MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

ASSEMBLY
(1) Install the crash reinforcement (29). (Fig. 17)
(2) Install the bolts (28) and tighten to 21 N´m (15
ft. lbs.).
(3) Install upper roller arm (2). (Refer to 23 -
BODY/DOORS - SLIDING/UPPER ROLLER -
INSTALLATION)
(4) Install stabilizer wedges (6). (Refer to 23 -
BODY/DOORS - SLIDING/STABILIZER - INSTAL-
LATION)
(5) Install center roller arm (20). (Refer to 23 -
BODY/DOORS - SLIDING/LOWER ROLLER ARM -
INSTALLATION)
(6) Install exterior handle (10). (Refer to 23 -
BODY/DOORS - SLIDING/EXTERIOR HANDLE -
INSTALLATION)(7) Install the latch/lock control (14). (Refer to 23 -
BODY/DOORS - SLIDING/LATCH / LOCK CON-
TROL - INSTALLATION)
(8)
Install the rear latch (22). (Refer to 23 - BODY/
DOORS - SLIDING/REAR LATCH - INSTALLATION)
(9) Install lock rod (25) and connect to latch/lock
control.
(10) Install the lock knob (27).
(11) Install the trim panel (24). (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
(12) Install inside handle actuator (7). (Refer to 23
- BODY/DOORS - SLIDING/INSIDE HANDLE
ACTUATOR - INSTALLATION)
(13) Install the center roller arm cover (23).
(14) Install the door. (Refer to 23 - BODY/DOORS
- SLIDING/SLIDING DOOR - INSTALLATION)
Fig. 17 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
VADOORS - SLIDING 23 - 43
SLIDING DOOR (Continued)

INSTALLATION
(1) Install the door by inserting the center and
upper rollers into the tracks and sliding the door for-
ward to the front of each track.
(2) Connect the lower roller arm and install the
screws.
(3) Tighten the screws to 25 N´m (18 ft. lbs.).
(4) Install door stop and screws.
(5) Tighten the screws to 10 N´m (89 in. lbs.).
(6) Install the center track end piece and install
the screw.
(7) Tighten the screw to 10 N´m (89 in. lbs.).
(8) Check and adjust door if necessary. (Refer to 23
- BODY/DOORS - SLIDING/SLIDING DOOR -
ADJUSTMENTS)
(9) Connect battery negative cable.
ADJUSTMENTS
ADJUSTMENT
NOTE: Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
A suitable body sealant should be used when
removing or moving the hinges.
(1) Remove bolts and remove striker. (Fig. 18)
(2) Check gaps and ridge pattern on door all the
way around. (Refer to 23 - BODY/BODY STRUC-
TURE/GAP AND FLUSH - SPECIFICATIONS)
NOTE: It must be possible to move the guide wedge
during the entire adjusting procedure. In order to
close the door during adjustment move guide
wedge if necessary.(3) Loosen guide wedge screws.
Gaps and Ridge Adjustment
(1) Loosen screw and adjust rear ridge pattern by
lifting and lowering sliding door at center roller arm.
(Fig. 19)
(2) Tighten bolt to 45 N´m (33 ft. lbs.).
(3) Loosen upper roller arm screws. (Fig. 20)
(4) Loosen lower roller arm screws.
(5) Adjust front ridge pattern by raising or lower-
ing door.
(6) Tighten upper and lower roller arm bolts to 25
N´m (18 ft. lbs.).
Fig. 18 LATCH STRIKER
1 - STRIKER
2 - BOLTS
Fig. 19 ADJUST CENTER ROLLER ARM
1 - BOLT
2 - CENTER ROLLER ARM
Fig. 20 UP/DOWN ADJUST
1 - SCREWS (2) UPPER ROLLER ARM
2 - SCREWS (2) LOWER ROLLER ARM
23 - 44 DOORS - SLIDINGVA
SLIDING DOOR (Continued)

(7) Loosen center roller bolt and adjust the front
and rear gaps.
(8) Check rear ridge pattern alignment and
tighten bolt to 45 N´m (33 ft. lbs.).
Flush Adjustment
(1) Loosen upper roller arm screw. (Fig. 21)
(2) Loosen lower roller arm screws.
(3) Adjust front of door flushness by altering posi-
tion of top and bottom roller arms.
(4) Tighten upper and lower roller arm adjustment
screws.
(5) Install door striker and hand tighten the bolts.
(6) Adjust door striker in and out to adjust rear
door flushness.
(7) Tighten striker bolts to 25 N´m (18 ft. lbs.).
(Fig. 18)
(8) Loosen stabilizer closing wedge screws. (Fig.
22)
(9) Close sliding door to adjust closing wedge.
(10) Open door and tighten screws to 10 N´m (89
in. lbs.).
Door Stop Bumper Adjust
(1) Loosen door stop bumper bolts.
(2) Open sliding door and hold tight in end posi-
tion.
(3) Hold stop bumper tight against c-pillar and
tighten bolts to 10 N´m (89 in. lbs.).
STABILIZER
REMOVAL
(1) Remove screws and remove stabilizers. (Fig.
23)
INSTALLATION
(1) Install receiver and install screws.
(2) Tighten screws to 10 N´m (89 in. lbs.).
(3) Install wedge and install screws.
(4) Close sliding door to adjust closing wedge.
(5) Open door and tighten screws to 10 N´m (89 in.
lbs.).
Fig. 21 IN/OUT ADJUST
1 - IN/OUT ADJUSTMENT SCREW - UPPER ARM
2 - IN/OUT ADJUSTMENT SCREWS - LOWER ARM
Fig. 22 SLIDING DOOR STABILIZER
1 - SCREWS
2 - GUIDE WEDGES (2)
3 - SCREWS
4 - RECEIVERS (2)
Fig. 23 SLIDING DOOR STABILIZER
1 - SCREWS
2 - GUIDE WEDGES (2)
3 - SCREWS
4 - RECEIVERS (2)
VADOORS - SLIDING 23 - 45
SLIDING DOOR (Continued)

TRIM PANEL
REMOVAL
Upper
(1) Remove rivets and remove panel.
Lower
(1) Remove the bolts and remove the stop bumper.
(Fig. 24)
(2) Remove the inside handle actuator. (Refer to 23
- BODY/DOORS - SLIDING/INSIDE HANDLE
ACTUATOR - REMOVAL)
(3) Remove the push pin fasteners and remove the
trim panel.
INSTALLATION
Upper
(1) Install trim panel and replace rivets.
Lower
(1) Install the trim panel and push pin fasteners.
(2) Install the inside handle actuator. (Refer to 23 -
BODY/DOORS - SLIDING/INSIDE HANDLE
ACTUATOR - INSTALLATION)
(3) Install stop bumper, bolts and adjust if neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
DOOR GLASS
REMOVAL
(1) Position an assistant on one side of the door 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.
NOTE: Use mineral spirits as a lubricant to aid seal
installation in the window opening.
(3)
Position the glass and seal in the window opening.
(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. 25).
(7)
Test the window for water leaks. (Refer to 23 -
BODY - DIAGNOSIS AND TESTING - WATER LEAKS)
Fig. 25 Glass & Weatherstrip Seal Installation
1 - BODY PANEL
2 - WEATHERSTRIP SEAL
3 - INSTALLATION CORD
4 - WINDOW OPENING
Fig. 24 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
23 - 46 DOORS - SLIDINGVA

EXTERIOR
TABLE OF CONTENTS
page page
FUEL FILL DOOR
REMOVAL.............................47
INSTALLATION.........................47
GRILLE
REMOVAL.............................47
INSTALLATION.........................47
LICENSE PLATE BRACKET
REMOVAL.............................47
INSTALLATION.........................47RADIATOR CROSSMEMBER
REMOVAL.............................47
INSTALLATION.........................48
SIDE VIEW MIRROR
REMOVAL.............................48
INSTALLATION.........................48
SIDE VIEW MIRROR - GLASS
REMOVAL.............................49
INSTALLATION.........................49
FUEL FILL DOOR
REMOVAL
(1) Open passenger compartment door.
(2) Open fuel fill door.
(3) Using a trim stick C-4755 or equivalent, dis-
connect the filler cap tether.
(4) Remove two bolts and remove filler door.
INSTALLATION
(1) Install the door and bolts.
(2) Connect filler cap tether.
(3) Close doors.
GRILLE
REMOVAL
(1) Remove screw rivets. (Fig. 1)
(2) Loosen lower screws.
(3) Remove upper screws.
(4) Remove grille.
INSTALLATION
(1) Install grille.
(2) Install upper screw.
(3) Tighten lower screws.
(4) Install screw rivets.
LICENSE PLATE BRACKET
REMOVAL
(1) Remove two lower push-pin fasteners
(2) Remove two screws.
(3) Remove bracket.
INSTALLATION
(1) Install bracket.
(2) Install screws.
(3) Install push-pin fasteners.
RADIATOR CROSSMEMBER
REMOVAL
(1) Remove grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - REMOVAL)
(2) Remove headlamps. (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - EXTERIOR/FRONT
LAMP UNIT - REMOVAL)
(3) Remove heat shield. (Fig. 2)
(4) Remove retaining clamps and rubber mounts.
Fig. 1 GRILLE
1 - UPPER SCREW
2 - GRILLE
3 - LOWER SCREWS (2)
4 - SCREW RIVETS
VAEXTERIOR 23 - 47

(5) Remove bolts.
(6)
Remove crossmember and disconnect hood cable.
INSTALLATION
(1) Connect hood release cable and install cross-
member.
(2) Install crossmember bolts and tighten to 14
N´m (10 ft. lbs.).
(3) Install rubber mounts and retaining clamps.
(4) Install heat shield.
(5) Install headlamps. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/FRONT LAMP
UNIT - INSTALLATION)
(6) Install grille. (Refer to 23 - BODY/EXTERIOR/
GRILLE - INSTALLATION)
SIDE VIEW MIRROR
REMOVAL
Driver's Side
(1) Disconnect and isolate battery negative cable.
(2) Remove trim plug. (Fig. 3)
NOTE: If the vehicle is not equipped with power
mirrors, skip to step 5.
(3) Remove trim panel. (Refer to 23 - BODY/DOOR
- FRONT/TRIM PANEL - REMOVAL)
(4) Remove tape, expose electrical connector and
disconnect. (Fig. 3)
(5) Remove bolts and remove mirror.
(6) If equipped, Pull wire harness through.
Passenger Side
(1) Disconnect and isolate battery negative cable.
(2) Remove trim plug. (Fig. 4)
NOTE: If the vehicle is not equipped with power
mirrors, skip to step 5.
(3) Separate dust boot from a-pillar.
(4) Disconnect the electrical connector.
(5) Remove bolts and remove mirror.
(6) If equipped, pull wire harness through.
INSTALLATION
Driver's Side
(1) If equipped, pull wire harness through door.
(2) Install mirror and bolts.
(3) Tighten the bolts to 25 N´m (18 ft. lbs.).
NOTE: If vehicle is not equipped with power mir-
rors, skip to step 6.
(4) Connect electrical connector and replace tape.
(5) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
(6) Install trim plug.
(7) Connect battery negative cable.
Fig. 2 RADIATOR CROSSMEMBER
1 - HEAT SHIELD
2 - HOOD CABLE
3 - CROSSMEMBER
4 - RUBBER MOUNTS
5 - RETAINING CLAMP
Fig. 3 DRIVERS SIDE MIRROR
1 - ELECTRICAL CONNECTOR
2 - MIRROR
3 - EXTERIOR BOLTS
4 - INNER BOLT
5 - TRIM PLUG
6 - TAPE
23 - 48 EXTERIORVA
RADIATOR CROSSMEMBER (Continued)

Passenger Side
(1) If equipped, pull wire harness through door.
(2) Install mirror and bolts.
(3) Tighten the bolts to 25 N´m (18 ft. lbs.).
NOTE: If vehicle is not equipped with power mir-
rors, skip to step 6.
(4) Connect the electrical connector.
(5) Connect dust boot to a-pillar.
(6) Install trim plug.
(7) Connect battery negative cable.
SIDE VIEW MIRROR - GLASS
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Press mirror glass in at bottom.
(3) Pull mirror glass up and out of the guides.
(Fig. 5)
(4) Disconnect the electrical connectors, if
equipped.
INSTALLATION
(1) Connect the electrical connectors, if equipped.
(2) Push mirror glass down into the guides.
(3) Straighten mirror glass.
(4) Connect battery negative cable.
Fig. 4 PASSENGER SIDE MIRROR
1 - OUTER BOLTS
2 - INNER BOLT
3 - TRIM PLUG
4 - MIRROR
5 - ELECTRICAL CONNECTOR
6 - DUST BOOT
Fig. 5 SIDE VIEW MIRROR - GLASS
1 - MIRROR GLASS
2 - ELECTRICAL CONNECTORS
3 - GUIDES
VAEXTERIOR 23 - 49
SIDE VIEW MIRROR (Continued)

HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL.............................50
INSTALLATION.........................50
HOOD
REMOVAL.............................50
INSTALLATION.........................50
ADJUSTMENTS
ADJUSTMENT........................51
LATCH
REMOVAL.............................51
INSTALLATION.........................51
LATCH RELEASE CABLE
REMOVAL.............................51INSTALLATION.........................51
LATCH RELEASE HANDLE
REMOVAL.............................52
INSTALLATION.........................52
PROP ROD
REMOVAL.............................52
INSTALLATION.........................52
SAFETY LATCH
REMOVAL.............................52
INSTALLATION.........................52
HINGE
REMOVAL
NOTE: It is not necessary to remove the hood to
replace one or both hinges. The hinges can be
replaced one at a time.
(1) Open hood and support as needed.
(2) Using a grease pencil or equivalent, mark the
position of the hinge on the hood and cowl.
(3) Remove the two hood nuts.
(4) Remove the two cowl bolts and remove hinge.
INSTALLATION
(1) Position hinge on vehicle and align reference
marks.
(2) Install cowl bolts and tighten to 23 N´m (17 ft.
lbs.).
(3) Install hood nuts and tighten to 23 N´m (17 ft.
lbs.).
(4) Check and adjust hood if necessary. (Refer to
23 - BODY/HOOD/HOOD - ADJUSTMENTS)
HOOD
REMOVAL
(1) Raise and support hood.
(2) Remove the prop rod retaining clip. (Fig. 1)
(3) Separate the prop and spring from the hood.
(4) Using a grease pencil or equivalent, mark loca-
tion of hood hinges on hood for installation align-
ment.(5) Remove nuts attaching hinges to hood.
(6) With the aid of a helper, remove hood from
vehicle.INSTALLATION
(1) Position hood on hinges.
(2) Install nuts finger-tight.
(3) Connect spring and prop onto hood and install
the retaining spring.
Fig. 1 HOOD
1 - PROP ROD RETAINING CLIP
2 - PROP SPRING
3 - PROP ROD
4 - HINGE
5 - NUTS (2)
23 - 50 HOODVA

(4) Align hinges with installation reference marks
and tighten bolts to 23 N´m (17 ft. lbs.).
(5) Check and adjust as necessary. (Refer to 23 -
BODY/HOOD/HOOD - ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Left and right hood gaps 5   0.5 mm
Flush offset for
hood/fender·1.0 mm
(1) Check hood to fender gap. Refer to the SPECI-
FICATIONS table.
(2) Loosen hinge to cowl bolts and adjust hood side
to side, if necessary.
(3) Tighten bolts to 23 N´m (17 ft. lbs.).
(4) Check hood to fender flushness. Refer to the
SPECIFICATIONS table.
(5) Loosen hinge to hood nuts and adjust hood up
and down, if necessary.
(6) Tighten nuts to 23 N´m (17 ft. lbs.).
(7) Loosen safety latch bolts. (Fig. 2)
(8) Adjust latch to align with hood latch, if neces-
sary.
(9) Tighten safety latch bolts.
(10) Loosen safety latch striker pin lock nut and
adjust striker pin up and down to adjust front of
hood to fender flushness. Refer to the SPECIFICA-
TIONS table.
(11) Tighten lock nut fully.
(12) Adjust hood slam bumpers up or down if nec-
essary.
LATCH
REMOVAL
(1) Remove bolts and remove latch. (Fig. 3)
(2) Disconnect latch cable.
INSTALLATION
(1) Connect latch cable and install latch.
(2) Install the bolts and tighten.
LATCH RELEASE CABLE
REMOVAL
(1) Remove the release handle screws and release
handle.
(2) Disconnect the cable from the handle.
(3) Remove the latch. (Refer to 23 - BODY/HOOD/
LATCH - REMOVAL)
(4) Route cable through cowl panel and remove
from engine compartment.
INSTALLATION
(1) Route cable through engine compartment and
into passenger compartment as necessary.
(2) Install latch. (Refer to 23 - BODY/HOOD/
LATCH - INSTALLATION)
(3) Connect cable to release handle.
(4) Install release handle and install the screws.Fig. 2 SAFETY LATCH
1 - SAFETY LATCH
2 - BOLTS
Fig. 3 HOOD LATCH
1 - BOLTS
2 - LATCH CABLE
3-LATCH
VAHOOD 23 - 51
HOOD (Continued)

LATCH RELEASE HANDLE
REMOVAL
(1) Remove the screws and remove the release
handle.
(2) Disconnect the cable from handle.
INSTALLATION
(1) Connect latch cable to release handle.
(2) Install handle and install the screws.
PROP ROD
REMOVAL
(1) Open and support hood.
(2) Remove the prop rod retaining clip. (Fig. 1)
(3) Separate the prop and spring from the hood.
(4) Remove nut and position the washer bottle
aside. (Fig. 4)
(5)
Remove stud nut and remove hood prop. (Fig. 5)
INSTALLATION
(1) Install hood prop and install the stud nut.
(2) Position washer bottle back and install the nut
and washer.
(3) Connect spring and prop onto hood and install
the retaining spring.
SAFETY LATCH
REMOVAL
(1) Open hood.
(2) Using a grease pencil or equivalent, mark the
position of the safety latch to aid installation.(3) Remove the bolts and remove the latch. (Fig. 6)
INSTALLATION
(1) Install the latch and install the bolts.
(2) Adjust the latch if necessary. (Refer to 23 -
BODY/HOOD/HOOD - ADJUSTMENTS)
Fig. 4 Washer Reservoir Remove/Install
1 - RIGHT INNER FENDER
2 - WASHER RESERVOIR
3 - NUT & WASHER
4 - ROUTING CLIP
Fig. 5 Washer Reservoir Mounting
1 - RIGHT INNER FENDER
2 - STUD NUT
3 - DASH PANEL
4 - RIGHT FRONT WHEEL HOUSE
5 - GROMMET (2)
6 - HOOD PROP
Fig. 6 SAFETY LATCH
1 - SAFETY LATCH
2 - BOLTS
23 - 52 HOODVA