AMP Research Power Step User manual

www.amp-research.com IM75163 rev 01.02.201/10
INSTALLATION GUIDE
APPLICATION MODEL YR PART #
Sprinter Van 2007 - 2018 75163-01A
3-5 Hours
Professional installation recommended
TOOLS REQUIRED
q Safety goggles
q Measuring tape
q 13mm wrench
q 19mm wrench
q 13mm socket
q 10mm socket
q Ratchet wrench and extension
q Wire stripper / cutter
q 3/16” hex key ( allen wrench )
q 4mm hex key ( allen wrench )
q Electrical tape
SKILL LEVEL
4= Experienced
12 3 4
INSTALLATION TIME
AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 7:00 AM - 5:00 PM PST
5-Year Limited Warranty
WARRANTY
Invented, engineered and manufactured exclusively by AMP Research in the USA. May be covered by one of the following patents:
6,641,158; 6,830,257; 6,834,875; 6,938,909; 7,055,839; 7,380,807; 7,398,985; 7,584,975 ©2012 AMP Research. All rights reserved.
Printed in USA.

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AMP RESEARCH POWERSTEPTM – SPRINTER
INSTALLATION GUIDE
Attaching motor to linkage assembly
The motors must be attached to the linkage assemblies before continuing the
installation process.
CAUTION: HANDLE WITH CARE.
To ensure our customers receive all components with full integrity, we pack the motors separate from their linkage
assemblies. This requires that the installer position and fasten the motor before continuing with the install. Please
follow the instructions below and handle the assembly carefully.
CAUTION: Dropping the assembly or any excessive impact MAY cause damage to the motor.
Instructions:
1. Position the gear cover in place as shown if not already in place.
2. Seat motor into position on the three mounting bosses. This may require an adjustment of the gear by moving the
swing arms.
3. After seating into place, fasten the motor with the three motor mount screws with 4mm Hex Head. Tighten screws to
36 in-lbs (4N-m). Do not over torque.
EXPLODED VIEW
• Motor
• Socket cap screw
• Washer
• Drive Gear Housing Cover

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Motor Linkage Assembly
3
Idler Linkage Assembly
1
Running board assembly
D
B
(A) End cap left (x1)
(B) End cap right (x1)
(C) T-nut insert (x2)
(D) Socket cap screw (x2)
(E) End cap wedge right (x1)
(F) End cap wedge left (x1)
A
CE
F
4
Wire Harness
5
Controller STA
6x4
M8 Hex bolt
7x4
Washer (SS)

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Drill Template
TAPE TAPE
TAPE
TAPE
BEND DOWN 90 Degrees
SPRINTER POWERSTEP DRILL TEMPLATE
Use center punch, pilot drill (1/8”),
then drill final hole size (17/32”)
8x4
Socket Cap
Screw
9x20
Cable Tie (7”)
10 x2
Cable Tie (11”)
PARTS LIST AND HARDWARE IDENTIFICATION
12 x4
M8x12 Flange Bolt
14 x2
Large Washer
11 x2
Posi-TapTM
Connector
17 x4
Butt Connector
16 x2
LED Lamp
13 x2
M8x25 Flange Bolt
18
Rivet Nut Tool
15 x6
M8 Rivet Nut
19
Rear Support Bracket
20
Front Support Bracket

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3
5
Pre Drill holes with an 1/8” Drill and then drill to
17/32”. Then insert rivet nuts into position. Refer
to install card in rivet nut tool bag. Then pre
thread m8 screws and washers into position
Set template up to marked line. Center punch holes.
13mm
4
6
Rear Drive Linkage install: Locate rear linkage
location. Clean undercoating so any proud edges
are knocked off and mounting surface is at.
Set Upper mount up to bump in sheetmetal and
mark side of linkage near mounting slot.
Warning: Rivet nuts not
properly collapsed will not
hold securely to sheet metal.
Set rear linkage over bolts. Using a 13mm box
wrench snug up two bolts on linkage.
Using supplied Flange bolts install bracket onto
Drive linkage Upper mount. Do not tighten to allow
for adjustment. Use shorter bolts to prevent bolt and
linkage arm interference.
13mm

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2 3
4
7
9 10
11
1
8
Front Idler Linkage Install: Locate front linkage
mounting position. Location is approx 11” forward of
tab in unibody crossmember as show. Tape template
in place and center punch holes.
Pre Drill holes with an 1/8” Drill and then drill to
17/32”. Then insert rivet nuts into position. Refer
to install card in rivet nut tool bag. Then pre
thread m8 screws and washers into position
Warning: Rivet nuts not
properly collapsed will not
hold securely to sheet metal.
Using supplied Flange bolts install bracket onto Idler
linkage Upper mount. Do not tighten to allow for
adjustment. Use shorter bolts to prevent bolt and
linkage arm interference.
13mm
Set front idler linkage over bolts. Using a 13mm box
wrench snug up two bolts on linkage.
13mm
Install Running board onto lower mounts. Measure 9 inches from end of board to side of linkage as shown
below.
9”

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15 10
10 10
10
12
13
16
10
14
Using light pressure pull out from the inside edge of the running board to get the step in the level position.
Hold the running board in position. Mark upper hole location in rear bracket.
Remove bracket bolts on side of upper mount to rotate
out of way. Center punch, Pre drill with 1/8” and then
nal drill to 17/32”. Install rivet nut. Install longer ange
bolt and reassemble bolts on bracket at linkage.
With front bracket in place mark hole. Center punch,
Pre drill with 1/8” and then nal drill to 17/32”. Install
rivet nut. Install longer ange bolt and reassemble
bolts on bracket at linkage. Note: 2 Washers
are provided to space out multiple layers of
sheetmetal.
Mount controller under vehicle attach to loom that runs
along the bottom of the battery box.
Run Positive and negative terminals up through the
large rubber boot just rearward of where controller
is mounted. Zip tie around boot may need to be
removed to route wire through. If so use one
supplied and re-seal boot.

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9
17 18
Ground terminal located
on floor.
19
21 22
9
20
Remove Drivers seat box cover. Be careful not to
damage wire that runs across cover.
Connect positive terminal on power lead using a
10mm socket or wrench. Connect ground to body
ground in bottom of seat box. Remove Fuse.
Insert Tighten Strip 3/8” Insert and
Tighten
Splice Power Step trigger wires into the Door
Ajar wires with provided Posi-TapTM splicers. The
Power Step trigger wires color coordinate with the
factory Door Ajar wires. Follow the steps below to
correctly splice wires.
Route remaining wires up and over exhaust heat
shield and back along passenger side to motor.
Remove side access panel. Locate grommet under
passenger side seat. Pull trigger wires up through
grommet in oor.
Rear Door: Located in the loom under the seat look
for the pink with a white stripe wire for the rear door.
Attach pink trigger wire on harness to pink with a
white stripe wire.

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30
32 33
23
28
24
28
25 28
26
Measure from the front edge of door line on the pinch weld to the specied lengths below. Measure at 12”
for the front LED Light and 60” for the rear LED Light.
Afx lamp (16) to rocker panel surface. Make sure
lamp is afxed to a at, clean surface.
Front Door: Located in the loom in passenger foot well. Remove mat covering jack. Route Blue Trigger wire
up through opening in side of seat base. Route under oor paneling and route up towards foot well. Factory
wire will be Blue with a Green stripe
Drill a 9/32” hole through the pinch weld at marked
locations. Debur all holes.

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27 28
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Reinstall fuse.
Check that all doors activate the Power Step and the LED Lights work when
doors open and close. Reinstall any remaining trim panels.
Close and wrap with conduit and electrical tape.
Secure all loose wires with cable ties, with lamp
wires pulled upward to avoid any wire snagging.
CORRECT OPERATION OF LIGHTS: All four lamps will illuminate upon opening any door of vehicle. Lamps
will stay on until restowing of both Power Steps or until 5 minutes has expired with the doors open. When the
lights timeout after 5 minutes, they can be reillumintated by closing and opening any door of vehicle.
FINAL SYSTEM CHECK
Check that all doors activate the PowerStep and the LED lights work when doors open and close.
NORMAL OPERATION: When the doors open, PowerStep automatically deploys from under the vehicle.
When the doors are closed, PowerStep will automatically return to the stowed/retracted position. Note that
17
Using supplied butt connectors (17), connect the
lamp wires. Red to Red, Black to Black