MERCEDES-BENZ SPRINTER 2006 Service Manual

(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.
(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.
Fig. 7 SLIDING DOOR CENTER TRACK
1 - NUTS
2 - QUARTER TRIM PANEL
3 - BOLT
4 - BOLT
5 - CENTER TRACK
Fig. 8 SLIDING DOOR
1 - STOP BUMPER
2 - SCREWS (2)
3 - SCREWS (2)
4 - LOWER ROLLER ARM
5 - END PIECE
6 - SCREWS (2)
23 - 38 DOORS - SLIDINGVA

(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)
(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.
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. 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
VADOORS - SLIDING 23 - 39

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.
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. 13 REAR LATCH
1 - LATCH OPENING
2 - SCREWS
3 - LATCH ASSEMBLY
4 - CONTROL CABLE
Fig. 14 LATCH STRIKER
1 - STRIKER
2 - BOLTS
23 - 40 DOORS - SLIDINGVA

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

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 - INSTALLA-
TION)
(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).
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

(14) Install the door. (Refer to 23 - BODY/DOORS
- SLIDING/SLIDING DOOR - INSTALLATION)
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 toclose 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

(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.).
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

(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.).
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 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. 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

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
VADOORS - SLIDING 23 - 47