Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 497

(6) Install the headrest sleeves.
(7) Install the headrests. (Refer to 23 - BODY/

SEATS/HEADREST - INSTALLATION)

(8) Install the seat belt buckles. (Refer to 8 -

ELECTRICAL/RESTRAINTS/REAR

SEAT

BELT

BUCKLE - INSTALLATION)

(9) Install the seat belts. (Refer to 8 - ELECTRI-

CAL/RESTRAINTS/REAR SEAT BELT & RETRAC-
TOR - INSTALLATION)

(10) Install the seat back shield. (Refer to 23 -

BODY/SEATS/REAR

SEAT

BACK

SHIELD

-

INSTALLATION)

(11) Install seat. (Refer to 23 - BODY/SEATS/

SEAT - REAR - INSTALLATION)

SEAT CUSHION / COVER -
REAR

REMOVAL

(1) Remove seat. (Refer to 23 - BODY/SEATS/

SEAT - REAR - REMOVAL)

(2) Remove seat back shield. (Refer to 23 - BODY/

SEATS/REAR SEAT BACK SHIELD - REMOVAL)

(3) Remove the lower seat belt anchors as neces-

sary. (Refer to 8 - ELECTRICAL/RESTRAINTS/
REAR SEAT BELT & RETRACTOR - REMOVAL)

(4) Remove seat belt buckles as necessary. (Refer

to

8

-

ELECTRICAL/RESTRAINTS/REAR

SEAT

BELT BUCKLE - REMOVAL)

(5) Partially de-trim lower part of seat back.
(6) Separate the cushion/cover j-straps and remove

the seat cushion and cover from seat frame.

INSTALLATION

(1) Install seat cushion and cover.
(2) Connect the cover j-straps.
(3) Position seat back cover, back.
(4) Install the seat belt buckles. (Refer to 8 -

ELECTRICAL/RESTRAINTS/REAR

SEAT

BELT

BUCKLE - INSTALLATION)

(5) Install the seat belt anchors. (Refer to 8 -

ELECTRICAL/RESTRAINTS/REAR SEAT BELT &
RETRACTOR - INSTALLATION)

(6) Install the seat back shield. (Refer to 23 -

BODY/SEATS/REAR

SEAT

BACK

SHIELD

-

INSTALLATION)

(7) Install seat. (Refer to 23 - BODY/SEATS/SEAT

- REAR - INSTALLATION)

VA

SEATS

23 - 83

STATIONARY GLASS

TABLE OF CONTENTS

page

page

BACKLITE - BULKHEAD TRIM PANEL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 84

QUARTER WINDOW

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 84

WINDSHIELD

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 GLASS

VA

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.

•

URETHANE ADHESIVES ARE APPLIED AS A

SYSTEM. USE GLASS CLEANER, GLASS PREP

SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.

•

DAIMLERCHRYSLER 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.

•

BE SURE TO REFER TO THE URETHANE MAN-

UFACTURER’S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.

•

VAPORS THAT ARE EMITTED FROM THE URE-

THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.

•

SKIN CONTACT WITH URETHANE ADHESIVE

SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.

•

ALWAYS 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

VA

STATIONARY 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 GLASS

VA