MERCEDES-BENZ SPRINTER 2006 Service Manual

LEFT DOOR
(1) Install lock rods (2, 13) and install lock rod
guides (1, 16). (Fig. 7)
(2) Using locking pliers, hold upper lock rod (2) in
place.
(3) Install clips (15).
(4) Install the lock rod actuator (10). The bolts
should reach into the holes (arrows) of the lock rods
(2, 13). Place and o-ring (dia. 6 mm) on each of the
lock rod actuator bolts to prevent the lock rods from
chattering against the lock.
(5) Install rear door seal.
(6) Install bottom closing wedge (21) and replace
rivets (22).
(7) Install closing wedge (4).
(8) Install door hinge (6). (Refer to 23 - BODY/
DOORS - REAR/HINGE - INSTALLATION)
(9) Install door check (23). (Refer to 23 - BODY/
DOORS - REAR/CHECK - INSTALLATION)(10) Install lock rod handle (11) and replace roll
pin (12).
(11) Connect the electrical connector and install
switches (17).
(12) Connect electrical connectors and install
license plate lighting (18, 19).
(13) Install trim panel (20). (Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - INSTALLATION)
(14) Install door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - INSTALLATION)
INSTALLATION
CAUTION: If the door is being replaced a suitable
seam sealer must be used prior to painting.
(1) Support the door with a suitable lifting device,
install door and install the hinge bolts.
Fig. 7 LEFT DOOR
1 - UPPER LOCK ROD GUIDE 15 - CLIPS (2)
2 - UPPER LOCK ROD 16 - BOTTOM LOCK ROD GUIDE
3 - LEFT REAR DOOR 17 - SWITCHES
4 - TOP CLOSING WEDGE 18 - ELECTRICAL CONNECTOR
5 - BOLTS (2) 19 - LICENSE PLATE LIGHTING
6 - HINGE 20 - TRIM PANEL
7 - BOLTS (2) 21 - BOTTOM CLOSING WEDGE
8 - REAR DOOR SEAL 22 - RIVETS (2)
9 - SCREWS (2) 23 - DOOR CHECK
10 - LOCK ROD ACTUATOR 24 - BOLTS (2)
11 - LOCK ROD HANDLE 25 - FELT STRIP
12 - ROLL PIN 26 - O-RINGS (2)
13 - BOTTOM LOCK ROD 27 - THREADED PLATE
14 - SCREWS (2)
23 - 28 DOORS - REARVA

(2) Tighten bolts to 25 N´m (18 ft. lbs.).
(3) Engage check arm into receiver.
(4) Adjust the door as necessary. (Refer to 23 -
BODY/DOORS - REAR/DOOR - ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
NOTE: Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
(1) Check door gap around door. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
(2) Open doors and loosen the torx bolts. (Fig. 8)
NOTE: Close and adjust each door individually.
(3) Close the door and check gap measurement.
(4) Loosen allen screw through hole in hinge. (Fig.
9)NOTE: Adjust so that bottom closing wedges make
contact and door gaps are uniform all the way
around.
(5) Adjust rear door and tighten allen screw to 25
N´m (18 ft. lbs.).
(6) Open doors and tighten torx bolts to 25 N´m
(18 ft. lbs.).
(7) Loosen door striker and adjust so right door is
flush with the left door. (Fig. 10)
NOTE: Striker should engage in latch at center.
Door should not be lifted or pushed downward with
striker.
(8) Tighten striker.
Fig. 8 HINGE BOLTS
1 - HINGE
2 - BODY
3 - TORX BOLTS
Fig. 9 HINGE ADJUSTMENT
1 - BODY
2 - ALLEN SCREW
3 - HINGE
VADOORS - REAR 23 - 29

CAUTION: Since the rear doors are components
with static functions it is very important that they
are fastened while driving. This prevents excessive
torsion of the vehicle and leaky rear doors. The rear
doors are fastened by adjusting the closing
wedges.
(9) Closing wedges at bottom must be resting free
of play on plastic closing plates when rear doors are
closed. To adjust, loosen door hinges and raise or
lower complete doors.
(10) Loosen upper closing wedge screws and move
top closing wedge up against plastic closing plate free
of play with rear door closed and tighten screws to 10
N´m (89 in. lbs.).
(11) Check and adjust the hinges. On rear doors,
the retaining magnets should run up to the middle of
the mating plate at the side wall. If this is not the
case, correct as listed. (Fig. 11)
CAUTION: Adjustment range of screw (3) maximum
1 turn (risk of control cam breaking, 4)
²Retaining magnet is too far forward relative to
mating plate. Turn in adjustment screw (2) at top
and bottom hinge.
²Retaining magnet is too far back relative to mat-
ing plate. Turn out adjustment screw (2) at top and
bottom hinge.
²Retaining magnet is too deep relative to mating
plate. Turn in adjustment screw (2) at top hinge,
turn out adjustment screw (2) at bottom hinge.
²Retaining magnet is too high relative to mating
plate. Turn out adjustment screw (2) at top hinge,
turn in adjustment screw (2) at bottom hinge.²Retaining magnet strikes too hard against mat-
ing plate. Turn in adjustment screw (1) at top and
bottom hinge.
²Retaining magnet does not make contact with
mating plate. Turn out adjustment screw (1) at top
and bottom hinge.
²Door projects at corner paneling when closed.
Turn out adjustment screw (3) at hinge.
²Door is too far recessed at corner paneling when
closed. Turn in adjustment screw (3) at hinge.
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 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.
Fig. 10 STRIKER ADJUSTMENT
1 - STRIKER
2 - LOCK ROD HANDLE ASSEMBLY
3 - LEFT DOOR
Fig. 11 REAR HINGE ADJUSTMENT
1 - ADJUSTMENT SCREW
2 - ADJUSTMENT SCREW
3 - ADJUSTMENT SCREW
4 - CONTROL ARM
23 - 30 DOORS - REARVA

NOTE: Remove any mineral spirits with a clean
cloth after glass installation.
(6) Verify that the seal is seated in the window
opening (Fig. 12).
(7) Test the window for water leaks. (Refer to 23 -
BODY - DIAGNOSIS AND TESTING - WATER
LEAKS)
EXTERIOR HANDLE
REMOVAL
(1) Remove handle bolt. (Fig. 13)
NOTE: Front door shown, rear door similar.(2) Slide handle assembly towards front of door.
(Fig. 14)
NOTE: Front door shown, rear door similar.
(3) Pull rear of handle out away from door and dis-
engage the latch levers.
(4) Slide handle towards the rear of door and
remove.
INSTALLATION
(1) Position front of handle into front slot in door.
(Fig. 15)
NOTE: Front door shown, rear door similar.
Fig. 12 Glass & Weatherstrip Seal Installation
1 - BODY PANEL
2 - WEATHERSTRIP SEAL
3 - INSTALLATION CORD
4 - WINDOW OPENING
Fig. 13 EXTERIOR HANDLE
1 - EXTERIOR HANDLE BOLT
2-LATCH
3 - LATCH BOLTS (3)
Fig. 14 LATCH/HANDLE FASTENERS
1 - EXTERIOR HANDLE
2 - DOOR
VADOORS - REAR 23 - 31

(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.).
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)
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)
23 - 32 DOORS - REARVA

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
VADOORS - REAR 23 - 33

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. 20 LATCH
1 - DOOR LOCK KNOB
2 - ELECTRIC
3 - CABLE
4 - LOCK ROD
5 - LATCH ASSEMBLY
6 - ELECTRICAL CONNECTORS ROUTING
7 - SCREWS (3)
Fig. 21 TRIM PANEL
1 - TRIM
2 - INSIDE HANDLE ACTUATOR
3 - TRIM PANEL
4 - CONTROL CABLE
23 - 34 DOORS - REARVA

DOORS - SLIDING
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................35
INSTALLATION.........................36
INSIDE HANDLE ACTUATOR
REMOVAL.............................36
INSTALLATION.........................36
UPPER ROLLER ARM
REMOVAL.............................36
INSTALLATION.........................36
CENTER ROLLER ARM
REMOVAL.............................36
INSTALLATION.........................37
LOWER ROLLER ARM
REMOVAL.............................37
INSTALLATION.........................37
CENTER TRACK
REMOVAL.............................37
INSTALLATION.........................38
LATCH / LOCK CONTROL
REMOVAL.............................38
INSTALLATION.........................39
REAR LATCH
REMOVAL.............................40INSTALLATION.........................40
REAR LATCH STRIKER
REMOVAL.............................40
INSTALLATION.........................40
SLIDING DOOR
REMOVAL.............................40
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.
Fig. 1 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - CATCH POINTS
3 - BOLT
4 - TRIM CAP
VADOORS - SLIDING 23 - 35

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.
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
23 - 36 DOORS - SLIDINGVA

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)
Fig. 4 CENTER ROLLER ARM
1 - TRIM COVER
2 - SLIDING DOOR
3 - CENTER ROLLER ARM RUBBER COVER
4 - CENTER ROLLER ARM
5 - BOLT
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
VADOORS - SLIDING 23 - 37