2006 MERCEDES-BENZ SPRINTER light

described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL ± BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN
RESULT.AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL ± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING / BUFFING
& POLISH
DESCRIPTION
CAUTION: Do not remove more than.5 mils of
clearcoat finish, if equipped. Basecoat paint must
retain clearcoat for durability.
Use a Paint Thickness Gauge #PR-ETG-2X or equiv-
alent to determine film thickness before and after
the repair.
Minor acid etching, orange peel, or smudging in
clearcoat or single-stage finishes can be reduced with
light finesse sanding, hand buffing, and polishing.If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
23 - 78 PAINTVA

(4) Disconnect the electrical connectors, if
equipped.
INSTALLATION
(1) Position seat in vehicle and connect the electri-
cal connectors, if equipped.
(2) Install the mounting bolts and tighten to 25
N´m (18 ft. lbs.).
(3) Install the seat belt anchor and bolt.
(4) Tighten anchor bolt to 35 N´m (26 ft. lbs.).
(5) Connect battery negative cable.
SEAT BACK - FRONT
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove seat cushion. (Refer to 23 - BODY/
SEATS/SEAT CUSHION - FRONT - REMOVAL)
(3) Verify that seat back is in full upright position.
(4) Disconnect lumbar support hose, if equipped.
(Fig. 3)
(5) Remove seat back bolts and remove seat
back.
INSTALLATION
(1) Remove stop screw.
(2) Install seat back locking spline side first.
NOTE: For better centering of seat back in the
mounting bore during installation, operate the seat
back release lever once.
(3) Install the spline side seat back bolt.
(4) Install remaining seat back side.
NOTE: It may be necessary to press the guide tabs
apart slightly.
(5) Install the remaining seat back bolt.
(6) Tighten the seat back bolts to 20 N´m (15 ft.
lbs.).
(7) Place seat back in the foremost position until
the hold down spring latches audibly.
(8) Install stop bolt and tighten to 20 N´m (15 ft.
lbs.).
(9) Connect the lumbar support hose, if equipped.
(10) Check seat back operation.
(11) Install the seat cushion. (Refer to 23 - BODY/
SEATS/SEAT CUSHION - FRONT - INSTALLA-
TION)
SEAT CUSHION - FRONT
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Move seat to the foremost position.
(3) On standard cushion equipped vehicles, remove
the front two screws. (Fig. 4)
Fig. 2 FRONT SEAT
1 - SEAT BELT ANCHOR BOLT
2 - BOLTS (6)
Fig. 3 FRONT SEAT BACK
1 - SEAT BACK
2 - STOP BOLT
3 - LUMBAR SUPPORT HOSE
4 - GUIDE TAB
5 - RELEASE LEVER
6 - SEAT BACK BOLTS (2)
23 - 80 SEATSVA

(2) Position windshield seal onto windshield start-
ing at one corner and quickly moving up and down.
(Fig. 7)
CAUTION: Never moisten windshield seal with lubri-
cants to facilitate installation.
(3) Position windshield in center of windshield
opening.
(4) Apply adhesive tape to the locations shown to
aid with final installation. (Fig. 8)(5) Verify windshield gap is parallel to with wind-
shield.
(6) Cut tape with a sharp knife and remove wind-
shield.
(7) Clean and dry area of glass to be re-glued with
a suitable glass preparation solvent and rag.
(8) Using a flash light, verify that glass primer is
without damage.
(9) Re-prime any damaged area. If old adhesive
has been exposed for more than 12 hours, entire
adhesive area needs to be re-primed. (Fig. 9)
(10) Allow primer to air dry for at least 10 min-
utes.
(11) Using a flash light, verify that glass primer is
without damage.
Fig. 6 WINDSHIELD ADHESIVE PREPARATION
1 - WINDSHIELD
2 - SCRAPER
3 - OLD ADHESIVE
Fig. 7 WINDSHIELD SEAL INSTALLATION
1 - WINDSHIELD
2 - WINDSHIELD SEAL
Fig. 8 WINDSHIELD POSITIONING
1 - TAPE
2 - WINDSHIELD FRAME
Fig. 9 WINDSHIELD PRIMER
1 - PRIMER
2 - WINDSHIELD SEAL
VASTATIONARY GLASS 23 - 87

Windshield Preparation - Installing A New Wind-
shield
(1) Clean and check windshield for damage.
(2) Position windshield seal onto windshield start-
ing at one corner and quickly moving up and down.
(Fig. 7)
CAUTION: Never moisten windshield seal with lubri-
cants to facilitate installation.
(3) Position windshield in center of windshield
opening.
(4) Apply adhesive tape to the locations shown to
aid with final installation. (Fig. 8)
(5) Verify windshield gap is parallel to with wind-
shield.
(6) Cut tape with a sharp knife and remove wind-
shield.
(7) Clean and dry area of glass to be glued with a
suitable glass preparation solvent and rag.
(8) Apply primer to gluing surface at windshield
seal. (Fig. 9)
(9) Allow primer to air dry for at least 10 minutes.
(10) Using a flash light, verify that glass primer is
without damage.
Windshield Opening Preparation
(1) Clean and vacuum windshield opening.
(2) Level old bead of windshield opening adhesive
to a thickness of approximately 1 mm (0.04 in.) and
remove loose adhesive. (Fig. 10)
(3) Clean and dry area of windshield opening to be
re-glued with a suitable glass preparation solvent
and rag.
(4) Re-prime any damaged area. If old adhesive
has been exposed for more than 12 hours, entire
adhesive area needs to be re-primed. (Fig. 11)(5) Allow primer to air dry for at least 10 minutes.
Windshield Installation
(1) Apply bead of glue with a triangular nozzle
directly to the windshield seal starting at bottom in
center of windshield. (Fig. 12)
CAUTION: Always apply bead of adhesive to the
windshield. Always install the windshield within 5
minutes after applying adhesive.
(2) Allow end of adhesive bead to run out parallel
to the start of the bead and smooth ends flush. (Fig.
13)
Fig. 10 WINDSHIELD OPENING PREPARATION
1 - OLD ADHESIVE
2 - SCRAPER
3 - WINDSHIELD OPENING
Fig. 11 WINDSHIELD OPENING PRIMER
1 - PRIMER
2 - WINDSHIELD OPENING
Fig. 12 WINDSHIELD ADHESIVE APPLICATION
1 - ADHESIVE BEAD
2 - WINDSHIELD SEAL
23 - 88 STATIONARY GLASSVA

Condition Possible Causes Correction
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.1. Low refrigerant system
charge.1. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
2. Refrigerant flow through the
A/C evaporator is restricted.2. See A/C Evaporator in this group. Replace
the restricted A/C evaporator, if required.
3. Faulty A/C compressor. 3. See A/C Compressor in this group. Re-
place the A/C compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.1. A/C condenser air flow re-
stricted.1. Check the A/C condenser for damaged
fins, foreign objects obstructing air flow
through the condenser fins, and missing or
improperly installed air seals. Clean, repair, or
replace components as required.
2. Refrigerant flow through the
receiver/drier is restricted.2. See Receiver/Drier in this group. Replace
the restricted receiver/drier, if required.
3. Inoperative radiator cooling
fan.3. Test the radiator cooling fan and replace, if
required. Refer to Group 7 - Cooling.
4. Refrigerant system over-
charged.4. See Refrigerant System Charge in this
group. Recover the refrigerant from the refrig-
erant system. Charge the refrigerant system
to the proper level, if required.
5. Air in the refrigerant system. 5. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
6. Engine overheating. 6. Test the engine cooling system and repair,
if required. Refer to Group 7 - Cooling.
The low side pressure is too
high, and the high side pres-
sure is too low.1. Accessory drive belt slip-
ping.1. Inspect the accessory drive belt condition
and tension. Repair as required. Refer to
Group 7 - Cooling.
2. Faulty A/C expansion valve. 2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Faulty A/C compressor. 3. See A/C Compressor in this group. Re-
place the A/C compressor, if required.
The low side pressure is too
low, and the high side pres-
sure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid Line, Suction Line and Dis-
charge Line in this group. Inspect the refriger-
ant lines for kinks, tight bends or improper
routing. Correct the routing or replace the re-
frigerant line, if required.
2. Restricted refrigerant flow
through the A/C expansion
valve.2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Restricted refrigerant flow
through the A/C condenser.3. See A/C Condenser in this group. Replace
the restricted A/C condenser, if required.
HEATER PERFORMANCE TEST
Before performing the following tests, perform the
ATC Function Test using the DRBIIItand refer to
Cooling for the procedures to check the radiator cool-
ant level, serpentine drive belt tension, radiator air
flow and the radiator fan operation.
MAXIMUM HEATER OUTPUT
Engine coolant is provided to the heater core
through a heater valve and heater hose. With the
engine idling at normal operating temperature, set
the heater-A/C controls as follows:
²Temperature control in the full hot position
VAHEATING & AIR CONDITIONING 24 - 5

²Mode control in the floor heat position
²Blower motor control in the highest speed posi-
tion
Using a test thermometer, check the temperature
of the air being discharged at the floor outlets. Com-pare the test thermometer reading to the Tempera-
ture Reference chart.
TEMPERATURE REFERENCE CHART
Ambient Temperature Minimum Floor Outlet Temperature
Celsius Fahreheit Celsius Fahreheit
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
If the floor outlet air temperature is insufficient,
check for a faulty heater valve (perform ATC Func-
tion Test) and verify that the cooling system is oper-
ating to specifications (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS AND TESTING).
Both of the heater hoses should be HOT to the touch
(the coolant return heater hose should be slightly
cooler than the supply hose. If the coolant return
hose is much cooler than the supply hose, locate and
repair the engine coolant flow obstruction in the
heater system.
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²Inoperative or stuck heater water valve.
²Plugged heater core.
If proper coolant flow is verified, and heater floor
outlet air temperature is insufficient, a mechanical
problem may exist.
POSSIBLE LOCATIONS OR CAUSE OF INSUFFI-
CIENT HEAT
²An obstructed cowl air intake.
²Obstructed heater system outlets.
²Heater water valve not functioning properly.
TEMPERATURE CONTROL
If outlet air temperature cannot be adjusted with
the A/C-heater temperature control, one of the follow-
ing could require service:
²Faulty A/C-heater control switch.
²Faulty temperature sensor.²Faulty A/C-heater control cable or actuator.
²Faulty A/C-heater control module.
ATC FUNCTION TEST
The automatic temperature control (ATC) system
can perform an self-test, which can be activated by
the DRBIIItscan tool to confirm that the A/C system
is performing satisfactorily. This test provides a
quick confirmation of heating and A/C system perfor-
mance to the service technician. Refer to Body Diag-
nostic Procedures for the appropriate diagnostic
information.
SPECIFICATIONS
HEATING-A/CSYSTEM
FRONT A/C SYSTEM
Item Description Notes
A/C Compres-
sorDenso 7SBU16C ND-8 PAG oil
Freeze-up Con-
trolEvaporator tem-
perature sensorHVAC hous-
ing mounted -
input to A/C-
heater control
- operating
range of -10É
C (14É F) to
40É C (104É
F)
24 - 6 HEATING & AIR CONDITIONINGVA

(6) Tap the clutch plate lightly with a plastic mal-
let to release it from the splines on the compressor
shaft. Remove the clutch plate and shim(s) from the
compressor shaft (Fig. 3).Be certain not to lose
the shim or shims.
CAUTION: Do not pry between the clutch plate and
the pulley to remove it from the compressor shaft.
Prying may damage the clutch plate.
(7) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the compressor clutch pulley to the front of
the compressor, then slide the pulley off of the com-
pressor (Fig. 4).(8) Remove the screw that secures the clutch coil
wire harness connector bracket and ground clip to
the top of the compressor housing.
(9) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the compressor clutch coil to the front of the
compressor, then slide the clutch coil off of the com-
pressor (Fig. 5).
Fig. 2 Compressor Shaft Bolt and Clutch Plate
1 - COMPRESSOR CLUTCH PLATE
2 - COMPRESSOR SHAFT BOLT
Fig. 3 Clutch Plate And Shim(s)
1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM
Fig. 4 Pulley Snap Ring
1 - SNAP RING
24 - 10 CONTROLS-FRONTVA

motor, while relay 2 when activated, sends power
directly to the blower motor.
The rear blower motor switch cannot be repaired
and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING
REAR BLOWER MOTOR SWITCH
Before testing the rear blower motor switch, verify
that the front A/C system is functional by performing
the ATC Fuction Test using the DRBIIItscan tool.
Use a volt/ohmmeter to test the rear blower motor
switch. For circuit descriptions and diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, details of wire har-
ness routing and retention, connector pin-out infor-
mation and location views for the various wire
harness connectors, splices and grounds.
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precau-
tions could result in accidental airbag deployment.
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the wire harness connector from the
rear blower motor switch.
(3) Check for continuity between terminal 10 and
terminals 1, 7 and 4 of the blower motor switch. In
all instances, there should be continuity.
NOTE: To check the switch's internal circuits, con-
nect the negative lead of the ohmmeter to terminal
10 and the positive ohmmeter lead to terminals 1, 7
and 4. To check the switch's integral light emitting
diodes, reverse the ohmmeter leads.
(4) Check for continuity between the rear blower
motor switch terminals 3 and 7 as you move the
blower motor switch to each of the two speed posi-
tions, and the Off position. There should be continu-
ity in only one blower motor switch speed position.
(5) Check for continuity between the rear blower
motor switch terminals 4 and 8 as you move the
blower motor switch to each of the two speed posi-
tions, and the Off position. There should be continu-ity in only the other blower motor switch speed
position.
(6) If OK, test and repair the rear blower motor
switch wire harness circuits. If not OK, replace the
faulty rear blower motor switch.
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precau-
tions could result in accidental airbag deployment.
NOTE: The rear A/C blower motor switch is used on
vehicles with the optional rear A/C system.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the accessory switch panel from the
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/ACCESSORY SWITCH BEZEL -
REMOVAL).
(3) Disconnect the wire harness connector from the
rear A/C blower motor switch (Fig. 14).
(4) Disengage the retaining tabs and remove the
rear A/C blower motor switch from the accessory
switch panel.
24 - 36 CONTROLS - REARVA