2005 MERCEDES-BENZ SPRINTER Service Repair Manual

INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION.............................67
A-PILLAR TRIM
REMOVAL.............................67
INSTALLATION.........................68
ASSIST HANDLE
REMOVAL.............................68
INSTALLATION.........................68
B-PILLAR TRIM
REMOVAL.............................68
INSTALLATION.........................69
BULKHEAD TRIM PANEL
REMOVAL.............................69
INSTALLATION.........................69
CARPETS AND FLOOR MATS
REMOVAL.............................69
INSTALLATION.........................70
COWL TRIM
REMOVAL.............................70
INSTALLATION.........................70
D-PILLAR TRIM
REMOVAL.............................70INSTALLATION.........................70
HEADLINER
REMOVAL.............................70
INSTALLATION.........................71
QUARTER TRIM PANEL
REMOVAL.............................71
INSTALLATION.........................72
REAR VIEW MIRROR
REMOVAL.............................72
INSTALLATION
INSTALLATION.......................72
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET...................72
STEPWELL SCUFF PADS
REMOVAL.............................72
INSTALLATION.........................73
SUN VISOR
REMOVAL.............................73
INSTALLATION.........................73
INTERIOR
CAUTION
CAUTION:: Do not attempt to remove interior trim
panels/moldings without first removing the neces-
sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
A-PILLAR TRIM
REMOVAL
(1) Using a trim stick C-4755 or equivalent, sepa-
rate the top of the a-pillar trim.
(2) Pull top of a-pillar trim out and pull trim up
and remove. (Fig. 1)
Fig. 1 A-PILLAR TRIM
1 - A-PILLAR
2 - TRIM PANEL
VAINTERIOR 23 - 67

(3) Remove the four screws and remove the foam
trim support. (Fig. 2)
INSTALLATION
(1) Install the foam support and install the screws.
(2) Install the a-pillar trim bottom and push the
top in toward a-pillar.
(3) Seat the retaining clips fully.
ASSIST HANDLE
REMOVAL
(1) Hold the handle in the down position and
remove the screws. (Fig. 3)
INSTALLATION
(1) Install the handle and install the screws.
B-PILLAR TRIM
REMOVAL
(1) Remove the lower seat belt anchor bolt. (Fig. 4)
(2) Pull door opening weatherstrip away from
flange along the b-pillar. (Fig. 5)
(3) Using a trim stick C-4755 or equivalent,
release the trim clips and remove the trim. (Fig. 6)
Fig. 2 A-PILLAR SUPPORT FOAM
1 - SUPPORT FOAM
2 - SCREWS (4)
Fig. 3 ASSIST HANDLE
1 - SCREWS (2)
2 - ASSIST HANDLE
Fig. 4 Front Seat Belt Lower Anchor
1 - FRONT SEAT BELT
2 - COVER AND/OR SCREW
23 - 68 INTERIORVA
A-PILLAR TRIM (Continued)

INSTALLATION
(1) Route the seat belt through the trim and
mount the trim panel.
(2) Seat the mounting clips fully.
(3) Position the door opening weatherstrip back
along the mounting flange.
(4) Install the seat belt and mounting bolt.
(5) Tighten the bolt to 35 N´m (26 ft. lbs.).
BULKHEAD TRIM PANEL
REMOVAL
(1) Remove the rivets and remove the lower panel.
(Fig. 7)
(2) Remove the rivets and remove the upper panel.
INSTALLATION
(1) Install the upper panel and replace rivets.
(2) Install the lower panel and replace rivets.
CARPETS AND FLOOR MATS
REMOVAL
Cargo/Passenger Van - Front
(1) Remove the stepwell scuff pads. (Refer to 23 -
BODY/INTERIOR/STEPWELL SCUFF PADS -
REMOVAL)
(2) Remove the three bolts and tray behind drivers
seat.
(3) Remove cup holder. (Refer to 23 - BODY/IN-
STRUMENT PANEL/CUP HOLDER - REMOVAL)
(4) Remove the jack storage cover.
(5) Remove carpet/mat.
Passenger Van - Rear
(1) Remove seats. (Refer to 23 - BODY/SEATS/
SEAT - REAR - REMOVAL)
(2) Remove the screws and retaining strips.
(3) Remove the seat striker assemblies.
(4) Remove carpet/mat.
Fig. 5 B-PILLAR TRIM
1 - FRONT DOOR WEATHERSTRIP
2 - B-PILLAR
3 - B-PILLAR TRIM
Fig. 6 B-PILLAR TRIM MOUNTING CLIPS
1 - RETAINING CLIPS (5)
2 - B-PILLAR TRIM
Fig. 7 BULKHEAD TRIM PANEL
1 - RIVETS
2 - UPPER PANEL
3 - PANEL GLASS
4 - LOWER PANEL
VAINTERIOR 23 - 69
B-PILLAR TRIM (Continued)

Cargo Van - Rear
(1) Remove the screws and retaining strips.
(2) Remove carpet/mat.
INSTALLATION
Cargo/Passenger Van - Front
(1) Position carpet/mat in vehicle.
(2) Install the jack storage cover.
(3) Install the cup holder. (Refer to 23 - BODY/IN-
STRUMENT PANEL/CUP HOLDER - INSTALLA-
TION)
(4) Install the tray behind the driver's seat and
install the three bolts.
(5) Install the stepwell scuff pads. (Refer to 23 -
BODY/INTERIOR/STEPWELL SCUFF PADS -
INSTALLATION)
Passenger Van - Rear
(1) Position carpet/mat in vehicle.
(2) Install the seat striker assemblies.
(3) Install the retaining strips and screws.
(4) Install the seats. (Refer to 23 - BODY/SEATS/
SEAT - INSTALLATION)
Cargo Van - Rear
(1) Position carpet/mat in vehicle.
(2) Install the retaining strips and screws.
COWL TRIM
REMOVAL
(1) Position door weatherstrip aside.
(2) Remove the jack storage cover, if necessary.
(3) Position aside carpet/mat, if necessary.
(4) Using a trim stick C-4755 or equivalent,
remove the cowl trim panel.
INSTALLATION
(1) Position the cowl trim panel and seat the clips
fully.
(2) Install the jack storage cover, if necessary.
(3) Position the carpet/mat back.
(4) Position the door weatherstrips back.
D-PILLAR TRIM
REMOVAL
(1) Remove the three plastic twist screws and
remove the panel.
INSTALLATION
(1) Install the panel and install the three twist
screws.
HEADLINER
REMOVAL
Cab Section
(1) Remove the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - REMOVAL)
(2) Remove the sun visors. (Refer to 23 - BODY/
INTERIOR/SUN VISOR - REMOVAL)
(3) Remove the b-pillar trim. (Refer to 23 - BODY/
INTERIOR/B-PILLAR TRIM - REMOVAL)
(4) Remove the assist handle. (Refer to 23 - BODY/
INTERIOR/ASSIST HANDLE - REMOVAL)
(5) Remove the dome light. (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - INTERIOR/CARGO
LAMP UNIT - REMOVAL)
(6) Carefully separate the headliner and remove.
Number 2 Section
(1) Disconnect and isolate battery negative cable.
(2) Remove the second and third row seats. (Refer
to 23 - BODY/SEATS/SEAT - REAR - REMOVAL)
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(3) Remove the push pin fasteners and remove the
rear air front duct cover.
(4) Disconnect the electrical connector at front of
cover.
(5) Remove the push pin fasteners and remove the
rear air middle duct cover.
(6) Disconnect the electrical connector.
(7) Remove the three push-pins and three screws
and remove the rear air cover.
(8) Remove the duct work.
(9) Release clips at front and rear of headliner and
remove.
Number 3 Section
(1) Disconnect and isolate battery negative cable.
(2) Remove the third and fourth row seats. (Refer
to 23 - BODY/SEATS/SEAT - REAR - REMOVAL)
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(3) Remove the push pin fasteners and remove the
rear air front duct cover.
(4) Disconnect the electrical connector at front of
cover.
(5) Remove the push pin fasteners and remove the
rear air middle duct cover.
(6) Disconnect the electrical connector.
(7) Remove the three push-pins and three screws
and remove the rear air cover.
(8) Remove the duct work.
23 - 70 INTERIORVA
CARPETS AND FLOOR MATS (Continued)

(9) Release clips at front and rear of headliner and
remove.
Number 4 Section
(1) Disconnect and isolate battery negative cable.
(2) Remove the third and fourth row seats. (Refer
to 23 - BODY/SEATS/SEAT - REAR - REMOVAL)
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(3) Remove the push pin fasteners and remove the
rear air front duct cover.
(4) Disconnect the electrical connector at front of
cover.
(5) Remove the push pin fasteners and remove the
rear air middle duct cover.
(6) Disconnect the electrical connector.
(7) Remove the three push-pins and three screws
and remove the rear air cover.
(8) Remove the duct work.
(9) Release clips at front and rear of headliner and
remove.
INSTALLATION
Cab Section
(1) Position the headliner in vehicle and seat fully.
(2) Install dome light. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - INTERIOR/CARGO LAMP
UNIT - INSTALLATION)
(3) Install assist handle. (Refer to 23 - BODY/IN-
TERIOR/ASSIST HANDLE - INSTALLATION)
(4) Install b-pillar trim. (Refer to 23 - BODY/IN-
TERIOR/B-PILLAR TRIM - INSTALLATION)
(5) Install the sun visors. (Refer to 23 - BODY/IN-
TERIOR/SUN VISOR - INSTALLATION)
(6) Install the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION)
(7) Connect battery negative cable.
Number 2 Section
(1) Position the headliner in vehicle and seat fully.
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(2) Install rear air unit duct work.
(3) Install the rear air unit rear cover and install
the three screws and push-pins.
(4) Connect the electrical connector and install the
middle duct work cover.
(5) Install the push pin fasteners.
(6) Connect the electrical connector and install the
front duct work cover.
(7) Install the push pin fasteners.(8) Install the second and third row seats. (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Connect battery negative cable.
Number 3 Section
(1) Position the headliner in vehicle and seat fully.
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(2) Install rear air unit duct work.
(3) Install the rear air unit rear cover and install
the three screws and push-pins.
(4) Connect the electrical connector and install the
middle duct work cover.
(5) Install the push pin fasteners.
(6) Connect the electrical connector and install the
front duct work cover.
(7) Install the push pin fasteners.
(8) Install the third and fourth row seats. (Refer to
23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Connect battery negative cable.
Number 4 Section
(1) Position the headliner in vehicle and seat fully.
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(2) Install rear air unit duct work.
(3) Install the rear air unit rear cover and install
the three screws and push-pins.
(4) Connect the electrical connector and install the
middle duct work cover.
(5) Install the push pin fasteners.
(6) Connect the electrical connector and install the
front duct work cover.
(7) Install the push pin fasteners.
(8) Install the third and fourth row seats. (Refer to
23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Connect battery negative cable.
QUARTER TRIM PANEL
REMOVAL
Passenger Van
(1) Remove seats as necessary. (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL)
(2) Remove d-pillar trim if necessary. (Refer to 23 -
BODY/INTERIOR/D-PILLAR TRIM - REMOVAL)
(3) Using a trim stick C-4755 or equivalent, sepa-
rate the push-pin fasteners and remove trim panels.
VAINTERIOR 23 - 71
HEADLINER (Continued)

Cargo Van
(1) Remove bolts and remove tie down rings, if
equipped.
(2) Remove rivets and remove paneling
INSTALLATION
Passenger Van
(1) Position trim panels and seat push-pin fasten-
ers fully.
(2) Install d-pillar trim, if necessary. (Refer to 23 -
BODY/INTERIOR/D-PILLAR TRIM - INSTALLA-
TION)
(3) Install seats, if necessary. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
Cargo Van
(1) Install paneling and replace rivets.
(2) Install tie down rings and bolts, if equipped.
REAR VIEW MIRROR
REMOVAL
(1) Slide mirror off support bracket.
INSTALLATION
INSTALLATION
(1) Install the support bracket if necessary. (Refer
to 23 - BODY/INTERIOR/REAR VIEW MIRROR -
INSTALLATION - SUPPORT BRACKET)
(2) Slide mirror onto support bracket fully.
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET
(1) Mark the position for the mirror bracket on the
outside of the windshield glass with a wax pencil.
(2) Clean the bracket contact area on the glass.
Use a mild powdered cleanser on a cloth saturated
with isopropyl (rubbing) alcohol. Finally, clean the
glass with a paper towel dampened with alcohol.
(3) Sand the surface on the support bracket with
fine grit-sandpaper. Wipe the bracket surface clean
with a paper towel.
(4) Apply accelerator to the surface on the bracket
according to the following instructions:
(a) Crush the vial to saturate the felt applicator.
(b) Remove the paper sleeve.
(c) Apply accelerator to the contact surface on
the bracket.
(d) Allow the accelerator to dry for five minutes.
(e) Do not touch the bracket contact surface
after the accelerator has been applied.(5) Apply adhesive accelerator to the bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute. Do not touch the glass
contact surface after the accelerator has been
applied.
(6) Install the bracket according to the following
instructions:
(a) Apply one drop of adhesive at the center of
the bracket contact-surface on the windshield
glass.
(b) Apply an even coat of adhesive to the contact
surface on the bracket.
(c) Align the bracket with the marked position
on the windshield glass.
(d) Press and hold the bracket in place for at
least one minute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Allow the adhesive to cure for 8-10 minutes.
Remove any excess adhesive with an alcohol-damp-
ened cloth.
(8) Allow the adhesive to cure for an additional
8-10 minutes before installing the mirror.
STEPWELL SCUFF PADS
REMOVAL
(1) Remove screws and remove seat bracket if nec-
essary.
(2) Remove trim plugs and screws. (Fig. 8) and
(Fig. 9)
(3) Remove stepwell scuffs.
Fig. 8 STEPWELL SCUFF PADS
1 - TRIM PLUGS
2 - STEPWELL
23 - 72 INTERIORVA
QUARTER TRIM PANEL (Continued)

INSTALLATION
(1) Install scuff pad and install the screws.
(2) Install the trim plugs.
(3) Install the seat bracket, if necessary.
SUN VISOR
REMOVAL
(1) Remove the support screws and remove the
visor. (Fig. 10)
INSTALLATION
(1) Position visor and support on header.
(2) Install the screws.
Fig. 9 SLIDING DOOR SCUFF PAD
1 - TRIM PLUGS
2 - SCREWS (5)
3 - SCUFF PAD
Fig. 10 SUN VISOR
1 - SUN VISOR
2 - SCREWS
3 - SUPPORTS (2)
VAINTERIOR 23 - 73
STEPWELL SCUFF PADS (Continued)

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES..........74
BASECOAT/CLEARCOAT FINISH
DESCRIPTION.........................74
PAINT TOUCH-UP
DESCRIPTION.........................74STANDARD PROCEDURE - PAINT TOUCH-UP . 75
FINESSE SANDING/BUFFING & POLISH
DESCRIPTION.........................75
PAINT
SPECIFICATIONS - PAINT CODES
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Steel Blue MB 5389
Brilliant Blue MB 5362
Orchid Green MB 6464
Flame Red MB 3534
Arctic White MB 9147
Black Blue MB 7103
Calcite Yellow MB 1234
Piedmont Red MB 3636
Hycanith Blue MB 5376
Black Gray MB 7103
Stone Gray MB 7160
Silver Gray MB 7708
BASECOAT/CLEARCOAT
FINISH
DESCRIPTION
The original equipment finish is a multi step pro-
cess that involves cleaning, applying electro de-posi-tion (E-coat), anti-chip primer, basecoat, and
clearcoat steps.
On most vehicles a two-part paint application
(basecoat/clearcoat) is used. Color paint that is
applied to primer is called basecoat. The clear coat
protects the basecoat from ultraviolet light and pro-
vides a durable high-gloss finish.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents
on painted surfaces. Damage to finish or color can
result.
PAINT TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-
ble to avoid corrosion. For best results, use MOPARt
Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat.
WARNING: USE AN OSHA APPROVED RESPIRATOR
AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
INJURY CAN RESULT.
23 - 74 PAINTVA