2005 MERCEDES-BENZ SPRINTER wheel

RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC
PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITELURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENETERLURAN9A9PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVINDOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUNDBMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMERSURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDEMPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLONFENDERS, QUARTER
PANELS
PET THERMOPLASTIC
POLYESTERRYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATEPBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOYBEXLOY,9M9, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PCTAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSEDOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPOINTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/
POLYAMIDPPO/PA, GTX 910 FENDERS, QUARTER
PANELS
PR/FV FIBERGLASS REINFORCED
PLASTICFIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUNDRTM BODY PANELS
SMC SHEET MOLDED
COMPOUNDSMC BODY PANELS
23 - 4 BODYVA
BODY (Continued)

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
TMC TRANSFER MOLDING
COMPOUNDTMC GRILLES
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
RRIM REINFORCED REACTION
INJECTED MOLDEDPUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGSBUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE,
POLYESTERTPU, HYTREL, TEXIN,
ESTANEBUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
VABODY 23 - 5
BODY (Continued)

²The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
damage part to its original strength and appearance
without exceeding the value of the replacement part.
²When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.
VISUAL INSPECTION
Composite materials can mask the severity of an
accident. Adhesive bond lines, interior structure of
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close
inspection may require partial removal of interior
trim or inner panels.
Identify the type of repair: Puncture or Crack -
Damage that has penetrated completely through the
panel. Damage is confined to one general area; a
panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must
be bonded from behind (Fig. 7) (Fig. 6).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area mustbe stopped or removed. To stop a running crack in a
panel, drilla6mm(0.250 in.) hole at the end of the
crack farthest away from the damage. If spider web
cracks can not be stopped, the panel would require
replacement. The surfaces around the damaged area
should be stripped of paint and freed from wax and
oil. Scuff surfaces around repair area with 360 grit
wet/dry sandpaper, or equivalent, to assure adhesion
of repair materials.
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have
access to the back of the panel to install a patch.
Bevel edges of cutout at 20 degrees to expose a larger
bonding area on the outer side. This will allow for an
increased reinforcement areas.
PANEL PATCH FABRICATIONS
A patch can be fabricated from any rigid fiberglass
panel that has comparable contour with the repair
area. Lift gates and fenders can be used to supply
patch material. If existing material is not available
or compatible, a patch can be constructed with adhe-
sive and reinforcement mesh (dry wall tape). Perform
the following operation if required:
(1) Cover waxed paper or plastic with adhesive
backed nylon mesh (dry wall tape) larger than the
patch required (Fig. 8).
(2) Tape waxed paper or plastic sheet with mesh to
a surface that has a compatible contour to the repair
area.
Fig. 4 BEVELING ANGLE - 20 DEGREE
Fig. 5 FIBERGLASS TAPE
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
VABODY 23 - 7
BODY (Continued)

LATCH RELEASE HANDLE
REMOVAL
(1) Remove the screws and remove the release
handle.
(2) Disconnect the cable from handle.
INSTALLATION
(1) Connect latch cable to release handle.
(2) Install handle and install the screws.
PROP ROD
REMOVAL
(1) Open and support hood.
(2) Remove the prop rod retaining clip. (Fig. 1)
(3) Separate the prop and spring from the hood.
(4) Remove nut and position the washer bottle
aside. (Fig. 4)
(5)
Remove stud nut and remove hood prop. (Fig. 5)
INSTALLATION
(1) Install hood prop and install the stud nut.
(2) Position washer bottle back and install the nut
and washer.
(3) Connect spring and prop onto hood and install
the retaining spring.
SAFETY LATCH
REMOVAL
(1) Open hood.
(2) Using a grease pencil or equivalent, mark the
position of the safety latch to aid installation.(3) Remove the bolts and remove the latch. (Fig. 6)
INSTALLATION
(1) Install the latch and install the bolts.
(2) Adjust the latch if necessary. (Refer to 23 -
BODY/HOOD/HOOD - ADJUSTMENTS)
Fig. 4 Washer Reservoir Remove/Install
1 - RIGHT INNER FENDER
2 - WASHER RESERVOIR
3 - NUT & WASHER
4 - ROUTING CLIP
Fig. 5 Washer Reservoir Mounting
1 - RIGHT INNER FENDER
2 - STUD NUT
3 - DASH PANEL
4 - RIGHT FRONT WHEEL HOUSE
5 - GROMMET (2)
6 - HOOD PROP
Fig. 6 SAFETY LATCH
1 - SAFETY LATCH
2 - BOLTS
23 - 52 HOODVA

INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL.............................53
INSTALLATION.........................54
ACCESSORY SWITCH BEZEL
REMOVAL.............................54
INSTALLATION.........................54
INSTRUMENT PANEL CENTER BEZEL
REMOVAL.............................55
INSTALLATION.........................55
ASH RECEIVER
REMOVAL.............................55
INSTALLATION.........................55
CUP HOLDER
REMOVAL.............................55
INSTALLATION.........................56
GLOVE BOX
REMOVAL.............................56INSTALLATION.........................56
INSTRUMENT PANEL ASSEMBLY
REMOVAL.............................57
INSTALLATION.........................61
TOP COVER - CLUSTER
REMOVAL.............................62
INSTALLATION.........................62
TOP COVER - TRAY
REMOVAL.............................63
INSTALLATION.........................64
TOP COVER
REMOVAL.............................64
INSTALLATION.........................65
STEERING COLUMN OPENING COVER
REMOVAL.............................66
INSTALLATION.........................66
CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Unscrew screws. (Fig. 1)
(3) Using a trim stick C-4755 or equivalent, sepa-
rate cover.
(4) Disconnect electrical connectors and remove
bezel.
Fig. 1 CLUSTER BEZEL
1 - CLUSTER BEZEL
2 - SCREWS (2)
3 - ELECTRICAL CONNECTOR
4 - ELECTRICAL CONNECTORS
VAINSTRUMENT PANEL 23 - 53

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Connect the electrical connectors.
(2) Position cluster bezel into place and seat clips
fully.
(3) Install screws.
(4) Connect battery negative cable.
ACCESSORY SWITCH BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Move selector lever to position9D9.
(2) Using a trim stick C-4755 or equivalent,
remove shift lever frame trim. (Fig. 2)
(3) Using a trim stick C-4755 or equivalent,
remove storage compartment.
(4) Remove ashtray.
(5) Remove screw and using a trim stick C-4755 or
equivalent, remove bezel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position bezel and seat clips fully.
(2) Install screw.
(3) Install ashtray.
(4) Install storage compartment.
(5) Install shift lever trim.
Fig. 2 ACCESSORY SWITCH BEZEL
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - ACCESSORY SWITCH BEZEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
23 - 54 INSTRUMENT PANELVA
CLUSTER BEZEL (Continued)

INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove accessory switch bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/ACCESSORY
SWITCH BEZEL - REMOVAL)
(2) Remove the screws and using a trim stick
C-4755 or equivalent, remove bezel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install the bezel and install the screws.
(2) Install the accessory switch bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/ACCESSORY
SWITCH BEZEL - INSTALLATION)
ASH RECEIVER
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Open ash receiver and remove two screws.
(3) Pull out ash receiver and disconnect electrical
connector.
(4) Remove ash receiver.
INSTALLATION
(1) Connect electrical connector.
(2) Install ash receiver and install the two screws.
(3) Connect battery negative cable.
CUP HOLDER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Fig. 3 INSTRUMENT PANEL CENTER BEZEL
1 - SCREWS (4)
2 - BEZEL
VAINSTRUMENT PANEL 23 - 55

(1) Remove rubber mat from both cup holders.
(2) Unscrew screws (1) and remove cup holder top
section (2). (Fig. 4)
(3) Remove vent hose (1). (Fig. 5)
(4) Unscrew bolts (2) and remove cup holder bot-
tom section (3) from cab floor.INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install bottom section and install the bolts.
(2) Install vent hose.
(3) Install top section and install the screws.
(4) Install rubber mats.
GLOVE BOX
REMOVAL
(1) Open glove box and remove the screws. (Fig. 6)
(2) Remove glove box and disconnect electrical con-
nector.
INSTALLATION
(1)Connect electrical connector and install glove box.
(2) Install three screws.
Fig. 4 CUP HOLDER
1 - SCREWS
2 - CUPHOLDER
Fig. 5 CUP HOLDER BOTTOM
1 - VENT HOSE
2 - BOLTS (4)
3 - BOTTOM SECTION
Fig. 6 GLOVE BOX
1 - SCREWS (3)
2 - GLOVE BOX DOOR
23 - 56 INSTRUMENT PANELVA
CUP HOLDER (Continued)