Disassemble/assemble rear-end door (left door wing)

AR72.20-D-2401F

Disassemble/assemble rear-end door (left door wing)

30.11.2016

Model

900, 906.6/7

Shown with CODE D03 (Roof ad rear-end doors, high version)

1

Rear-end door

15

Lock

29

Rear window wiper ((model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

2

Upper door lock (with CODE D03 (Roof and rear-end door, high version))

16

Bottom hinge

30

Cover

3

Screw

17

Screw

31

Rear window (model 900, 906.6/7 with code W61 (Window in liftgate/rear door) or model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

4

Upper door paneling (with CODE D03 (Roof and rear-wend doors, high version))

18

Nut

32

Center rear-end door seal

5

Screw

19

Stop buffer

33

Electrical connector (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

6

Top hinge

20

Bottom door lock

34

Washer fluid hose (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

7

Cable grommet (model 906.6/7 with code H22 (Heated rear window))

21

Screw

35

Bottom door lock cable

8

Bellows mount

22

Lower door trim

36

Nut (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

9

Bellows

23

Screw

37

Cover (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

10

Bolt (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

24

Lock striker

38

Washer fluid hose (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

11

Screw

25

Screw

39

Upper door lock cable

12

Door catch

26

Lock handle

E19/1

Left license plate lamp (MODEL 906.6/7)

13

Screw

27

Cover (model 906.6/7)

E19/2

Right license plate lamp (MODEL 906.6/7)

14

Cable grommet (MODEL 906.6/7)

28

Sealant grommet (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

M6/10

Left rear door wiper motor (model 906.6/7 with code W78 (Window in liftgate or hinged rear door with wiper and washer system))

 Danger !

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

 Danger !

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 

Disassemble/assemble

1

Remove rear door (1)

AR72.20-D-1901F

2

Remove upper door trim (4) and lower door trim (22) from rear-end door (1)

Model 906.633
with code ZO1 (Camper James Cook Compact)
with code ZO2 (Camper James Cook Classic)Left rear door

AR72.20-S-6615JCB

Model 900
with code ZU1 (Minibus)

AR72.20-D-6615CH

Model 900.6
except code ZU1 (Minibus)
Model 906.6
except code ZO1 (Camper James Cook Compact)
except code ZO2 (Camper James Cook Classic)
Model 906.7

AR72.20-D-6615A

3

Pull off bellows (9)

4

Unclip bellows mount (8) on rear-end door (1) and remove

 Installation: Insert bellows mount (8) into bellows (9) before installing.

5

Remove center rear-end door seal (32) and check for damage

 Installation: First position center rear-end door seal (32) at top and bottom flush in relation to rear-end door (1) and then install from outside toward inside.

If center rear-end door seal (32) is damaged:



Replace center rear-end door seal (32).

6

Remove lock (15) with cables

AR72.20-D-4844A

7

Mark installation position of lock striker (24)

8

Remove locking eye (24) and stop buffer (19)

 Installation: Align lock striker (24) according to markings.

 Bolt, locking eye to body/left door

*BA72.20-N-1006-01C

9

Remove door catch (12)

 Bolt, door catch to rear-end door/body

*BA72.20-N-1002-01C

10

Remove upper hinge (6) and lower hinge (16) from rear-end door (1)

AR72.20-D-2650A

11

Remove left rear-end door wiper motor (M6/10)

Model 906.6/7
with code W78 (Window in tailgate or hinged rear door with wipe/wash system)

AR82.30-D-6551A

12.1

Remove cover (30)

Model 900
Model 906.6/7
except code W78 (Window in tailgate or hinged rear door with wipe/wash system)

12.2

Remove covering (30) with sealing grommet (28)

Model 906.6/7
with code W78 (Window in tailgate or hinged rear door with wipe/wash system)

13

Remove water fluid hose (34) for windshield wiper system from rear-end door (1)

Model 906.6/7
with code W78 (Window in tailgate or hinged rear door with wipe/wash system)

14

Remove rear window (31)

Model 900, 906.6/7
with code W61 (Window in tailgate / Rear hinged doors)

AR67.20-D-5145H

15

Remove cable grommet (7) for electrical wiring harness on rear window heater

Model 906.6/7
with code H22 (Back pane heatable)

16

Unclip left license plate lamp (E19/1) and right license plate lamp (E19/2) at outside of cover (27) and disconnect electrical connector

Model 906.6/7

17

Remove cover (27)

Model 906.6/7

18

Remove cable grommet (14) on wiring harness from left license plate lamp (E19/1) and right license plate lamp (E19/2)

Model 906.6/7

19

Remove rear license plate adapter plate

Model 900

AR88.50-D-5053CH

20

Remove electrical wiring harness from rear-end door (1)

21

Measure openings for pull-in nuts on rear school bus warning sticker and transfer to new rear-end door (1)

MODEL 906.657 with CODE PE4 (Mastercode Bus DCAA, Argen) rear school bus warning sticker or with CODE PE5 (Mastercode Bus platform seating, Argen) rear school bus warning sticker
When replacing rear-end door (1).

22

Drill openings and install pull-in nuts for rear school bus warning sticker

MODEL 906.657 with CODE PE4 (Mastercode Bus DCAA, Argen) rear school bus warning sticker or with CODE PE5 (Mastercode Bus platform seating, Argen) rear school bus warning sticker
When replacing rear-end door (1).

23

Assemble in the reverse order

 Tailgate

Number

Designation

Model 900

Model 906.6/7

BA72.20-N-1002-01C

Bolt, door catch to rear-end door/body

M6

Nm

9

9

 Tailgate

Number

Designation

Model 900

Model 906.6/7

BA72.20-N-1006-01C

Bolt, locking eye to body/left door

M8

Nm

20

20