‐
spection booklet.
Lifting mechanism
The lifting mechanism (flange console, also lifting arm, closing
arm and underbody protection) leaves the factory with the surface
completely finished and painted black (RAL 9005).
All bearing points are maintenance-free and do not have to be
lubricated. Lubrication measures are only necessary in the event
of repairs when the pins are inserted in the bearing points.
If a supporting element should break, the load bearing construc‐
tion and drive mechanism, including safety equipment, are to be
inspected. Furthermore, an inspection is to be carried out in the
event of cable, chain or support nut breakage or gear failure or
leaks in the hydraulic or pneumatic line system to prevent col‐
lapse or lowering of the load bearing equipment. Damaged parts
must be renewed.
Platform wage
es n
lks ot g
Vo
The platform consists of interlinked hollow aluminium profileesec‐ d by ua
ran
tions that are given their ultimate level of stability by means hor of
is tee
pointed and final profiles. aut or
ac
ss
ce
3.2 Data
e
nl
pt
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itte
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erm
ab
ility
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hole
spec
Note
es, in part or in w
t to the co
♦ The factory number is bonded to the type plate on the closing arm, on the right as seen in the direction of
travel. A second type plate is bonded to the inside of the assembly hood, on the right as seen in the direction
rrectness of i
of travel.
l purpos
♦ In addition, the equipment number is stamped in the securing flange, on the left as seen in the direction of
travel. nf
ercia
orm
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Type plate -arrow- with factory number is located on closing arm

of tail lift on right (as seen in direction of travel).

Crafter 2006 ➤
3.2.2 Safety information
Note
♦ Observe specifications of tail lift manufacturer.

♦ Observe the maximum load of the tail lift platform for every operating state (raising and lowering).
♦ The position of the safety instructions in the box body is for example purposes only. It may differ from
manufacturer to manufacturer.
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Safety instructions -arrow- are located at rear right on inside of

box body.

Crafter 2006 ➤
3.3 Electrical system

⇒ “3.3.1 Tail lift switch”, page 33
⇒ “3.3.2 Removing and installing hazard warning light”,
page 33
⇒ “3.3.3 Removing and installing foot switch”, page 34
⇒ “3.3.4 Removing and installing operating panel”, page 34
⇒ “3.3.5 Removing and installing tilt angle sensor”, page 34
3.3.1 Tail lift switch

Tail lift operating switch -1- is located on left next to steering wheel
and is controlled from this point.
– Remove tail lift operating switch -1- ⇒ Electrical system; Rep.
gr. 96 ; Lights and control elements in dash panel; Removing
and installing left and right switch unit next to steering wheel .
wage
3.3.2 Removing and installing hazard warning lks es n
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♦ For the safety of approaching traffic, the tail lift platform must
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signs and flashing lights in accordance with paragraph 53b

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section 5 of the German road traffic act (StVZO).

spec
♦ The removal and installation procedure is described for the t to the co

left-hand side. The removal and installation procedure for the
right-hand side is basically the same.
rrectne
♦ The hazard warning lights flash as soon as the tail lift is switch‐
ed on.
s
♦ The electrical wires must not be subjected to abrasion nor may

s o
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inform
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♦ The hazard warning light is connected to the wiring in the plat‐

atio
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Crafter 2006 ➤
Removing
– Select off position on switch for tail lift operation ⇒ page 33 .
– Remove hazard warning light -2- from tail lift, separating elec‐
trical connector to do so.
Installing
Specified torques
Bolt 9.5 Nm
3.3.3 Removing and installing foot switch
Note

they be crushed.
♦ The foot control is connected to the wiring in the platform.
Removing
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– Select off position on switch for tail lift
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– Remove bolts -1-. e db ran
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– Remove foot controls ut
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Installing
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Specified torques
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spec
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Bolt 9.5 Nm
t to the co
3.3.4 Removing and installing operating panel

rrectness of i

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– Cut through cable tie along wiring harness.

nform
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– Separate electrical connector to operating panel.

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– Remove bolts.
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– Remove operating panel from bracket.

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3.3.5 Removing and installing tilt angle sensor

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Note
The tilt angle sensor is electrically connected to the foot switch

and right hazard warning light.

Crafter 2006 ➤

– Unscrew bolts of side strips (aluminium profile sections).
– Remove side strips (aluminium profile sections) from platform.
– Separate electrical connector to foot switch.
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– Separate electrical connector to right hazard warning
lksw
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– Unscrew nuts from tilt angle sensor. ir se
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– Remove tilt angle sensor from aut
platform, separating electrical ra
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connector to tail lift controls when doing so.
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3.4 Platform
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spec
⇒ “3.4.1 Removing and installing platform”, page 35
t to the co
⇒ “3.4.2 Adjusting platform to floor of vehicle”, page 36
⇒ “3.4.3 Adjusting platform to body”, page 36
rrectne
⇒ “3.4.4 Adjusting platform angle”, page 37
⇒ “3.4.5 Removing and installing warning flag”, page 37
ss o
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3.4.1 Removing and installing platform
inform
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♦ Before working on the platform, it must be secured to prevent

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platform, and to secure it with commercially available trestles
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– Detach cap on platform, pull out and separate electrical con‐
nector.
– Remove bolts.
– Drive out pins, placing platform on trestles when doing so.
Installing

Crafter 2006 ➤
3.4.2 Adjusting platform to floor of vehicle
Note
♦ The setting bolt is used to adjust the lifting mechanism so that

the rear frame and platform are parallel to one another.
♦ The adjustment is performed on the adjusting clevis on the
right lifting arm.
♦ When carrying out the adjustment, the lifting arms must not
come into contact with the rear frame.
♦ There should be a gap of approx. 10 mm between the rear
frame and lifting arm when adjusting.
♦ Turning the setting bolt clockwise moves the lifting arm higher
up to the rear frame.
♦ Turning the setting bolt anti-clockwise lowers the lifting arm
further away from the rear frame.
– Move the lifting mechanism hydraulically behind the rear

frame with the platform open.
– Loosen bolt.
G. Volkswage
– Turn the setting bolt until the rear frame
lksw
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3.4.3 Adjusting platform to body
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♦ During the hydraulic closing procedure, the cylinder must

h re
hole
move against the stop (restriction in cylinder) when the plat‐

spec
form is moved lightly against the rear portal or 90° to the floor
es, in part or in w
t to the co
of the vehicle.
♦ If the platform moves with full pressure against the body, the
piston rod of the tilt cylinder must be adjusted.
rrectness of i
♦ To relieve the load on the tilt cylinder, the platform must be

l purpos
opened by 10° - 15°.

♦ Before the upper pin of the tilt cylinder is released, the platform
nform
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must be secured by suitable means to prevent it from falling

m
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– Loosen lock nut on piston rod.

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– Unscrew bolt.
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– Drive out pin and, when doing so, secure piston rod head to
t.
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Note Prote AG.
Grease the pin before any trial run in the platform, drive it in and
secure it with the bolt to prevent it from turning.
– Screw piston rod head in and out until a light preload is built
up during hydraulic closing of platform.

Crafter 2006 ➤
– Once it has been assured that a preload is set, secure pin with
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– Tighten lock nut on piston rod.
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3.4.4 Adjusting platform angle ss
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♦ Adjustment of the platform angle is carried out by means of a
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key combination on the operating panel.
h re
hole
spec
♦ Each time the tail lift is repaired or installed, the platform angle
es, in part or in w
must be readjusted.
t to the co
– Move platform to horizontal position using manual switch.
rrectness of i
– Press upper left button three times.
l purpos
– Then press upper right button three times.
nf
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Note
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The set position is moved to each time until re-programming is

or
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carried out.
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3.4.5 Removing and installing warning flag
en
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Note
co Vo
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♦ The warning flags are secured to the tail lift from the outside.
Removing
– Pull out warning flag -2- from side -arrow-.
Installing
Specified torques
Bolt 2.7 Nm

Crafter 2006 ➤
3.5 Hydraulic system

⇒ “3.5.1 Removing and installing lift cylinder”, page 38
⇒ “3.5.2 Removing and installing closing cylinder”, page 38
⇒ “3.5.3 Removing and installing hydraulic pump”, page 39
⇒ “3.5.5 Bleeding the hydraulic system”, page 39
⇒ “3.5.6 Removing and installing pressure switch”, page 40
⇒ “3.5.7 Removing and installing solenoid valve with valve insert”,
page 40
3.5.1 Removing and installing lift cylinder
Note
♦ Before removing the hydraulic cylinder, the platform must be

propped up and secured by suitable means to prevent it from
falling down.
♦ When loosening the hydraulic lines, pressure switch and valve
insert, collect any escaping hydraulic oil.
Removing
– Drive out split pin from upper pin.
– Unscrew hydraulic line connection.
– Remove pressure switch ⇒ page 40 .
– Remove solenoid valve with valve insert ⇒ page 40 .
– Unscrew securing bolt from lower pin. agen AG. Volkswagen AG do
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– Drive out both pins, securing liftedcylinder
by when doing so to ua
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prevent it from falling down.horis tee
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– Remove lift cylinder fromsslifting arm.
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Note
hole
spec
es, in part or in w
After installing the lift cylinder, it must first be moved to the lift
t to the co
position. Check the hydraulic oil level when doing so and replen‐
ish. Only then may the supports be removed.
rrectness of i
– Bleed hydraulic system by raising and lowering several times.

l purpos
– Check hydraulic fluid level and replenish as necessary.

nform
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3.5.2 Removing and installing closing cylinder

m
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Note
r
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♦ Before removing the hydraulic cylinder, the platform must be

rp
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propped up and secured by suitable means to prevent it from

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falling down.
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♦ When loosening the hydraulic lines, pressure switch and valve
gh ht
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insert, collect any escaping hydraulic oil.
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Crafter 2006 ➤
Removing
– Unscrew bolt securing upper pin.
– Unscrew hydraulic line connection.
– Remove pressure switch ⇒ page 40 .
– Remove solenoid valve with valve insert ⇒ page 40 .
– Drive out upper pin.
– Unscrew securing bolt in lower pin.
– Drive out both pins, securing closing cylinder when doing so
to prevent it from falling down.
– Remove closing cylinder from lifting arm.
Installing
Note
After installing the closing cylinder, it must first be moved to the

closed position. Check the hydraulic oil level when doing so and swagen AG. Volkswagen AG does
replenish. Only then may the supports be removed. by
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– Bleed hydraulic system by opening and closing several
au
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– Check hydraulic fluid level and replenish as necessary.
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3.5.3 Removing and installing hydraulic pump
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For technical reasons, instructions for this repair group could not
wit
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be completed in time for publication in this workshop manual. The
h re
repair procedures will be published in a later revision.
hole
spec
es, in part or in w
3.5.4 Renewing hydraulic fluid
t to the co
Note
rrectness of i
l purpos
♦ It is recommended to extract the hydraulic fluid by suitable

means as there is no drain plug.
nf
ercia
♦ Before the hydraulic fluid is extracted, the tail lift must be
orm
opened and lowered down to ground level. By doing this, the
m
atio
m
hydraulic fluid is forced out of the hydraulic cylinders back into

o
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c
the hydraulic fluid reservoir.

or
thi
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– Pull out cap with dipstick from hydraulic fluid reservoir.

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– Extract hydraulic fluid from hydraulic fluid reservoir by suitable

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– Remove filter in fuel tank, clean and reinstall. copy Vo
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– Replenish with new hydraulic fluid according to manufacturer's
AG.
specifications up to upper marking of cap with dipstick.

– Bleed hydraulic system ⇒ page 39 .
3.5.5 Bleeding the hydraulic system

Raise, lower, open and close tail lift several times to bleed hy‐
draulic system.

Crafter 2006 ➤
Note
Once the hydraulic system has been bled, the oil level must be
checked via the cap with dipstick and replenished as necessary.
3.5.6 Removing and installing pressure switch
Note
To ensure that the hydraulic cylinder is depressurised, the plat‐

form must be lowered down to ground level.
Removing
– Separate electrical connector on service switch in hydraulic
unit (2 x pin S4).
– Detach cable up to pressure switch.
– Unscrew pressure switch, collecting any escaping hydraulic
fluid when doing so.
Installing
Note
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gen AG
Make sure that the new part is fitted
Vol
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does
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– Bleed hydraulic system
ss ⇒ page
a 39 . c
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3.5.7 Removing and installing solenoid valve

un
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with valve insert

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Note
ole,
spec
To ensure that the hydraulic cylinder is depressurised, the plat‐

t to the co
form must be lowered down to ground level.

rrectne
Removing
– Unscrew cap nut on solenoid valve.
ss o
– Pull off coil from valve insert and detach cable up to service
cial p
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switch in hydraulic unit.

form
mer
– Separate electrical connector on service switch in hydraulic

atio
m
unit.
o
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c
i
or
n thi
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– Unscrew valve insert, collecting any escaping hydraulic fluid

t
sd
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when doing so.

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Installing
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op py
Install in reverse order, but note the following: t. C rig
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horis Box bodies - Edition
nte
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aut ra
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Note
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♦ Make sure that the new part is fitted with a new seal when
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installing.
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♦ Make sure that the wire does not become trapped when the
hole
spec
solenoid valve is installed.
es, in part or in w
t to the co
– Bleed hydraulic system ⇒ page 39 .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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for
en
ng
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
4 Tail lift (BÄR - Cargolift)

⇒ “4.1 Data”, page 42
⇒ “4.2 Electrical system”, page 44
⇒ “4.3 Platform”, page 46
⇒ “4.4 Hydraulic system”, page 47
4.1 Data
4.1.1 Identificationlkswplate
agen
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For technical reasons, ris
einstructions
db for this repair group couldarnot
an
te
be completed in time
uth for publication in this workshop manual. Thee o
o
ra
repair procedures
ss will be published in a later revision.
a c
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4.1.2 Safety information

un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
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h re
hole
♦ Observe specifications of tail lift manufacturer.
spec
es, in part or in w
♦ Observe maximum load of tail lift platform for every operating
t to the co
state (raising and lowering).
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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t.
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Cop py
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Vo
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Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
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ab
ility
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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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nf
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or c
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t.
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Safety instructions -arrow- are located at rear right on inside of
Co
Cop py
box body.
t. rig
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Vo
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Prote AG.
4. Tail lift (BÄR - Cargolift) 43

Crafter 2006 ➤
4.2 Electrical system AG. Volkswagen AG d

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⇒ “4.2.1 Tail lift switch”, page 44 by Vo gu
ara
d
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⇒ “4.2.2 Removing and installing hazard warning light”, uthor eo
page 44 ss a ra
c
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e
⇒ “4.2.3 Removing and installing foot controls”, page 45
nl
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⇒ “4.2.4 Removing and installing control box”, page 45
erm
ab
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⇒ “4.2.5 Removing and installing foot switch electronics”,
wit
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page 45
h re
hole
spec
4.2.1 Tail lift switch
es, in part or in w
t to the co
Tail lift operating switch -1- is located on left next to steering wheel
and is controlled from this point.
rrectness of i
– Remove tail lift operating switch -1- ⇒ Electrical system; Rep.
gr. 96 ; Lights and control elements in dash panel; Removing
l purpos
and installing left and right switch unit next to steering wheel .
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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4.2.2 Removing and installing hazard warning
Co
Cop py
t. rig
light
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ For the safety of approaching traffic, the tail lift platform must
be clearly identifiable during operation by means of warning
signs and flashing lights in accordance with paragraph 53b
section 5 of the German road traffic act (StVZO).
♦ The hazard warning lights flash as soon as the tail lift is switch‐
ed on.
they be crushed.
♦ The hazard warning light is connected to the wiring in the plat‐
form.
Removing
– Drill out rivets.
– Remove hazard warning light from tail lift, separating electrical
connector to do so.
Installing

Crafter 2006 ➤
4.2.3 Removing and installing foot controls
Note
♦ The foot control is connected to the wiring in the A

platform.
G. Volkswagen gen AG do
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♦ Avoid cutting injuries and cable damage
by
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olk sharp edges on ot g
ua
the platform. ris
ed ran
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Removing ss
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nl
pt
– Open tail lift.
du
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erm
ab
ility
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– Remove bolts.
wit
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h re
– Remove foot control from tail lift, separating electrical connec‐
hole
spec
tor to do so.
es, in part or in w
t to the co
Installing
rrectness of i
l purpos
Note
nform
ercia

they be crushed.
m
at
om
io
♦ The electrical connector must not work loose or become dam‐
n
c
in t
r
aged.
o
his
ate
do
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♦ The surplus cable of the triangle foot switch must be laid as a

p
cum
or
loop.
f
en
ng
t.
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♦ Do not kink the cable grommet as it will otherwise be damaged Cop py
and rendered ineffective.
t. rig
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4.2.4 Removing and installing control box
Prote AG.
4.2.5 Removing and installing foot switch

electronics

Crafter 2006 ➤
4.3 Platform
⇒ “4.3.1 Removing and installing platform”, page 46
⇒ “4.3.2 Adjusting platform to floor of vehicle”, page 46
⇒ “4.3.3 Adjusting platform to body”, page 47
⇒ “4.3.4 Adjusting platform angle”, page 47
⇒ “4.3.5 Removing and installing warning flag”, page 47
4.3.1 Removing and installing platform
Note
♦ Before working on the platform, it must be secured to prevent

any unintentional movement.
♦ It is recommended to open the hydraulics before removing the
platform, and to secure it by suitable means.
♦ When performing the repair, the pins may only be fitted using
e.g. a nylon-faced hammer as otherwise there is a risk of rust
formation and mechanical deformation.
Removing
– Disconnect electrical connector.
– Unscrew self-locking bolts from left pin.
– Unscrew self-locking bolts with self-locking nuts from right pin.
– Drive out eye pin from main pin.
– Drive out pins and place platform on trestles at same time.
AG. Volkswagen AG d
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Install in reverse order, but note the following: rise
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Note
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♦ Self-locking nuts and bolts must be renewed.

erm
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ility
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♦ If the bearing seals of the lifting arm are damaged, these must
wit
is n
be renewed.
h re
ole,
spec
♦ After installing the platform, the bearing points must be lubri‐

cated via the tapered grease nipples until grease escapes on

t to the co
both sides and a band of grease can be seen.

♦ The part numbers of the materials of the tail lift can be found
rrectne

s
– Clean and grease insides of bearings.

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cial p
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Specified torques
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Self-locking bolt 72 Nm
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Self-locking bolt 80 Nm
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4.3.2 Adjusting platform to floor of vehicle

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Crafter 2006 ➤
4.3.3 Adjusting platform to body

4.3.4 Adjusting platform angle

4.3.5 Removing and installing warning flag
Note

♦ The warning flags are secured to the tail lift from the outside.
Removing
– Pull out warning flag -2- from side -arrow-.
Installing
Specified torques
Bolt 2.7 Nm
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4.4 Hydraulic system aut
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⇒ “4.4.1 Removing and installing lift cylinder”, page 47 ce
le
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⇒ “4.4.2 Removing and installing tilt cylinder”, page 47 y li

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⇒ “4.4.3 Removing and installing hydraulic pump”, page 47
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⇒ “4.4.5 Bleeding the hydraulic system”, page 48

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4.4.1 Removing and installing lift cylinder

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4.4.2 Removing and installing tilt cylinder

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4.4.3 Removing and installing hydraulic pump

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Crafter 2006 ➤
4.4.4 Renewing hydraulic fluid

4.4.5 Bleeding the hydraulic system

Raise, lower, open and close tail lift several times to bleed hy‐
draulic system.
Note
Once the hydraulic system has been bled, the oil level must be wage
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checked via the cap with dipstick and replenished as necessary.
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Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D4B8057952F

1.3 Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Box body, exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Exterior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.6 Box body, interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Tail lift (Sörensen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

⇒ “1.1 Data”, page 1

⇒ “1.3 Interior lighting”, page 7

⇒ “1.1.2 Operating and maintenance instructions”, page 2

1. Box body (Junge) 1

1.1.2 Operating and maintenance instructions

Operating and maintenance instructions -arrow- are located at

2 Rep. gr.66 - Exterior equipment

1.2 Exterior lighting

1.2.1 Removing and installing tail light cluster

The removal and installation procedure is described for the left-

– Turn light switch to “0” position.

– Remove tail light cluster -1- from box body.

1. Box body (Junge) 3

1.2.2 Removing and installing rear fog light

– Remove rear fog light -1- from box body.

– Remove bolt -1-.

– Remove cap -2-.

4 Rep. gr.66 - Exterior equipment

– Separate electrical connectors -1- from connector contacts.

The removal and installation procedure is described for the left-

1. Box body (Junge) 5

1.2.6 Removing and installing side marker

♦ The removal and installation procedure is described for the

– Remove side marker light -1- from box body.

The removal and installation procedure is described for the left-

6 Rep. gr.66 - Exterior equipment

– Detach cable tie.

– Remove lower marker light -1- from box body.

1.3 Interior lighting

1.3.1 Interior light switch

1. Box body (Junge) 7

1.3.2 Removing and installing interior lighting

– Detach sealed and bonded joint -1- around circumference.

– Remove roof corner from box body.

– Remove sealing and adhesive compound residue.

– Lightly sand down bonding surfaces and clean.

8 Rep. gr.66 - Exterior equipment

– Open tail lift.

1. Box body (Junge) 9

– Pull off gas strut from ball heads -2-.

– Remove bolts -1-.

Installation is carried out in reverse order.

– Remove seal from tail flap.

1.5.4 Removing and installing box body seals

The removal and installation procedure is described for the left-

10 Rep. gr.66 - Exterior equipment

1.6 Box body, interior

1.6.1 Removing and installing securing strap

♦ The removal and installation procedure is described for the