2006 MERCEDES-BENZ SPRINTER warning

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

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

(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 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. FAILURETO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install steering column shroud and install the
two screws and one nut.
(2) Install Power Distribution Center cover and
twist lock 1/4 turn to secure in place.
Fig. 27 ELECTRICAL CENTER COVER
1 - COVER LOCK
2 - COVER
Fig. 28 STEERING COLUMN SHROUD
1 - SHROUD
2 - SCREWS (2)
3 - NUT
VAINSTRUMENT PANEL 23 - 69

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES..........77
BASECOAT/CLEARCOAT FINISH
DESCRIPTION.........................77
PAINT TOUCH-UP
DESCRIPTION.........................77STANDARD PROCEDURE - PAINT TOUCH-UP . 77
FINESSE SANDING/BUFFING & POLISH
DESCRIPTION.........................78
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 FIN-
ISH
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.
STANDARD PROCEDURE - PAINT TOUCH - UP
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MOPARtTar/Road
Oil Remover or equivalent, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the scratch or chip without run-
ning. Do not stroke brush applicator on body surface.
Allow the filler/primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clearcoat, the touch-up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clearcoat, apply clear top coat
to touch-up paint with the same technique as
VAPAINT 23 - 77

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

STATIONARY GLASS
TABLE OF CONTENTS
page page
BACKLITE - BULKHEAD TRIM PANEL
REMOVAL.............................84
INSTALLATION.........................84
QUARTER WINDOW
REMOVAL.............................84
INSTALLATION.........................84WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS.....85
REMOVAL.............................85
INSTALLATION.........................86
BACKLITE - BULKHEAD TRIM
PANEL
REMOVAL
(1) Position an assistant opposite side of the bulk-
head trim panel to receive the glass and weatherstrip
seal.
(2) Start at an upper corner and separate the seal
from the window opening. Push the glass and seal
outward from the window opening. Remove the glass
and seal.
(3) Remove seal from glass if necessary.
(4) Clean the window opening.
INSTALLATION
(1) Install the weatherstrip seal on the window
glass. Verify that the glass is seated in the groove
around the edge of the seal.
(2) Insert an installation cord in the weatherstrip
seal inner groove.
NOTE: Use mineral spirits as a lubricant to aid seal
installation in the window opening.
(3) Position the glass and seal in the trim panel
opening.
(4) Pull the installation cord outward and force the
seal lip over the panel flange around the edge of the
opening. (Fig. 1)
(5) Seat the seal inner lip on the panel flange.
Press against the lip around the edge of the seal.
NOTE: Remove any mineral spirits with a clean
cloth after glass installation.
(6) Verify that the seal is seated in the trim panel
opening.
QUARTER WINDOW
REMOVAL
(1) Position an assistant outside the vehicle to
receive the glass and weatherstrip seal.
(2) Start at an inside, upper corner. Separate the
seal from the window opening. Push the glass and
seal outward from the window opening. Remove the
glass and seal.
(3) Clean the window opening.
INSTALLATION
(1) Install the weatherstrip seal on the window
glass. Verify that the glass is seated in the groove
around the edge of the seal.
(2) Insert an installation cord in the weatherstrip
seal inner groove.
Fig. 1 Glass & Weatherstrip Seal Installation
1 - BULKHEAD TRIM PANEL
2 - WEATHERSTRIP SEAL
3 - INSTALLATION CORD
4 - TRIM PANEL FRAME
23 - 84 STATIONARY GLASSVA

NOTE: Use mineral spirits as a lubricant to aid seal
installation in the window opening.
(3) Position the glass and seal in the window open-
ing.
(4) Pull the installation cord outward and force the
seal lip over the panel flange around the edge of the
opening.
(5) Seat the seal inner lip on the panel flange.
Press against the lip around the edge of the seal.
NOTE: Remove any mineral spirits with a clean
cloth after glass installation.
(6) Verify that the seal is seated in the window
opening (Fig. 2).
(7) Test the window for water leaks. (Refer to 23 -
BODY - DIAGNOSIS AND TESTING - WATER
LEAKS)
WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
²URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREPSOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
²DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
²BE SURE TO REFER TO THE URETHANE MAN-
UFACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
²VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
²SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
²ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
(1) Remove wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(2) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL)
(3) Remove rear view mirror. (Refer to 23 - BODY/
INTERIOR/REAR VIEW MIRROR - REMOVAL)
CAUTION: Cover instrument panel and vents to pro-
tect against splinters and damage.
(4) Using a trim stick C-4755 or equivalent,
remove windshield seal. (Fig. 3)
Fig. 2 Glass & Weatherstrip Seal Installation
1 - BODY PANEL
2 - WEATHERSTRIP SEAL
3 - INSTALLATION CORD
4 - WINDOW OPENING
VASTATIONARY GLASS 23 - 85

CAUTION: Fabricate a protection guard from 2 mm
sheet plastic or equivalent to protect rubber instru-
ment panel from damage.
(5) Place protection guard between windshield and
instrument panel seal. (Fig. 4)
(6) Using a windshield cut-out wire separate the
adhesive. (Fig. 5)(7) Carefully remove windshield.
INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The windshield fence should be cleaned of most of
its old urethane bonding material. A small amount of
old urethane, approximately 1 mm in height, should
remain on the fence. Do not grind off or completely
remove all old urethane from the fence, the paint fin-
ish and bonding strength will be adversely affected.
Windshield Preparation - Installing A Previously
Installed Windshield
(1) Level old bead of windshield adhesive to a
thickness of approximately 1 mm (0.04 in.) and
remove loose adhesive. (Fig. 6)
Fig. 3 WINDSHIELD SEAL
1 - WINDSHIELD SEAL
2 - TRIM STICK #4755
Fig. 4 INSTRUMENT PANEL SEAL
1 - WINDSHIELD
2 - SEAL PROTECTOR
3 - INSTRUMENT PANEL
4 - INSTRUMENT PANEL SEAL
Fig. 5 ADHESIVE SEPARATION
1 - T-HANDLE
2 - WINDSHIELD ADHESIVE
3 - COUNTER SUPPORT
4 - CUTTING WIRE
23 - 86 STATIONARY GLASSVA