2006 MERCEDES-BENZ SPRINTER steering rack replacement

straight out from the inflator to disconnect it from
the receptacle.
(7) Remove the passenger airbag and airbag door
from the instrument panel as a unit.
INSTALLATION
The following procedure is for replacement of a
faulty or damaged passenger airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the passenger airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
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.
WARNING: To avoid personal injury or death, use
extreme care to prevent any foreign material from
entering the passenger 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 deployment.
WARNING: To avoid personal injury or death, the
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. Failure to
observe this warning could result in occupant inju-
ries upon airbag deployment.
(1) Carefully position the passenger airbag and
airbag door unit to the instrument panel (Fig. 29).
(2) When installing the passenger airbag, recon-
nect the vehicle wire harness connector to the airbag
inflator connector receptacle by pressing straight in
on the connector. You can be certain that the connec-tor is fully engaged by listening carefully for a dis-
tinct, audible click as the connector snaps into place.
(3) Push the passenger airbag unit forward far
enough to engage the lower edge of the airbag door
with the two lower clips in the instrument panel.
(4) Install and tighten the two screws that secure
the flange of the passenger airbag housing to the
bracket on the instrument panel structural support.
Tighten the screws to 10 N´m (89 in. lbs.).
(5) Install and tighten the two screws that secure
the passenger airbag door upper clips to the instru-
ment panel base trim. Tighten the screws to 2 N´m
(18 in. lbs.).
(6) Reinstall the instrument panel top cover tray
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL TOP
COVER - TRAY - INSTALLATION).
(7) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
PASSENGER AIRBAG
BRACKET
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.
(1) Remove the passenger airbag from the instru-
ment panel. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/PASSENGER AIRBAG - REMOVAL).
(2) Remove the four screws that secure the passen-
ger airbag bracket to the instrument panel structural
support (Fig. 30).
VARESTRAINTS 8O - 27

(3) Remove the passenger airbag bracket from the
instrument panel structural support.
INSTALLATION
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) Position the passenger airbag bracket onto the
instrument panel structural support (Fig. 30).
(2) Install and tighten the four screws that secure
the passenger airbag bracket to the instrument panel
structural support. Tighten the screws to 10 N´m (89
in. lbs.).
(3) Reinstall the passenger airbag into the instru-
ment panel. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/PASSENGER AIRBAG -
INSTALLATION).
REAR SEAT BELT & RETRAC-
TOR
REMOVAL
WARNING: To avoid personal injury or death, during
and following any seat belt service, carefully
inspect all seat belts, buckles, mounting hardware,retractors, and anchors for proper installation, oper-
ation, or damage. Replace any belt that is cut,
frayed, or torn. Straighten any belt that is twisted.
Tighten any loose fasteners. Replace any belt that
has a damaged or inoperative buckle or retractor.
Replace any belt that has a bent or damaged latch
plate or anchor plate. Never attempt to repair a seat
belt component. Always replace damaged or faulty
seat belt components with the correct, new and
unused replacement parts listed in the
DaimlerChrysler Mopar Parts Catalog.
(1) Remove the rear bench seat containing the rear
seat belt and retractor unit to be serviced from the
vehicle.
(2) Lift the seat belt webbing to access and remove
the plastic push pin fastener that secures the rear
seat belt turning loop trim cover to the turning loop
bracket at the top of the seat back (Fig. 31).
(3) Remove the turning loop trim cover from the
turning loop bracket.
(4) Remove the push nut at the back of the turn-
ing loop bracket that secures the pin on which the
two turning loops pivot (Fig. 32).
Fig. 30 Passenger Airbag Bracket Remove/Install
1 - BRACKET
2 - STRUCTURAL SUPPORT
3 - SCREW (4)
Fig. 31 Turning Loop Trim Cover
1 - TRIM COVER
2 - SEAT BELT
3 - RETAINER
4 - REAR SEAT BACK
8O - 28 RESTRAINTSVA

(8) Remove the seat belt turning loop height
adjuster from the inner B-pillar.
INSTALLATION
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, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
WARNING: To avoid personal injury or death, during
and following any seat belt service, carefully
inspect all seat belts, buckles, mounting hardware,
retractors, and anchors for proper installation, oper-
ation, or damage. Replace any belt that is cut,
frayed, or torn. Straighten any belt that is twisted.
Tighten any loose fasteners. Replace any belt that
has a damaged or inoperative buckle or retractor.
Replace any belt that has a bent or damaged latch
plate or anchor plate. Never attempt to repair a seat
belt component. Always replace damaged or faulty
seat belt components with the correct, new and
unused replacement parts listed in the
DaimlerChrysler Mopar Parts Catalog.
(1) Position the seat belt turning loop height
adjuster onto the inner B-pillar (Fig. 42).
(2) Install and tighten the two screws that secure
the seat belt turning loop height adjuster to the
upper inner B-pillar. Tighten the screws to 35 N´m
(26 ft. lbs.).
(3) Position the front seat belt turning loop onto
the height adjuster on the upper B-pillar (Fig. 41).
(4) Install and tighten the nut that secures the
front seat belt turning loop to the height adjuster.
Tighten the nut to 35 N´m (26 ft. lbs.).
(5) Position the height adjuster trim to the upper
B-pillar so that the driver on the back of the trim
engages the lug of the height adjuster (Fig. 40).
(6) Reinstall the trim panel onto the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
TRIM - INSTALLATION).
(7) Reconnect the battery negative cable.
SIDE CURTAIN AIRBAG
DESCRIPTION
Optional side curtain airbags are available for this
model when it is also equipped with dual front air-
bags. These airbags are passive, inflatable, Supple-
mental Restraint System (SRS) components (Fig. 43).
This system is designed to reduce injuries to the
vehicle occupants in the event of a side impact colli-
sion.
Vehicles equipped with side curtain airbags have
two individually controlled curtain airbag units.
These airbag units are concealed and mounted above
the front door openings where they are each secured
to one of the roof side rails. Each folded airbag cush-
ion is contained within a channel in the molded plas-
tic garnish molding that extends along the roof rail
from the A-pillar at the front of the vehicle to just
behind the B-pillar. A tether extends down the A-pil-
lar from the front of the airbag cushion, where it is
secured to the base of the pillar near the belt line
with a screw.
The hybrid-type inflator for each airbag is con-
nected to the airbag cushion by a tubular manifold.
The inflator bracket and the airbag cushion channel
are located with a stamped metal lug to a bore in the
roof rail, then secured with screws at the A-pillar in
the front and the B-pillar in the rear. A two-wire pig-
tail wire is routed from the airbag inflator down the
B-pillar where it connects the unit to a take out of
the vehicle body wire harness with a keyed and
latched connector insulator.
The side curtain airbag unit cannot be adjusted or
repaired and must be replaced if deployed, faulty, or
Fig. 43 Side Curtain Airbag
1 - GRAB HANDLE
2 - B-PILLAR TRIM
3 - SIDE CURTAIN AIRBAG
VARESTRAINTS 8O - 35

INSTALLATION
The following procedure is for replacement of a
faulty or damaged side curtain airbag. If the airbag
is faulty or damaged, but not deployed, review the
recommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the side curtain airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
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.
WARNING: To avoid personal injury or death, when
removing a deployed airbag, rubber 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 depos-
its may cause irritation to the skin and eyes.WARNING: To avoid personal injury or death, use
extreme care to prevent any foreign material from
entering the side curtain airbag, or becoming
entrapped between the side curtain airbag cushion
and the roof rail garnish molding. Failure to
observe this warning could result in occupant inju-
ries upon airbag deployment.
(1) Position the side curtain airbag into the vehicle
as a unit.
(2) Engage the lug that secures the side curtain
airbag bracket into the bore in the roof side rail (Fig.
50).
(3) Install and tighten the screw that secures the
rear of the side curtain airbag to the B-pillar (Fig.
48). Tighten the screw to 23 N´m (17 ft. lbs.).
(4) Install and tighten the screw that secures the
front of the side curtain airbag to the A-pillar.
Tighten the screw to 9 N´m (80 in. lbs.).
(5) Install and tighten the screw that secures the
side curtain airbag front tether retainer to the base
of the A-pillar near the belt line (Fig. 47). Tighten
the screw to 5 N´m (44 in. lbs.).
(6) Install a new tie wrap to secure the side cur-
tain airbag pigtail wire to the inside of the B-pillar
(Fig. 46).
(7) Reconnect the pigtail wire connector for the
side curtain airbag to the vehicle wire harness con-
nector on the B-pillar. Be certain the connector is
fully engaged and latched.
(8) Reinstall the trim onto the A-pillar that con-
ceals the side curtain airbag front tether (Fig. 45).
Fig. 49 Side Curtain Airbag Remove
1 - ROOF SIDE RAIL
2 - SIDE CURTAIN AIRBAG
Fig. 50 Side Curtain Airbag Install
1 - ROOF SIDE RAIL
2 - BORE
3 - SIDE CURTAIN AIRBAG BRACKET
4 - LUG
8O - 38 RESTRAINTSVA

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