2006 MERCEDES-BENZ SPRINTER Service Manual

four wheel drive lug pattern seat memory spark plugs radio air bleeding

Page 2009 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 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 DIAGNOS

Page 2010 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual TOP COVER
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 DI

TOP COVER
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.
²WHEN REMOVING A DEPLOYED AIRBAG, RUB-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
²USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
²THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove radio. (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - REMOVAL)
(3) Remove passenger airbag. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER AIRBAG -
REMOVAL)
(4) Remove screws and remove passenger side air
nozzle cover. (Fig. 25)(5) Remove accessory switch bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/ACCESSORY
SWITCH BEZEL - REMOVAL)
(6) Remove a-pillar trim. (Refer to 23 - BODY/IN-
TERIOR/A-PILLAR TRIM - REMOVAL)
(7) Remove speaker covers. (Fig. 26)
(8) Remove screw and bracket.
(9) Remove lower screws.
(10) Remove upper screws.
(11) Pull top cover toward rear and remove.
Fig. 25 PASSENGER SIDE AIR NOZZLE COVER
1 - FRONT SCREWS (2)
2 - BRACKET
3 - BRACKET SCREWS
4 - NOZZLE COVER
5 - INSTRUMENT PANEL
VAINSTRUMENT PANEL 23 - 67

Page 2011 of 2305

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.
²WHEN REMOVING A DEPLOYED AIRBAG, RUB-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
²USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHIONAND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
²THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Position top cover and slide toward front of
vehicle.
NOTE: Observe cable routing for radio: The leads
should not be located above the air duct.
(2) Install upper and lower screws.
(3) Install screw and bracket.
(4) Position speaker covers and seat fully.
(5) Install a-pillar trim. (Refer to 23 - BODY/IN-
TERIOR/A-PILLAR TRIM - INSTALLATION)
(6) Install accessory switch bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/ACCESSORY
SWITCH BEZEL - INSTALLATION)
(7) Install passenger side air nozzle cover and
bracket and install the screws.
(8) Install passenger airbag. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER AIRBAG -
INSTALLATION)
(9) Install radio. (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - INSTALLATION)
(10) Connect battery negative cable.
STEERING COLUMN OPENING
COVER
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. 26 INSTRUMENT PANEL TOP COVER
1 - SPEAKER COVERS (2)
2 - CENTER NOZZLE COVER
3 - INSTRUMENT PANEL TOP COVER
4 - TOP SCREWS (6)
5 - BRACKET/SCREW
6 - LOWER SCREWS (2)
23 - 68 INSTRUMENT PANELVA

Page 2012 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (1) Twist cover lock 1/4 turn and remove Power
Distribution Center cover. (Fig. 27)
(2) Remove nut and screws and remove steering
column shroud. (Fig. 28)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WI

Page 2013 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION.............................70
A-PILLAR TRIM
REMOVAL.............................70
INSTALLATION.........................71
ASSIST HANDLE
REMOVAL.

Page 2014 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 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

Page 2015 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 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) Instal

Page 2016 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 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.
(

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.
VAINTERIOR 23 - 73

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