Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 494
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
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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
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INTERIOR
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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.
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INTERIOR
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(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.
Cargo Van
(1) Remove bolts and remove tie down rings, if
equipped.
(2) Remove rivets and remove paneling
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