MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

TOP COVER - TRAY
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 FURTHERDIAGNOSIS 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) Using a trim stick C-4755 or equivalent,
remove the tray. (Fig. 24)
Fig. 24 Passenger Airbag Remove/Install
1 - TRAY
2 - SCREW (2)
3 - UPPER CLIP (2)
4 - LOWER CLIP (2)5 - CONNECTOR
6 - PASSENGER AIRBAG
7 - SCREW (3)
VAINSTRUMENT PANEL 23 - 63

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 the tray and seat the clips fully.
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)
Fig. 25 PASSENGER SIDE AIR NOZZLE COVER
1 - FRONT SCREWS (2)
2 - BRACKET
3 - BRACKET SCREWS
4 - NOZZLE COVER
5 - INSTRUMENT PANEL
23 - 64 INSTRUMENT PANELVA
TOP COVER - TRAY (Continued)

(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.
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 COULDRESULT 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) 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.
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)
VAINSTRUMENT PANEL 23 - 65
TOP COVER (Continued)

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.
(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. FAILURE
TO 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
23 - 66 INSTRUMENT PANELVA

INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION.............................67
A-PILLAR TRIM
REMOVAL.............................67
INSTALLATION.........................68
ASSIST HANDLE
REMOVAL.............................68
INSTALLATION.........................68
B-PILLAR TRIM
REMOVAL.............................68
INSTALLATION.........................69
BULKHEAD TRIM PANEL
REMOVAL.............................69
INSTALLATION.........................69
CARPETS AND FLOOR MATS
REMOVAL.............................69
INSTALLATION.........................70
COWL TRIM
REMOVAL.............................70
INSTALLATION.........................70
D-PILLAR TRIM
REMOVAL.............................70INSTALLATION.........................70
HEADLINER
REMOVAL.............................70
INSTALLATION.........................71
QUARTER TRIM PANEL
REMOVAL.............................71
INSTALLATION.........................72
REAR VIEW MIRROR
REMOVAL.............................72
INSTALLATION
INSTALLATION.......................72
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET...................72
STEPWELL SCUFF PADS
REMOVAL.............................72
INSTALLATION.........................73
SUN VISOR
REMOVAL.............................73
INSTALLATION.........................73
INTERIOR
CAUTION
CAUTION:: Do not attempt to remove interior trim
panels/moldings without first removing the neces-
sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
A-PILLAR TRIM
REMOVAL
(1) Using a trim stick C-4755 or equivalent, sepa-
rate the top of the a-pillar trim.
(2) Pull top of a-pillar trim out and pull trim up
and remove. (Fig. 1)
Fig. 1 A-PILLAR TRIM
1 - A-PILLAR
2 - TRIM PANEL
VAINTERIOR 23 - 67

(3) Remove the four screws and remove the foam
trim support. (Fig. 2)
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) Hold the handle in the down position and
remove the screws. (Fig. 3)
INSTALLATION
(1) Install the handle and install the screws.
B-PILLAR TRIM
REMOVAL
(1) Remove the lower seat belt anchor bolt. (Fig. 4)
(2) Pull door opening weatherstrip away from
flange along the b-pillar. (Fig. 5)
(3) Using a trim stick C-4755 or equivalent,
release the trim clips and remove the trim. (Fig. 6)
Fig. 2 A-PILLAR SUPPORT FOAM
1 - SUPPORT FOAM
2 - SCREWS (4)
Fig. 3 ASSIST HANDLE
1 - SCREWS (2)
2 - ASSIST HANDLE
Fig. 4 Front Seat Belt Lower Anchor
1 - FRONT SEAT BELT
2 - COVER AND/OR SCREW
23 - 68 INTERIORVA
A-PILLAR TRIM (Continued)

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) Install the seat belt and mounting bolt.
(5) Tighten the bolt to 35 N´m (26 ft. lbs.).
BULKHEAD TRIM PANEL
REMOVAL
(1) Remove the rivets and remove the lower panel.
(Fig. 7)
(2) Remove the rivets and remove the upper panel.
INSTALLATION
(1) Install the upper panel and replace rivets.
(2) Install the lower panel and replace rivets.
CARPETS AND FLOOR MATS
REMOVAL
Cargo/Passenger Van - Front
(1) Remove the stepwell scuff pads. (Refer to 23 -
BODY/INTERIOR/STEPWELL SCUFF PADS -
REMOVAL)
(2) Remove the three bolts and tray behind drivers
seat.
(3) Remove cup holder. (Refer to 23 - BODY/IN-
STRUMENT PANEL/CUP HOLDER - REMOVAL)
(4) Remove the jack storage cover.
(5) Remove carpet/mat.
Passenger Van - Rear
(1) Remove seats. (Refer to 23 - BODY/SEATS/
SEAT - REAR - REMOVAL)
(2) Remove the screws and retaining strips.
(3) Remove the seat striker assemblies.
(4) Remove carpet/mat.
Fig. 5 B-PILLAR TRIM
1 - FRONT DOOR WEATHERSTRIP
2 - B-PILLAR
3 - B-PILLAR TRIM
Fig. 6 B-PILLAR TRIM MOUNTING CLIPS
1 - RETAINING CLIPS (5)
2 - B-PILLAR TRIM
Fig. 7 BULKHEAD TRIM PANEL
1 - RIVETS
2 - UPPER PANEL
3 - PANEL GLASS
4 - LOWER PANEL
VAINTERIOR 23 - 69
B-PILLAR TRIM (Continued)

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.
23 - 70 INTERIORVA
CARPETS AND FLOOR MATS (Continued)

(9) Release clips at front and rear of headliner and
remove.
Number 4 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.
(9) Release clips at front and rear of headliner and
remove.
INSTALLATION
Cab Section
(1) Position the headliner in vehicle and seat fully.
(2) Install dome light. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - INTERIOR/CARGO LAMP
UNIT - INSTALLATION)
(3) Install assist handle. (Refer to 23 - BODY/IN-
TERIOR/ASSIST HANDLE - INSTALLATION)
(4) Install b-pillar trim. (Refer to 23 - BODY/IN-
TERIOR/B-PILLAR TRIM - INSTALLATION)
(5) Install the sun visors. (Refer to 23 - BODY/IN-
TERIOR/SUN VISOR - INSTALLATION)
(6) Install the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION)
(7) Connect battery negative cable.
Number 2 Section
(1) Position the headliner in vehicle and seat fully.
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(2) Install rear air unit duct work.
(3) Install the rear air unit rear cover and install
the three screws and push-pins.
(4) Connect the electrical connector and install the
middle duct work cover.
(5) Install the push pin fasteners.
(6) Connect the electrical connector and install the
front duct work cover.
(7) Install the push pin fasteners.(8) Install the second and third row seats. (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Connect battery negative cable.
Number 3 Section
(1) Position the headliner in vehicle and seat fully.
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(2) Install rear air unit duct work.
(3) Install the rear air unit rear cover and install
the three screws and push-pins.
(4) Connect the electrical connector and install the
middle duct work cover.
(5) Install the push pin fasteners.
(6) Connect the electrical connector and install the
front duct work cover.
(7) Install the push pin fasteners.
(8) Install the third and fourth row seats. (Refer to
23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Connect battery negative cable.
Number 4 Section
(1) Position the headliner in vehicle and seat fully.
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
(2) Install rear air unit duct work.
(3) Install the rear air unit rear cover and install
the three screws and push-pins.
(4) Connect the electrical connector and install the
middle duct work cover.
(5) Install the push pin fasteners.
(6) Connect the electrical connector and install the
front duct work cover.
(7) Install the push pin fasteners.
(8) Install the third and fourth row seats. (Refer to
23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Connect battery negative cable.
QUARTER TRIM PANEL
REMOVAL
Passenger Van
(1) Remove seats as necessary. (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL)
(2) Remove d-pillar trim if necessary. (Refer to 23 -
BODY/INTERIOR/D-PILLAR TRIM - REMOVAL)
(3) Using a trim stick C-4755 or equivalent, sepa-
rate the push-pin fasteners and remove trim panels.
VAINTERIOR 23 - 71
HEADLINER (Continued)

Cargo Van
(1) Remove bolts and remove tie down rings, if
equipped.
(2) Remove rivets and remove paneling
INSTALLATION
Passenger Van
(1) Position trim panels and seat push-pin fasten-
ers fully.
(2) Install d-pillar trim, if necessary. (Refer to 23 -
BODY/INTERIOR/D-PILLAR TRIM - INSTALLA-
TION)
(3) Install seats, if necessary. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
Cargo Van
(1) Install paneling and replace rivets.
(2) Install tie down rings and bolts, if equipped.
REAR VIEW MIRROR
REMOVAL
(1) Slide mirror off support bracket.
INSTALLATION
INSTALLATION
(1) Install the support bracket if necessary. (Refer
to 23 - BODY/INTERIOR/REAR VIEW MIRROR -
INSTALLATION - SUPPORT BRACKET)
(2) Slide mirror onto support bracket fully.
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET
(1) Mark the position for the mirror bracket on the
outside of the windshield glass with a wax pencil.
(2) Clean the bracket contact area on the glass.
Use a mild powdered cleanser on a cloth saturated
with isopropyl (rubbing) alcohol. Finally, clean the
glass with a paper towel dampened with alcohol.
(3) Sand the surface on the support bracket with
fine grit-sandpaper. Wipe the bracket surface clean
with a paper towel.
(4) Apply accelerator to the surface on the bracket
according to the following instructions:
(a) Crush the vial to saturate the felt applicator.
(b) Remove the paper sleeve.
(c) Apply accelerator to the contact surface on
the bracket.
(d) Allow the accelerator to dry for five minutes.
(e) Do not touch the bracket contact surface
after the accelerator has been applied.(5) Apply adhesive accelerator to the bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute. Do not touch the glass
contact surface after the accelerator has been
applied.
(6) Install the bracket according to the following
instructions:
(a) Apply one drop of adhesive at the center of
the bracket contact-surface on the windshield
glass.
(b) Apply an even coat of adhesive to the contact
surface on the bracket.
(c) Align the bracket with the marked position
on the windshield glass.
(d) Press and hold the bracket in place for at
least one minute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Allow the adhesive to cure for 8-10 minutes.
Remove any excess adhesive with an alcohol-damp-
ened cloth.
(8) Allow the adhesive to cure for an additional
8-10 minutes before installing the mirror.
STEPWELL SCUFF PADS
REMOVAL
(1) Remove screws and remove seat bracket if nec-
essary.
(2) Remove trim plugs and screws. (Fig. 8) and
(Fig. 9)
(3) Remove stepwell scuffs.
Fig. 8 STEPWELL SCUFF PADS
1 - TRIM PLUGS
2 - STEPWELL
23 - 72 INTERIORVA
QUARTER TRIM PANEL (Continued)