B-Style 43.40.2.300/0 Build Manual Download Page 112

Page: 112 / 220

4340I300/1

112

17.

Installing the Diesel exhaust system (43.20.T.300)

Nbr. Qty.

Part number

Name

00.21.0.035

Pipe connector 42 mm

43.20.0.301

Replacement exhaust curve diesel

43.20.0.302

Replacement exhaust end tip

00.82.0.215

3th seatbelt bush 26mm

43.21.0.301

Rear exhaust support

43.21.0.302

Heatshield rear muffler

43.21.0.203

OEM Rubber

43.21.0.202

Exhaust bracket 3

43.21.0.303

Mid right exhaust support

00.03.0.196

Bolt M6x55 8.8-E DIN 931

00.03.0.818

Washer 3D M6 e

00.21.0.012

Exhaust clamp flat 46.7mm

00.21.0.015

Exhaust clamp 64.5 flat

01.03.0.238

Bolt flange without teeth M8x16 8.8-E DIN 6921

01.03.0.198

Bolt BHS flange M6x16 10.9-E ISO 7380

01.03.0.119

Rivet expanding ALU/ST 4,8x16

Summary of Contents for 43.40.2.300/0

Page 1: ...B style De Geerden 14 5334 LE Velddriel NL www b style eu Berlingo Rifter Combo L2 LOW FLOOR KIT 43 40 2 300 0 Build Manual 4340I300 1 16 12 2019...

Page 2: ...4340I300 1 2 Revision Sheet Revision Chapter Page numbers Date 1 Multiple Multiple 16 12 2019...

Page 3: ...cle is on a ramp while working because work on the underside of the vehicle is also required The vehicle must stand or hang flat on the ramp This is very important because the body can twist once the...

Page 4: ...8 Installing the rear beam 43 40 T 301 49 9 Installing middle frame brackets 43 40 T 201 54 10 Installing the shock absorber brackets 43 40 T 202 58 11 Installing the rear low floor 43 41 T 300 63 11...

Page 5: ...stalling taxi or folding tip ramp 43 44 2 300 43 44 2 304 168 25 1 Installing ramp 169 25 2 Installing gas strut 171 25 3 Installing anti vibration dampers 174 26 Installing 2nd seatrow 178 26 1 Insta...

Page 6: ...ka 206 G P Tighten all bolts with the right torque using the tightening specification table in the back of this manual Use a tool to mount the pop rivets Drill a hole or holes at the indicated places...

Page 7: ...gs shock absorbers 43 40 T 201 Middle beam brackets 01 03 0 240 M10x20 6x 43 40 0 201 2x 43 40 0 204 43 40 0 205 43 40 T 202 Shock absorber brackets 00 03 0 821 M10x60 2x 01 03 0 393 M12x1 5 2x 01 03...

Page 8: ...0 238 M8x16 8 8 4x 43 41 0 300 43 41 0 302 43 41 0 303 2x 43 46 T 300 43 46 T 301 43 40 T 301 Assembly rear beam RLF 00 03 0 038 M12x50 8 8 2x 00 03 0 092 5x12 St St 4x 00 03 0 165 M10x40 10 9 2x 00...

Page 9: ...14 4x 43 54 0 201 2x 43 54 0 207 43 54 0 210 43 80 T 301 Safety belt mounting point 01 03 0 423 4 8x50 4x 43 80 0 309 2x 43 82 T 102 Safety belt mounting point 00 03 0 584 M11 00 03 0 843 00 03 0 893...

Page 10: ...llowing Petrol or Diesel 43 23 2 300 Adaptation Diesel 43 20 T 300 Assembly exhaust system Diesel 00 03 0 196 M6x55 8 8 2x 00 03 0 818 M6 3D 3x 00 21 0 012 Exhaust clamp 46 7 mm 2x 00 21 0 015 Exhaust...

Page 11: ...0 M5 3D 00 03 0 860 4 8x25 00 03 0 878 M8x16 10 9 00 03 0 939 M8x25 10 9 8x 00 05 0 026 Clamp 40 mm 00 05 0 034 Hose clamp 19 28 3x 00 05 0 041 Hose clamp 50 65 3x 00 05 0 043 Hose clamp 38 50 3x 00 2...

Page 12: ...01 03 0 198 M6x16 10 9 6x 01 03 0 238 M8x16 8 8 2x 43 20 0 302 43 20 0 303 43 21 0 301 43 21 0 302 43 21 0 303 43 21 0 304 43 21 0 305 43 23 T 303 Assembly Petrol fuel tank 00 03 0 258 M6x20 8 8 4x 0...

Page 13: ...4x 43 41 0 305 43 41 0 306 Depending on type of ramp wanted Choose one of the following Taxi ramp or Folding tip 43 44 2 300 Ramp taxi 43 44 2 300 43 86 T 200 2x 43 44 T 303 01 03 0 370 M6x18 8 8 3x 4...

Page 14: ...0 300 43 44 0 310 00 44 0 100 01 03 0 238 M8x16 8 8 3x 00 03 0 724 M10 12x16 00 03 0 994 00 03 0 092 5x12 St St 5x 43 86 T 200 Anti vibration dampers FT 00 03 0 195 M6x50 8 8 2x 00 03 0 533 M6 4x 00 0...

Page 15: ...465 M6x16 10 9 12x 00 03 0 551 M6 6x 00 03 0 818 M6 3D 6x 00 07 0 904 9x11x16 00 05 0 937 5 8 x 14 4x 00 07 0 049 900 mm 43 54 0 002 4x 43 45 0 205 2x 43 54 0 207 43 54 0 210 43 54 0 301 43 54 0 303 4...

Page 16: ...43 80 0 307 43 80 0 308 00 82 2 104 Installation kit WTORS Optional 00 03 0 652 4 2x16 2x 00 03 0 762 4 2x19 3x 00 05 0 003 Cable base 5x 00 05 0 019 12mm 3x 00 07 0 212 00 60 0 003 1 5mm Brown 100cm...

Page 17: ...e vehicle equipped with 1 1 1 2nd row seating o 2nd seatrow right seat only 43 81 2 323 o 2nd seatrow no seat conversion 43 81 2 324 43 81 2 300 2nd seatrow 2 1 conversion 43 81 1 302 Assembly 2nd row...

Page 18: ...x1 6 43 81 1 303 Assembly 2nd row seating right seat 00 03 0 390 M8x20 12 9 3x 00 03 0 533 M6 00 03 0 804 M6x12 01 03 0 353 M10x30 10 9 01 03 0 417 43 81 0 311 43 81 0 319 43 81 0 320 43 81 0 322 43 8...

Page 19: ...ht seat 43 81 1 311 43 81 0 303 00 03 0 631 M8 3D 00 03 0 660 M8x16 10 9 01 03 0 421 M14x1 6 43 81 2 301 2nd seatrow 1 1 1 conversion 43 81 1 303 Assembly 2nd row seating right seat 00 03 0 390 M8x20...

Page 20: ...bly console right seat 00 03 0 390 M8x20 12 9 2x 43 81 0 312 43 81 0 314 43 81 T 318 Assembly seatbelt buckle right seat 43 81 1 311 43 81 0 303 00 03 0 631 M8 3D 00 03 0 660 M8x16 10 9 01 03 0 421 M1...

Page 21: ...t buckle middle seat 43 81 1 312 00 03 0 631 M8 3D 2x 01 03 0 421 M14x1 6 2x 00 03 0 660 M8x16 10 9 2x 43 81 1 305 Assembly 2nd row seating left seat 00 03 0 390 M8x20 12 9 3x 00 03 0 533 M6 00 03 0 8...

Page 22: ...1 03 0 422 12x14x11 2x 43 81 0 304 509900052 M10x16 10 9 43 81 T 316 Assembly left console 1 1 1 seat 00 03 0 390 M8x20 12 9 2x 43 81 0 312 43 81 0 323 43 81 T 320 Assembly seatbelt buckle left seat 4...

Page 23: ...8x20 12 9 3x 00 03 0 533 M6 00 03 0 804 M6x12 01 03 0 353 M10x30 10 9 01 03 0 417 43 81 0 311 43 81 0 318 43 81 0 320 43 81 0 322 43 81 0 327 150 mm 43 81 T 309 Assembly hinge point left seat 01 03 0...

Page 24: ...0 9 01 03 0 421 M14x1 6 43 81 2 322 2nd seatrow left and right seat only 43 81 0 208 43 81 0 210 43 81 0 310 2x 43 81 1 303 Assembly 2nd row seating right seat 00 03 0 390 M8x20 12 9 3x 00 03 0 533 M6...

Page 25: ...Assembly console right seat 00 03 0 390 M8x20 12 9 2x 43 81 0 312 43 81 0 314 43 81 T 318 Assembly seatbelt buckle right seat 43 81 1 311 43 81 0 303 00 03 0 631 M8 3D 00 03 0 660 M8x16 10 9 01 03 0 4...

Page 26: ...t seat 01 03 0 415 M10 12x12 2x 01 03 0 422 12x14x11 2x 43 81 0 304 509900052 M10x16 10 9 43 81 T 316 Assembly left console 1 1 1 seat 00 03 0 390 M8x20 12 9 2x 43 81 0 312 43 81 0 323 43 81 T 320 Ass...

Page 27: ...0 M8x20 12 9 3x 00 03 0 533 M6 00 03 0 804 M6x12 01 03 0 353 M10x30 10 9 01 03 0 417 43 81 0 311 43 81 0 319 43 81 0 320 43 81 0 322 43 81 0 327 150 mm 43 81 T 307 Assembly hinge point right seat 01 0...

Page 28: ...0 312 3rd seat row Depending on the ordered option you will receive the following Leather FLS seat Tunja cloth FLS seat Right side mounting 43 81 1 236 43 81 2 330 43 81 2 328 Left side mounting 43 81...

Page 29: ...81 1 326 Assembly 3rd row right seat mounting 00 03 0 286 M10x35 8 8 3x 00 03 0 554 M10 9x 00 03 0 568 M10 3D 13x 00 03 0 753 4 2x19 00 03 0 865 M10x35 10 9 43 81 0 340 43 81 0 342 43 81 0 344 43 81 0...

Page 30: ...579 M8 DIN125 4x 00 03 0 580 M10 DIN125 2x 43 40 M 301 43 40 M 302 4x 43 40 M 303 2x 43 40 M 305 43 40 M 306 43 40 M 307 43 54 M 200 43 54 M 201 43 80 M 301 Templates are not included in the kit If yo...

Page 31: ...red materials Glue primer anti corrosion package 00 05 2 001 Additional required materials are not included in the kit If you want to buy these products you can specify this on the purchase order or s...

Page 32: ...4340I300 1 32 5 Overview...

Page 33: ...Interior LED lighting 10 1 43 81 2 300 2nd seatrow 2 1 conversion 11 1 43 81 2 301 2nd seatrow 1 1 1 conversion 12 1 43 81 2 321 2nd seatrow left seat only 13 1 43 81 2 322 2nd seatrow left and right...

Page 34: ...e rear sill and the side panels over the wheel arches left and right Remove the carpet in the cargo area and underneath the 2nd row seat Disassemble the cargo securing rings 2 in the front and 2 in th...

Page 35: ...Remove the plugs from the frame rails left and right on the rear of the vehicle Right rear underside of vehicle Remove the plastic cover from the rear axle Remove the rear axle springs and shock abso...

Page 36: ...urn valve in the inlet of the tank It is advised to remove the diesel tank when almost empty or remove it with two people Remove the diesel tank Mark and disconnect the fuel lines and wiring loom duri...

Page 37: ...ts will be needed later NOTE the petrol tank cannot be fully drained because of the non return valve in the inlet of the tank It is advised to remove the petrol tank when almost empty or remove it wit...

Page 38: ...away from the body as possible Remove the wiring loom from the OEM floor and let it hang down at the point where it comes through the body Make sure the wiring loom will not be in the way when cuttin...

Page 39: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 40: ...M body 7 1 Cutting the floor without template set Cut the floor according the dimensions below with a circular saw Cut left and right Apply primer to all cut edges 1 Cut recess 29x6mm 2 Cut once 30mm...

Page 41: ...2 1x 4340M303 on top of each other on each side using M10 and M8 bolts Use template 4340M301 to mark a line for the front cut Cut the rear corners as shown below Cut left and right Apply primer to all...

Page 42: ...f the vehicle For right hand drive vehicles drill the next holes on the right hand side of the vehicle Drill one 12mm hole in the OEM floor as shown below on the left or right side The location of thi...

Page 43: ...to the drilled hole 7 4 Preparing body for 3rd seatrow consoles When the option 3rd row seating is bought Look at chapter 27 1 before continuing this chapter Drill hole on same side as before Measure...

Page 44: ...re the back of the vehicle cannot get out of alignment You can use tool 4340M305 out of the template set option When the back of the OEM body is secure remove the steel bumper Be sure to mark all cutt...

Page 45: ...all lines as shown o If this option is not bought mark only the outer lines 2x 450mm from the middle Be sure to cut around the marked mounting holes These should be attached to the outer corners of t...

Page 46: ...r corners Use template 1x 4354M200 and 1x 4354M201 first on the left side and then on the right side to mark the outer lines to cut Be sure to keep the mounting points attached to the outer corners o...

Page 47: ...ve all the existing body protection from the highlighted area s underneath the vehicle Make sure the surfaces are clean so that parts which will be mounted can lay flat against the metal of the OEM bo...

Page 48: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 49: ...earbeam R 4 1 43 40 0 305 Mudguard rearbeam L 5 2 43 40 0 201 Rearbeam framerail mounting plate 6 2 00 03 0 165 Bolt M10x40 10 9 G DIN 933 7 2 00 03 0 568 Washer 3D M10 E DIN9021 8 2 00 03 0 038 Bolt...

Page 50: ...0I300 1 50 00 03 0 038 M12x50 8 8 2x 00 03 0 704 M12 3D 2x 43 40 0 201 2x Use OEM bumper corners from chapter 7 5 and OEM bolts and washers Make sure the bumper corners are aligned with each other 80...

Page 51: ...an so that the rear beam will lay flat against the metal of the OEM body 00 03 0 165 M10x40 10 9 2x 00 03 0 568 M10 3D 2x 00 03 0 537 M12 2x 00 03 0 581 M12 2x 43 40 0 301 Rear beam should lay flat ag...

Page 52: ...860066 900 mm Remove the tool which holds the back sides in alignment as mentioned in chapter 7 5 43 40 0 306 00 03 0 092 5x12 St St 4x 43 40 0 305 After installing the lowered floor pop rivet the al...

Page 53: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 54: ...rackets 43 40 T 201 Nbr Qty Part number Name 1 6 01 03 0 240 Bolt flange without teeth M10x20 8 8E DIN 6921 2 2 43 40 0 201 Rear beam framerail mounting plate 3 1 43 40 0 204 Middle chassis bracket L...

Page 55: ...4340I300 1 55 43 40 0 201 2x Align with existing square hole left and right Place inside OEM chassis rail 1x left and 1x right...

Page 56: ...0I300 1 56 Left hand side right hand side 43 40 0 204 01 03 0 240 M10x20 6x 43 40 0 205 Assemble but not fully tighten the bolts yet Use 2 bolt here Use the other 4 bolt when installing the lowered fl...

Page 57: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 58: ...x60 12 9 D DIN 921 2 2 01 03 0 393 Nut flange M12 fine thread 3 2 01 03 0 408 Bolt flange M12x80 DIN 6921 fine thread 4 1 43 40 0 203 Rear beam shock absorber support L 5 1 43 40 0 207 Rear beam shock...

Page 59: ...upports as a template and make sure the supports are fully flush against the body Drill 2 holes 11mm in the OEM body and apply primer Tool 4340M307 can be used to drill a pilot hole in order to make s...

Page 60: ...3 40 0 210 2x Install shock absorber support including spacer and mounting plate on the left and right hand side of the chassis Use Loctite Tool 4340M307 can be used to drill a pilot hole in order to...

Page 61: ...4340I300 1 61 01 03 0 393 M12 2x 01 03 0 408 M12x1 5x80 10 9 2x Install bolt and nut when installing the shock absorber Close all seams around the support with sealant...

Page 62: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 63: ...3 RLF front support bracket 4 31 00 03 0 092 Rivet 5x12 st st 5 4 01 03 0 238 Bolt flange without teeth M8x16 8 8 E DIN 6921 6 4 01 03 0 240 Bolt flange without teeth M10x20 8 8 E DIN 6921 7 8 00 03 0...

Page 64: ...t the bottom and at the top It should be 820mm Make sure the lowered floor is in the middle of the OEM body and in the right length position the rear contour of the lowered floor should follow the OEM...

Page 65: ...4340I300 1 65 Template set 43 40 2 302 optional can be used to keep the flanges of the low floor at the correct width while drilling the holes for installation...

Page 66: ...y using the existing holes in the Low Floor 43 41 0 300 as a template top flanges and front flange Mark 4x threaded holes in the front of the low floor on the OEM body Remove the low floor and drill t...

Page 67: ...e vehicle after installation Clean the areas that need to be sealed Apply etching primer to any bare metal with the supplied brush 00 05 0 504 Apply the sealant to the specified areas in red Finish th...

Page 68: ...led holes in the OEM body and around the cut edges Apply glue to the top of the domes with the 5mm drilled holes Apply glue to the rear of the low floor which comes in contact with the rear beam Apply...

Page 69: ...00 03 0 092 5x12 St St 21x 43 41 0 300 00 03 0 092 5x12 St St 4x 00 03 0 940 M10x20 10 9 4x 43 41 0 302 Place the low floor in the OEM body as explained before and pop rivet it in place 21x Clamp down...

Page 70: ...6 8 8 4x 43 41 0 303 2x Mount the supports with the 2 bolts Left and Right Make sure the supports touches the OEM body Drill 3x hole 5mm Primer the bare metal of the holes Rivet the support to the OEM...

Page 71: ...4340I300 1 71 00 03 0 092 5x12 St St 5x 43 44 0 325 Attach reinforcement plate of the light weight function of the tailgate to the righter outside of the lowered floor Pop rivet from inside out...

Page 72: ...43 40 0 305 00 05 0 759 2x 43 46 T 300 00 03 0 820 M5 3D 8x 43 46 T 301 Install the aluminum covers on the rear beam Install the covers left and right They need a little bit of adjustment Install lock...

Page 73: ...floor over each other in a continuous radius Make sure the oval hole is still usable On the underside and rear of the low floor use sealant to close all gaps and corners where water could get inside t...

Page 74: ...ront threaded inserts in the low floor and the hole for the wheelchair seatbelt with tape When the Body protection spray is dry treat all cavities with wax Spray the whole underside of the low floor w...

Page 75: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 76: ...ame 1 1 00 03 0 002 Bolt 7 16 x1 1 4 UNF h e W 0071 2 2 00 03 0 005 Nut 7 16 UNF W 0331 3 2 00 03 0 584 Washer M11 7 16 E DIN 125 4 1 00 03 0 893 Bolt 7 16x2 1 2 E DIN931 5 1 52 81 0 011 spacer univer...

Page 77: ...4340I300 1 77 00 03 0 893 7 16x2 1 2 00 03 0 584 M11 1x 52 81 0 011 00 03 0 552 7 16 1x 00 03 0 552 7 16 1x 00 03 0 584 M11 1x 00 03 0 002 7 16x1 1 4 Install after finishing the interior 55 Nm 55 Nm...

Page 78: ...12 2 Safety belt mounting point 43 81 T 102 Nbr Qty Part number Name 1 1 00 03 0 584 Washer M11 e 2 1 00 03 0 843 Platenut 7 16 3 1 00 03 0 893 Bolt 7 16 x2 1 2 UNF h e 4 1 00 82 0 143 3th seatbelt co...

Page 79: ...I300 1 79 00 03 0 843 00 82 0 143 00 03 0 584 M11 00 03 0 893 7 16x2 1 2 Loosen grommet Insert the plate nut through this hole with a magnet Install other parts including the top seatbelt loop point 5...

Page 80: ...ional Mushroom 2 Optional Wheelchair retractor 3 2 00 03 0 055 Bolt HCS M10x45 8 8 S DIN 912 4 2 01 03 0 391 Bolt HCS M10x55 12 9 E DIN 912 5 2 00 03 0 554 Nut lock M10 E DIN985 6 10 00 03 0 568 Washe...

Page 81: ...chorage after the interior is finished Fill in the space between part 43 82 0 200 and the optional mushroom with M10 washers so that these parts are flat against each other Install the front retractor...

Page 82: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 83: ...he OEM wire loom through the left console for the 2nd row seating Position the wiring loom on the front lip of the low floor as low as possible Make sure the brown and black double wires are on the le...

Page 84: ...the front using the cable protection and the OEM line clamps Remove the underbody protection plate underneath the engine for better access in the front Lay the red wire with protection on the inside...

Page 85: ...the fuse housing securely as close as possible to the power supply Install the fuse after finishing all the wiring Lay the red black and brown wire of the wiring loom to the back side of the vehicle L...

Page 86: ...142 Connectors for switch red black brown Connect as shown Drill a hole with positioning recess for the switch in the interior rear side panel as shown right panel shown Install interior panel when f...

Page 87: ...4340I300 1 87 00 60 0 003 1 5mm Brown 100cm 400863 Point for wiring exit to magnetic switch in rear bumper Install the magnetic switch in the bumper covers as shown in chapter 14...

Page 88: ...d install components as shown before Connect all components according the wiring diagram below For installing the LED interior lights see chapter 23 Make sure a double wire is laid next to the top fla...

Page 89: ...4340I300 1 89 13 3 Wiring diagram WTORS set without interior LED light Lay the wiring loom and install components as shown before Connect all components according the wiring diagram below...

Page 90: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 91: ...1 2 00 03 0 258 Bolt M6x20 8 8 E DIN 933 2 4 00 03 0 551 Locknut M6 e 3 2 00 03 0 648 Bolt BHS M6x16 10 9 E ISO 7380 4 6 00 03 0 818 Washer 3D M6 e 5 4 00 05 0 937 Barbed push pin hole 5mm 6 2 43 54 0...

Page 92: ...x 00 03 0 648 M6x16 2x 00 03 0 818 M6 3D 2x 00 03 0 551 M6 2x Install the bumper support on the steel OEM bumper corners at the previously drilled hole on both sides L R Install the OEM bumper corners...

Page 93: ...pendicular and there is 890mm between them If the kit comes with the option of middle bumper assembly 43 54 2 300 perform this task in chapter 24 Drill a 4mm hole on the top and bottom lip to secure i...

Page 94: ...4340I300 1 94 Peugeot Rifter only Additional adjustments needed Cut away the additional bumper strip to make the bumper cover fit Or position the bumper cover over this bumper strip...

Page 95: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 96: ...in the bumper and write down the cable colors Write down which wire in the PDC connector goes to which wire in the PDC sensor Cut the wires for the middle two sensors and extend these with about 5 me...

Page 97: ...4340I300 1 97 Bumper connector PDC sensors Left PDC sensor Right PDC sensor Middle two PDC sensors Extension cable to middle two PDC sensors...

Page 98: ...4340I300 1 98 For installation of the middle bumper see chapter 24...

Page 99: ...______________________________________________________________ _____________________________________________________________________________________________ ___________________________________________...

Page 100: ...4340I300 1 100 16 Installing the Diesel fuel tank 43 23 T 302...

Page 101: ...pipe 10 2 43 23 0 202 Underride protection mounting plate 11 1 43 40 0 303 Underride protection Diesel 12 4 00 03 0 568 Washer 3D M10 E DIN9021 13 3 00 03 0 203 Bolt M8x50 8 8 E DIN 931 14 8 00 03 0 9...

Page 102: ...4340I300 1 102 16 1 Preparing components Ad Blue tank Shorten support on the Ad Blue tank until 12mm is left by cutting at the same angle 12mm...

Page 103: ...300 1 103 Diesel tank Enlarge the diameter of these mounting points to 14mm for easier mounting If not done already cut the filler pipe 60mm from shown surface Clean all debris out of the filler neck...

Page 104: ...4340I300 1 104 Filler neck Cut the top hose 140mm from the white support Cut the lower filler neck 80mm from the white support Clean all debris out of the filler neck...

Page 105: ...4340I300 1 105 16 1 Installing components 43 23 0 303 43 23 0 301 43 23 0 302 Install the tank mounting consoles 3x Use OEM tank mounting nuts M8 Do not fully tighten this support yet...

Page 106: ...43 23 0 203 3x Re connect the hose on top of the Ad Blue tank mount the tank to the consoles and lay the wire harness as shown Look for the alignment of the left console and tighten all bolts and nut...

Page 107: ...ect the fuel hoses on top and on the right front side and mount the fuel tank to the supports Install the diesel fuel tank Re connect the wiring loom and secure it Make sure the wiring loom cannot com...

Page 108: ...201 00 05 0 034 Hose clamp 19 28 3x 00 24 0 046 22 mm 90 Install the shown parts to re connect the Diesel filler neck to the diesel tank Install the shown parts to re connect the Ad Blue filler neck t...

Page 109: ...amp 40 mm Secure the Diesel filler neck to the body as shown Place clamp Max 50mm from center of black plug Use M8 nut as spacer between body and clamp Re connect the aeration hose on top of the Ad Bl...

Page 110: ...3 0 551 M6 2x 00 03 0 939 M8x25 10 9 4x 00 03 0 878 M8x16 10 9 43 40 0 303 Insert the Underride protection mounting plates in the chassis rails left and right Remove 2 bolts which hold the heat shield...

Page 111: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 112: ...exhaust support 6 1 43 21 0 302 Heatshield rear muffler 7 1 43 21 0 203 OEM Rubber 8 1 43 21 0 202 Exhaust bracket 3 9 1 43 21 0 303 Mid right exhaust support 10 2 00 03 0 196 Bolt M6x55 8 8 E DIN 931...

Page 113: ...4340I300 1 113 17 1 Cutting the exhaust Measure and mark the cutting lines as shown below Cut the exhaust in 4 pieces Deburr the two sections which will be used...

Page 114: ...1 Installing the exhaust 43 21 0 302 01 03 0 198 M6x16 10 9 6x 43 21 0 301 01 03 0 238 M8x16 8 8 2x 43 21 0 303 Install the heatshield Install the 2 exhaust supports Look for the D when installing the...

Page 115: ...M6x55 8 8 2x 00 21 0 035 Pipe connector 42 mm Install the 2 spacers between the OEM middle exhaust support and the body Install the exhaust pipe connector Use OEM exhaust section B Do not fully tight...

Page 116: ...aust clamp 64 5 mm 00 21 0 012 Exhaust clamp 46 7 mm 1x Use OEM exhaust section C Make sure the muffler exhaust section C is mounted horizontal and that there is 40mm between the low floor and the exh...

Page 117: ...1 117 01 03 0 119 4 8x16 ALU 00 03 0 818 M6 3D 1x To prevent vibration fasten the heatshields of the bottom of the vehicle to the heatshield of the fuel tank Install the skid plate as explained in cha...

Page 118: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 119: ...tection Petrol 3 2 43 23 0 202 Underride protection mounting plate 4 6 00 03 0 728 Bolt flange M8x20 10 9 G DIN 6921 5 1 01 03 0 405 Sleeve nut M8 L 17 steel zinc plated 6 3 00 03 0 568 Washer M10 E D...

Page 120: ...ing components See next page for more information Prepare the Petrol fuel tank as shown and on the next page Remove the top console Cut away top of the clamp Shorten the supports Assemble the supports...

Page 121: ...4340I300 1 121 Drill the holes and cut the supports as shown...

Page 122: ...4340I300 1 122 00 03 0 258 M6x20 8 8 4x 00 03 0 551 M6 4x 00 03 0 577 M6 8x Install the cut supports with the new hole pattern...

Page 123: ...405 00 03 0 568 M10 3D 3x 00 03 0 728 M8x20 10 9 2x Position the spacers over the indicated threaded studs Use a bit of glue to hold them in place until installing the Petrol Fuel tank Install the fu...

Page 124: ...3D 2x 00 03 0 551 M6 2x 00 03 0 728 M8x20 10 9 4x 43 40 0 304 Insert the Underride protection mounting plates in the chassis rails left and right Remove 2 bolts which hold the heat shield Mount the s...

Page 125: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 126: ...1 3 6 01 03 0 198 Bolt BHS flange M6x16 10 9 E ISO 7380 4 1 43 20 0 303 Replacement exhaust curve petrol 5 1 43 20 0 302 Replacement exhaust end tip 6 1 00 21 0 034 Pipe connector bi 50mm length 80mm...

Page 127: ...4340I300 1 127 19 1 Cutting the exhaust Measure and mark the cutting lines as shown below Cut the exhaust in 4 pieces Deburr the two sections which will be used...

Page 128: ...2 Installing the exhaust 43 21 0 302 01 03 0 198 M6x16 10 9 6x 43 21 0 301 01 03 0 238 M8x16 8 8 2x 43 21 0 303 Install the heatshield Install the 2 exhaust supports Look for the B when installing the...

Page 129: ...3 21 0 305 43 20 0 303 00 21 0 026 Exhaust clamp 54 5 mm 1x Install the exhaust pipe connector Use OEM exhaust section B Do not fully tighten the exhaust pipe connector yet This makes alignment easier...

Page 130: ...st Use OEM exhaust section C Make sure the muffler exhaust section C is mounted horizontal and that there is 20mm between the low floor and the exhaust curve over the rear axle The exhaust end tip is...

Page 131: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 132: ...d if they have a inconsistent resistance over the entire length while extending De aerating the shock absorbers is done in 2 steps that need to be repeated until the shock absorber doesn t show any mo...

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Page 141: ...21 Installing Support plate set 43 41 2 301 optional Nbr Qty Part number Name 1 1 43 41 0 301 RLF bottom support plate 2 4 43 41 0 304 Shimplate A 2mm 3 2 43 41 0 305 Shimplate B 2mm 4 1 43 41 0 306 S...

Page 142: ...4x 43 41 0 305 43 41 0 306 Glue the aluminum plate to the steel low floor Align the front holes and recesses Position the shim plates in the recesses underneath the seating rails installed later Seat...

Page 143: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 144: ...2 1 43 80 0 302 RLF interior front cover profile 3 1 43 80 0 303 RLF interior front left cover profile 4 1 43 80 0 304 RLF interior front right cover profile 5 2 43 80 0 305 RLF interior middle cover...

Page 145: ...l Make sure the top consoles of the 3rd seat row are installed See chapter 27 2 43 80 0 306 2x 01 03 0 221 4x10 Inox 8x Install the two outer seat consoles Depending on the configuration chosen 135mm...

Page 146: ...front carpet underneath the 2nd row seat and cut it in to shape like shown L R Re install L R the OEM side panels panels around the back windows covers from the C D pillars the cargo securing rings 2...

Page 147: ...with sealant for every spot where a filler block is placed to reduce noise Please use the table below Ordered 2nd seating row option To be installed filler blocks 43 81 0 310 marked in red 43 81 2 30...

Page 148: ...e it in to place starting in the front Cut out the strips in the front of the low floor depending where no filler blocks are placed and 2x 34mm around the front wheelchair anchorage points and 8x 17mm...

Page 149: ...4340I300 1 149 Remove the foam on the inside of the rear sill 35mm Mark and cut the contour as shown L R Try cut around the OEM mounting point Mark and cut a notch on the inside 30 x 15mm...

Page 150: ...4340I300 1 150 Install the rear sill corners in the vehicle Cut the excess of Vinyl Seal the corners with sealant...

Page 151: ...ox 4x Install the sliding rails from the 2nd row seat configuration Check where the rails should be installed in chapter 26 Do not yet install the most front bolt Align the front cover with the slidin...

Page 152: ...4340I300 1 152 43 80 0 304 01 03 0 221 4x10 Inox 6x 43 80 0 303 Right front shown Align the front corners L R with the front cover Drill 4mm holes Rivet the front covers 1 2 3 4 5 L R...

Page 153: ...0 Inox 6x 43 80 0 307 Clamp the side covers over the support profiles L R Drill 4mm holes Rivet the side covers L R Align the rear corners over the rear sill and side covers L R Drill 4mm holes Rivet...

Page 154: ...340I300 1 154 43 80 0 309 2x 01 03 0 423 4 8x50 4x Install the covers over the holes in the carpet Watch out for the wiring loom underneath the carpet Fasten the seatbelts of the 2nd row seating 64 Nm...

Page 155: ...43 46 T 301 Install locking plates L R Install front and rear wheelchair retractors as shown in 12 3 Make sure the retractors make steel to steel contact and are installed flush Install the wheelchair...

Page 156: ...________________________ _____________________________________________________________________________________________ _________________________________________________________________________________...

Page 157: ...I300 1 157 23 Installing interior LED light 43 64 2 300 optional Nbr Qty Part number Name 1 1 00 07 0 011 Grommet 6 4x9 5mm 2 3 01 03 0 279 Screw self drill 3 5x13 3 1 00 64 0 088 Upholstery lighting...

Page 158: ...4340I300 1 158 00 07 0 011 6 4x9 5 00 64 0 088 01 03 0 279 3x 3 5x13 Connect wire to the relay as shown in chapter 13 2...

Page 159: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 160: ...6 00 03 0 551 Locknut M6 e 4 6 00 03 0 818 Washer 3D M6 e 5 4 00 05 0 937 Barbed push pin hole 5mm 6 4 43 54 0 002 Mounting plate bumper fixation 7 1 43 54 0 301 Mounting plate rear hatch rubber 8 1...

Page 161: ...l rear bumper Set of bumper covers Mark the center of the bumper middle section and cut it into width On top remove the foam 220mm on each side of the center 220mm 220mm For the magnetic switch drill...

Page 162: ...side tailgate 43 54 0 303 00 03 0 465 M6x16 10 9 6x 43 54 0 002 4x Use tape to protect the underside of the rear hatch mark the center Use part 43 54 0 303 as a template to drill 8mm holes Make sure i...

Page 163: ...1x16 00 03 0 092 5x12 St St 4x 00 07 0 049 900 mm Mount part 43 54 0 301 over the support plate and against the rear hatch Drill 4x 5mm for the rivets Drill 1x 10mm for the grommet to guide through th...

Page 164: ...usly installed bumper corners Mark and drill 6x 8mm and install the middle bumper Install the OEM bumper middle part on the OEM steel middle bumper Use the bottom supports and glue the top to the supp...

Page 165: ...bumper with 2x 00 05 0 937 Fit the bumper covers over the OEM middle bumper Make sure they are parallel to the outer and there is about 5mm between them If the W tors kit is provided optional install...

Page 166: ...4340I300 1 166 Peugeot Rifter only Additional adjustments needed Cut away the additional bumper strip to make the bumper cover fit Or position the bumper cover over this bumper strip...

Page 167: ...4340I300 1 167 43 45 0 205 2x Replace OEM gas struts...

Page 168: ...p 43 44 2 300 43 44 2 304 43 44 2 300 Ramp taxi 43 44 2 300 43 86 T 200 2x 43 44 T 303 01 03 0 370 M6x18 8 8 3x 43 44 2 304 Ramp folding tip 43 44 2 304 43 86 T 200 2x 43 44 T 303 01 03 0 370 M6x18 8...

Page 169: ...4340I300 1 169 25 1 Installing ramp 00 03 0 994 2x 00 03 0 724 M10 12x16 2x Close the ramp Add or remove shims to find the right angle in which the OEM rear hatch closes nicely...

Page 170: ...4340I300 1 170 Re install the OEM rear hatch lock catcher on top of the tailgate Use the OEM bolts Adjust the locking plates so that the Locking pin and spring plunger are aligned L R...

Page 171: ...4340I300 1 171 25 2 Installing gas strut 43 44 0 310 01 03 0 370 M6x18 8 8 3x 43 44 0 207 01 03 0 238 M8x16 8 8 1x Do not fully tighten the bolt yet...

Page 172: ...1 172 00 44 0 100 00 03 0 994 00 03 0 724 M10 12x16 01 03 0 238 M8x16 8 8 2x Attach gas strut to ramp Install bearing and bolt Use an wrench to rotate the bracket to put tension in the gas strut 46 N...

Page 173: ...4340I300 1 173 If the gas strut is too strong for the wheelchair ramp you can release pressure by pressing the air valve Use a pop rivet in the gas strut rod to open the air valve...

Page 174: ...25 3 Installing anti vibration dampers The rubber dampers should touch on the side edges of the ramp Mark these edges on the steel frame of the OEM rear hatch as high as possible Drill 2 holes 6 5mm o...

Page 175: ...4340I300 1 175 00 03 0 195 M6x50 8 8 1x 00 03 0 533 M6 1x 00 03 0 551 M6 2x 00 03 0 818 M6 3D 2x L R...

Page 176: ...ng the interior panel It is shown without it for a better view of the assembly 00 07 0 033 00 03 0 533 M6 1x 00 03 0 890 M6 2x Drill 2 holes 6 5mm in the interior panel corresponding the bolts in the...

Page 177: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 178: ...d seatrow Nbr Qty Part number Chapter 1 1 43 81 T 302 See chapter 26 1 2 1 43 81 T 303 See chapter 26 2 Nbr Qty Part number Chapter 1 1 43 81 T 303 See chapter 26 2 2 1 43 81 T 304 See chapter 26 3 3...

Page 179: ...ench 6 3 43 81 0 311 Seat floor rail long 7 3 43 81 0 327 Seat floor rail cover 8 1 43 81 0 318 Weld assembly backrest locking left 9 1 00 03 0 804 Adjustable fork M6x12 10 1 01 03 0 417 Steel spring...

Page 180: ...4340I300 1 180 26 1 1 Preparing components Remove bench supports Remove metal bearing from right seatbelt buckle set only...

Page 181: ...4340I300 1 181 26 1 2 Installing components 00 03 0 467 M6x25 8 8 2x 43 81 0 316 43 81 0 315 Assemble left console and install at the OEM position with OEM bolts 64 Nm...

Page 182: ...0 43 81 0 303 01 03 0 421 M14x1 6 00 03 0 631 M8 3D 00 03 0 660 M8x16 10 9 Assemble the OEM seatbelt buckle set with the OEM components Assemble the OEM seatbelt buckle without bearing from chapter 26...

Page 183: ...4340I300 1 183 00 03 0 390 M8x20 12 9 3x Place the frame in the floor rails from the front Install the front bolts to fasten the rails 39 Nm...

Page 184: ...4340I300 1 184 43 81 0 327 450 mm Cut cover profile to length 3x 135mm Make incisions for the bolt heads...

Page 185: ...5 01 03 0 353 M10x30 10 9 43 81 0 318 43 81 0 320 00 03 0 804 M6x12 1x 00 03 0 533 M6 43 81 0 322 01 03 0 417 Install components to OEM backrest lock Left side is shown Install clip on the OEM interio...

Page 186: ...4340I300 1 186 509900052 M10x16 10 9 2x 43 81 0 304 2x 01 03 0 422 12x14x11 2x 01 03 0 415 M10 12x12 2x Install hinge plates on inside of bench leg L R Only use bearing if OEM bearing is damaged...

Page 187: ...t 4 1 43 81 0 311 Seat floor rail long 5 1 43 81 0 327 Seat floor rail cover 6 1 43 81 0 319 Weld assembly backrest locking right 7 1 43 81 0 320 Weld assembly clamp plate 8 1 43 81 0 322 Weld assembl...

Page 188: ...4340I300 1 188 26 2 1 Preparing components Remove seat supports Remove metal bearing from right seatbelt buckle set only...

Page 189: ...00 03 0 390 M8x20 12 9 2x 43 81 0 312 43 81 0 314 Assemble right console and install at the OEM position with OEM bolts Make sure these 2 rails are close to parallel to each other If not use spacing r...

Page 190: ...4340I300 1 190 00 03 0 660 M8x16 10 9 00 03 0 631 M8 3D 01 03 0 421 M14x1 6 43 81 0 303 43 81 1 311 Assemble the OEM seatbelt buckle without bearing from chapter 26 2 1 RED 32 Nm...

Page 191: ...4340I300 1 191 00 03 0 390 M8x20 12 9 2x Place the frame in the floor rails from the front Install the front bolts to fasten the rails 39 Nm...

Page 192: ...4340I300 1 192 43 81 0 327 150 mm Cut cover profile to length 1x 135mm Make incisions for the bolt heads...

Page 193: ...93 43 81 0 320 43 81 0 319 01 03 0 353 M10x30 10 9 00 03 0 804 M6x12 00 03 0 533 M6 43 81 0 322 01 03 0 417 Install components to OEM backrest lock Right side is shown Install clip on the OEM interior...

Page 194: ...4340I300 1 194 509900052 M10x16 10 9 43 81 0 304 01 03 0 422 12x14x11 2x 01 03 0 415 M10 12x12 2x Install hinge plates on inside of bench leg L R Only use bearing if OEM bearing is damaged...

Page 195: ...T 308 Assembly hinge point middle seat 2 1 43 81 T 319 Assembly seatbelt buckle middle seat 3 2 43 81 0 311 Seat floor rail long 4 2 43 81 0 327 Seat floor rail cover 5 1 00 46 0 119 Indexing plunger...

Page 196: ...4340I300 1 196 26 3 1 Preparing components Remove metal bearing from middle seatbelt buckle set...

Page 197: ...nd right Which are welded to the hinges Use a power file Be careful NOT to damage the OEM round locking mechanism Remove the surplus welds so the original shape of the studs is left Remove the paint i...

Page 198: ...4340I300 1 198 26 3 2 Installing components 00 03 0 660 M8x16 10 9 2x 00 03 0 631 M8 3D 2x 01 03 0 421 M14x1 6 2x 43 81 1 312 RED BLACK 32 Nm...

Page 199: ...4340I300 1 199 00 03 0 390 M8x20 12 9 2x Place the frame in the floor rails from the front and tighten the bolts M8 4x Install the front bolts to fasten the rails 39 Nm...

Page 200: ...4340I300 1 200 43 81 0 327 2x150 mm Cut cover profile to length 1x 135mm Make incisions for the bolt heads...

Page 201: ...eat 4 1 43 81 0 311 Seat floor rail long 5 1 43 81 0 327 Seat floor rail cover 6 1 43 81 0 318 Weld assembly backrest locking left 7 1 00 03 0 804 Adjustable fork M6x12 8 1 01 03 0 417 Steel spring cl...

Page 202: ...4340I300 1 202 26 4 1 Preparing components Remove seat supports Remove metal bearing from left seatbelt buckle set only...

Page 203: ...00 03 0 390 M8x20 12 9 2x 43 81 0 312 43 81 0 323 Assemble right console and install at the OEM position with OEM bolts Make sure these 2 rails are close to parallel to each other If not use spacing r...

Page 204: ...4340I300 1 204 43 81 1 313 43 81 0 303 01 03 0 421 M14x1 6 00 03 0 631 M8 3D 00 03 0 660 M8x16 10 9 Assemble the OEM seatbelt buckle without bearing from chapter RED 32 Nm...

Page 205: ...4340I300 1 205 00 03 0 390 M8x20 12 9 2x Place the frame in the floor rails from the front 39 Nm Install the front bolts to fasten the rails...

Page 206: ...4340I300 1 206 43 81 0 327 150 mm Cut cover profile to length 1x 135mm Make incisions for the bolt heads...

Page 207: ...07 01 03 0 353 M10x30 10 9 43 81 0 318 43 81 0 320 00 03 0 804 M6x12 00 03 0 533 M6 43 81 0 322 01 03 0 417 Install components to OEM backrest lock Left side is shown Install clip on the OEM interior...

Page 208: ...4340I300 1 208 01 03 0 422 12x14x11 2x 43 81 0 304 509900052 M10x16 10 9 01 03 0 415 M10 12x12 2x Install hinge plates on inside of bench leg L R Only use bearing if OEM bearing is damaged...

Page 209: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 210: ...9021 4 1 00 03 0 753 Screw self drill flange 4 2x19 B PH2 5 1 00 03 0 865 Bolt CHS M10x35 10 9 E DIN 7991 6 1 43 81 0 340 3rd row base frame right 1 43 81 0 341 3rd row base frame left 7 1 43 81 0 342...

Page 211: ...install the 3rd row seating consoles The right hand side is used for explaining the installation For left hand side the part numbers are also mentioned Flatten the shown lip of the OEM reinforcement...

Page 212: ...212 43 81 0 342 Right 43 81 0 343 Left 00 03 0 568 M10 3D 2x 00 03 0 554 M10 2x Use the console as template for drilling the holes in the OEM floor Drill 4x 11mm Install the bracket Do not tighten th...

Page 213: ...ith the installation of the low floor Chapter 7 5 00 03 0 865 M10x35 10 9 00 03 0 286 M10x35 8 8 3x 00 03 0 568 M10 3D 4x 00 03 0 554 M10 65 81 0 304 64 Nm 46 Nm Drill 4x 16mm holes in the horizontal...

Page 214: ...22 43 81 0 345 43 81 0 344 00 03 0 568 M10 3D 6x 00 03 0 554 M10 6x Install the spacer plate and the seat console Exact position can be adjusted when installing the interior 64 Nm The right hand side...

Page 215: ...unja cloth seat left 43 81 2 328 Tunja cloth seat right 43 81 2 329 Leather seat left 43 81 2 330 Leather seat right 00 03 0 022 M10x100 10 9 3x FLS Seat 3 5mm 64 Nm The right hand side is used for ex...

Page 216: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 217: ...4340I300 1 217 28 Tightening torque in Nm Size Quality 8 8 10 9 12 9 100 M 4 2 7 3 8 4 6 M 5 5 5 8 9 5 10 M 6 9 5 13 16 18 M 8 23 32 39 37 M 10 46 64 77 80 M 12 80 110 135 120...

Page 218: ..._______________________________________________________________ _____________________________________________________________________________________________ __________________________________________...

Page 219: ...4340I300 1 219 29 Warranty sticker Note For future service issues and questions you should put the ID sticker in the b pillar of the vehicle...

Page 220: ...ave been removed Check that everything has been properly finished Lowered floor Check if the bolts and nuts from the springs are tightened on torque Check if the thread from the bolts comes wide enoug...

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