MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

INSTALLATION
(1) Position front of handle into front slot in door.
(Fig. 15)
NOTE: Front door shown, rear door similar.
(2) Position rear of handle into latch opening and
engage lock and latch actuation levers with the latch
levers. (Fig. 16)
NOTE: Front door shown, rear door similar.(3) Slide exterior handle towards rear of door and
install bolt. (Fig. 17)
NOTE: Front door shown, rear door similar.
(4) Tighten bolt to 10 N´m (89 in. lbs.).
Fig. 15 EXTERIOR HANDLE INSTALLATION
1 - DOOR LATCH OPENING
2 - LOCK ACTUATION LEVER
3 - LATCH ACTUATION LEVER
4 - EXTERIOR HANDLE
Fig. 16 LATCH LEVERS
1 - LATCH LEVER
2 - LATCH OPENING
3 - LOCK LEVER
Fig. 17 EXTERIOR HANDLE
1 - EXTERIOR HANDLE BOLT
2-LATCH
3 - LATCH BOLTS (3)
VADOORS - REAR 23 - 33
EXTERIOR HANDLE (Continued)

HINGE
REMOVAL
NOTE: It is not necessary to remove the door to
replace the hinges if they are replaced one at a time.
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door.
(2)
Remove the bolts and remove the hinge. (Fig. 18)
INSTALLATION
(1) Install hinge and install bolts.
(2) Tighten bolts to 25 N´m (18 ft. lbs.).
(3) Adjust door if necessary. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the handle trim cover. (Fig. 19)
(2) Remove the screws and handle.
(3) Disconnect the latch cable.
INSTALLATION
(1) Connect the latch cable.
(2) Install handle and screws.
(3) Install trim cover.
LATCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove right side trim panel. (Refer to 23 -
BODY/DOORS - REAR/TRIM PANEL - REMOVAL)(3) Disconnect lock rod. (Fig. 20)
(4)
Remove the screws and pull out latch from door.
(5) Disconnect cable and electrical connectors.
Fig. 18 REAR DOOR HINGE
1 - TORX BOLTS BODY SIDE
2 - TORX BOLTS DOOR SIDE
3 - HINGE
4 - ALLEN BOLT
Fig. 19 TRIM PANEL
1 - TRIM
2 - INSIDE HANDLE ACTUATOR
3 - TRIM PANEL
4 - CONTROL CABLE
Fig. 20 LATCH
1 - DOOR LOCK KNOB
2 - ELECTRIC
3 - CABLE
4 - LOCK ROD
5 - LATCH ASSEMBLY
6 - ELECTRICAL CONNECTORS ROUTING
7 - SCREWS (3)
23 - 34 DOORS - REARVA

INSTALLATION
(1) Connect electrical connectors and cable to latch
assembly.
(2) Install latch in door and install screws.
(3) Connect lock rod.
(4) Install right side trim panel. (Refer to 23 -
BODY/DOORS - REAR/TRIM PANEL - INSTALLA-
TION)
(5) Connect battery negative cable.
TRIM PANEL
REMOVAL
(1) Remove trim and interior handle, if equipped
(Fig. 21). (Refer to 23 - BODY/DOORS - REAR/IN-
SIDE HANDLE ACTUATOR - REMOVAL)
(2) Remove push pin fasteners, if equipped.
(3) Using a trim stick C-4755 or equivalent,
remove the lower trim panel.
(4) Remove rivets and remove upper trim panel, if
equipped.
INSTALLATION
(1) Install upper trim panel and replace rivets.
(2) Install lower trim and install push pin fasten-
ers, if equipped.
(3) Install interior handle, if equipped. (Refer to 23
- BODY/DOORS - REAR/INSIDE HANDLE ACTUA-
TOR - INSTALLATION)
Fig. 21 TRIM PANEL
1 - TRIM
2 - INSIDE HANDLE ACTUATOR
3 - TRIM PANEL
4 - CONTROL CABLE
VADOORS - REAR 23 - 35
LATCH (Continued)

DOORS - SLIDING
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................36
INSTALLATION.........................36
INSIDE HANDLE ACTUATOR
REMOVAL.............................37
INSTALLATION.........................37
UPPER ROLLER ARM
REMOVAL.............................37
INSTALLATION.........................37
CENTER ROLLER ARM
REMOVAL.............................37
INSTALLATION.........................38
LOWER ROLLER ARM
REMOVAL.............................38
INSTALLATION.........................38
CENTER TRACK
REMOVAL.............................38
INSTALLATION.........................39
LATCH / LOCK CONTROL
REMOVAL.............................39
INSTALLATION.........................40
REAR LATCH
REMOVAL.............................40INSTALLATION.........................40
REAR LATCH STRIKER
REMOVAL.............................41
INSTALLATION.........................41
SLIDING DOOR
REMOVAL.............................41
DISASSEMBLY.........................42
ASSEMBLY............................43
INSTALLATION.........................44
ADJUSTMENTS
ADJUSTMENT........................44
STABILIZER
REMOVAL.............................45
INSTALLATION.........................45
TRIM PANEL
REMOVAL.............................46
INSTALLATION.........................46
DOOR GLASS
REMOVAL.............................46
INSTALLATION.........................46
EXTERIOR HANDLE
REMOVAL
(1) Remove trim cap. (Fig. 1)
(2) Remove bolt.
(3) Push handle back and remove.
INSTALLATION
(1) Install handle into door opening and push back
so the three catch points lock in place on both sides.
(Fig. 1)
(2) Install bolt and tighten to 10 N´m (89 in. lbs.).
(3) Install trim cap.
Fig. 1 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - CATCH POINTS
3 - BOLT
4 - TRIM CAP
23 - 36 DOORS - SLIDINGVA

INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the trim plug. (Fig. 2)
(2) Remove screw and remove handle.
INSTALLATION
(1) Install the handle and screw.
(2) Tighten screw to 10 N´m (89 in. lbs.).
(3) Install trim plug.
UPPER ROLLER ARM
REMOVAL
(1) Using a grease pencil or equivalent, mark posi-
tion of roller arm to aid installation.
(2) Support door with suitable device.
(3) Remove the bolts. (Fig. 3)
(4) Slide roller arm towards rear of vehicle and
remove from back of track.
INSTALLATION
(1) Install roller arm into upper track from back.
(2) Position roller arm on door and install the
bolts.
(3) Tighten bolts to 25 N´m (18 ft. lbs.).
(4) Adjust door as necessary. (Refer to 23 - BODY/
DOORS - SLIDING/SLIDING DOOR - ADJUST-
MENTS)
CENTER ROLLER ARM
REMOVAL
(1) Remove trim cover. (Fig. 4)(2) Remove trim panel if necessary. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(3) Remove rubber cover.
(4) Using a grease pencil or equivalent, mark the
horizontal position of the arm at the arrow.
(5) Support door with suitable lifting device.
(6) Remove bolt and remove roller arm from door.
(7) Remove roller arm from center guide track.
Fig. 2 INTERIOR HANDLE
1 - HANDLE
2 - SCREW
3 - TRIM PLUG
Fig. 3 UPPER ROLLER ARM
1 - ROLLER ARM
2 - BOLTS
Fig. 4 CENTER ROLLER ARM
1 - TRIM COVER
2 - SLIDING DOOR
3 - CENTER ROLLER ARM RUBBER COVER
4 - CENTER ROLLER ARM
5 - BOLT
VADOORS - SLIDING 23 - 37

INSTALLATION
(1) Position roller arm in guide track.
(2) Install arm into door opening and line up tab
with marks made previously.
(3) Install bolt and tighten to 45 N´m (33 ft. lbs.).
(4) Install rubber cover.
(5) Adjust door if necessary. (Refer to 23 - BODY/
DOORS - SLIDING/SLIDING DOOR - ADJUST-
MENTS)
(6) Install trim panel if necessary. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
(7) Install trim cover.
LOWER ROLLER ARM
REMOVAL
(1) Remove trim plugs and screws and remove
stepwell scuff pad. (Fig. 5)
(2) Remove the door screws and remove the roller
arm. (Fig. 6)
INSTALLATION
(1) Install roller arm and install door screws.
(2) Tighten screws to 25 N´m (18 ft. lbs.).
(3) Install stepwell scuff pad and install screws.
(4) Adjust door if necessary. (Refer to 23 - BODY/
DOORS - SLIDING/SLIDING DOOR - ADJUST-
MENTS)
CENTER TRACK
REMOVAL
(1) Remove center roller arm. (Refer to 23 - BODY/
DOORS - SLIDING/CENTER ROLLER ARM -
REMOVAL)
(2) Remove quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL)
(3) Remove the nuts. (Fig. 7)
(4) Remove the front bolts.
Fig. 7 SLIDING DOOR CENTER TRACK
1 - NUTS
2 - QUARTER TRIM PANEL
3 - BOLT
4 - BOLT
5 - CENTER TRACK
Fig. 5 SLIDING DOOR SCUFF PAD
1 - TRIM PLUGS
2 - SCREWS (5)
3 - SCUFF PAD
Fig. 6 SLIDING DOOR LOWER ROLLER ARM
1 - SCREWS
2 - ROLLER ARM
23 - 38 DOORS - SLIDINGVA
CENTER ROLLER ARM (Continued)

(5) Remove the screws and remove the center
track end piece. (Fig. 8)
(6) Using a heat gun or equivalent, heat track up
to approximately 60É C (140É F).
(7) Remove center track.
INSTALLATION
(1) Thoroughly clean all residue from the center
track attachment area of the door.
(2) Wipe area clean with a 50% solution of water
and alcohol and wipe dry.
(3) Remove protective foil from piece of adhesive
strip on center track.
(4) Apply new center track and apply pressure of
approximately 40 p.s.i. over the entire surface of the
track.
(5) Install the front bolts and tighten to 10 N´m
(89 in. lbs.).
(6) Install the interior nuts and tighten to 10 N´m
(89 in. lbs.).
(7) Install quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION)
(8) Install the center roller arm. (Refer to 23 -
BODY/DOORS - SLIDING/CENTER ROLLER ARM -
INSTALLATION)
(9) Install the center track end piece and install
the screw.
LATCH / LOCK CONTROL
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove trim panel. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - REMOVAL)
(3) Disconnect electrical connectors. (Fig. 9)
(4) Remove bolts and remove control assembly.
(Fig. 10)
Fig. 9 ELECTRICAL CONNECTORS
1 - CONNECTOR
2 - CONNECTOR
3 - CONNECTOR
Fig. 10 LOCK ASSEMBLY FASTENERS
1 - SCREWS
2 - POWER LOCK ACTUATOR
3 - LATCH/LOCK CONTROL ASSEMBLY
4 - EXTERIOR DOOR LEVER
Fig. 8 SLIDING DOOR
1 - STOP BUMPER
2 - SCREWS (2)
3 - SCREWS (2)
4 - LOWER ROLLER ARM
5 - END PIECE
6 - SCREWS (2)
VADOORS - SLIDING 23 - 39
CENTER TRACK (Continued)

(5) Disconnect lock knob rod. (Fig. 11)
(6) Disconnect cable.
INSTALLATION
(1) Position latch/lock control assembly at door and
connect the latch control assembly and lock rod.
(2) Install assembly and install new bolts. Make
sure that the lever of the door handle is in front of
the lever of the inside door lock. (Fig. 12)(3) Tighten bolts to 10 N´m (89 in. lbs.).
(4) Connect electrical connectors.
(5) Install trim panel. (Refer to 23 - BODY/DOORS
- SLIDING/TRIM PANEL - INSTALLATION)
(6) Connect battery negative cable.
REAR LATCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove trim panel. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - REMOVAL)
(3) Remove the screws and remove the latch from
door.
(4) Disconnect electrical connector, if equipped.
(5) Disconnect control cable.
INSTALLATION
(1) Connect control cable.
(2) Connect electrical connector, if equipped.
(3) Position latch in door and install screws.
(4) Tighten screws to 10 N´m (89 in. lbs.).
(5) Install trim panel. (Refer to 23 - BODY/DOORS
- SLIDING/TRIM PANEL - INSTALLATION)
(6) Connect battery negative cable.
Fig. 11 LOCK ASSEMBLY
1 - LATCH/LOCK CONTROL ASSEMBLY
2 - LOCK ROD
3 - LOCK KNOB
4 - LATCH CONTROL CABLE
5 - ELECTRICAL CONNECTOR
6 - ELECTRICAL CONNECTOR
7 - INTERIOR HANDLE ACTUATOR
8 - STOP BUMPER
9 - TRIM PANEL
Fig. 12 LOCK ASSEMBLY FASTENERS
1 - SCREWS
2 - POWER LOCK ACTUATOR
3 - LATCH/LOCK CONTROL ASSEMBLY
4 - EXTERIOR DOOR LEVER
Fig. 13 REAR LATCH
1 - LATCH OPENING
2 - SCREWS
3 - LATCH ASSEMBLY
4 - CONTROL CABLE
23 - 40 DOORS - SLIDINGVA
LATCH / LOCK CONTROL (Continued)

REAR LATCH STRIKER
REMOVAL
(1) Open door.
(2) Remove bolts and remove striker. (Fig. 14)
INSTALLATION
(1) Install striker and bolts.
(2) Tighten bolts to 25 N´m (18 ft. lbs.)
(3) Adjust striker if necessary. (Refer to 23 -
BODY/DOORS - SLIDING/SLIDING DOOR -
ADJUSTMENTS)
SLIDING DOOR
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove the screws and remove the center
track end piece. (Fig. 15)
(3) Remove the screws and remove the stop
bumper.
(4) Remove the screws attaching the lower roller
arm to door.
(5) Support door with a suitable lifting device and
roll off the upper and center tracks towards the rear
of vehicle.
Fig. 14 LATCH STRIKER
1 - STRIKER
2 - BOLTS
Fig. 15 SLIDING DOOR
1 - STOP BUMPER
2 - SCREWS (2)
3 - SCREWS (2)
4 - LOWER ROLLER ARM
5 - END PIECE
6 - SCREWS (2)
VADOORS - SLIDING 23 - 41

DISASSEMBLY
(1) Remove door.(Refer to 23 - BODY/DOORS -
SLIDING/REAR LATCH STRIKER - REMOVAL)
(2) Remove inside door handle actuator (7). (Refer
to 23 - BODY/DOORS - SLIDING/INSIDE HANDLE
ACTUATOR - REMOVAL)
(3) Remove center roller arm cover (23). (Fig. 16)
(4) Remove trim panel (24). (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - REMOVAL)
(5) Remove lock knob (27).
(6) Disconnect lock rod (25) and remove.
(7) Remove rear latch (22). (Refer to 23 - BODY/
DOORS - SLIDING/REAR LATCH - REMOVAL)
(8) Remove latch/lock control (14). (Refer to 23 -
BODY/DOORS - SLIDING/LATCH / LOCK CON-
TROL - REMOVAL)(9) Remove exterior handle (10). (Refer to 23 -
BODY/DOORS - SLIDING/EXTERIOR HANDLE -
REMOVAL)
(10) Remove center roller arm (20). (Refer to 23 -
BODY/DOORS - SLIDING/LOWER ROLLER ARM -
REMOVAL)
(11) Remove stabilizer wedges (6). (Refer to 23 -
BODY/DOORS - SLIDING/STABILIZER -
REMOVAL)
(12) Remove upper roller arm (2). (Refer to 23 -
BODY/DOORS - SLIDING/UPPER ROLLER -
REMOVAL)
(13) Remove bolts (28) and remove crash reinforce-
ment (29).
Fig. 16 SLIDING DOOR ASSEMBLY
1 - SLIDING DOOR 16 - BOLT
2 - UPPER ROLLER ARM 17 - RELEASE CABLE
3 - BOLTS (2) 18 - WASHER
4 - TRIM PLUG 19 - BOLT
5 - BOLTS (2) 20 - CENTER ROLLER ARM
6 - STABILIZER PIN 21 - RUBBER COVER
7 - INSIDE HANDLE ACTUATOR 22 - REAR LATCH
8 - SCREWS 23 - COVER
9 - TRIM PLUG 24 - TRIM PANEL
10 - EXTERIOR HANDLE 25 - CONNECTOR ROD
11 - TRIM PLUG 26 - GROMMET
12 - BOLT (1) 27 - LOCK KNOB
13 - NUT 28 - SCREWS
14 - LATCH/LOCK CONTROL 29 - CRASH REINFORCEMENT
15 - BOLT
23 - 42 DOORS - SLIDINGVA
SLIDING DOOR (Continued)