MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

DOOR - FRONT
TABLE OF CONTENTS
page page
CHECK
REMOVAL.............................13
INSTALLATION.........................13
DOOR
REMOVAL.............................14
INSTALLATION.........................14
ADJUSTMENTS
ADJUSTMENT........................15
DOOR GLASS
REMOVAL.............................15
INSTALLATION.........................15
EXTERIOR HANDLE
REMOVAL.............................16
INSTALLATION.........................16
HINGE
REMOVAL.............................17
INSTALLATION.........................17
LATCH
REMOVAL.............................18INSTALLATION.........................18
LATCH STRIKER
REMOVAL.............................18
INSTALLATION.........................18
LOCK CYLINDER
REMOVAL.............................18
INSTALLATION.........................18
TRIM PANEL
REMOVAL.............................19
INSTALLATION.........................20
WINDOW REGULATOR - POWER
REMOVAL.............................20
INSTALLATION.........................21
WINDOW REGULATOR - MANUAL
REMOVAL.............................22
INSTALLATION.........................23
CHECK
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove trim panel. (Refer to 23 - BODY/DOOR
- FRONT/TRIM PANEL - REMOVAL)
(3) Remove a-pillar bolts. (Fig. 1)(4) Remove the bolt/nut and remove check bracket.
(Fig. 2)
(5) Remove the door fasteners and remove check
from door.
INSTALLATION
(1) Install check through door opening and install
the fasteners.
Fig. 1 FRONT DOOR CHECK - BODY
1 - DOOR
2 - A-PILLAR BOLTS
3 - DOOR CHECK
Fig. 2 FRONT DOOR CHECK - DOOR
1 - DOOR FASTENERS
2 - CHECK BRACKET NUT
3 - CHECK BRACKET
4 - DOOR OPENING
VADOOR - FRONT 23 - 13

(2) Tighten door fasteners to 10 N´m (89 in. lbs.).
(3) Install bracket onto check and install bracket
bolt/nut.
(4) Tighten bracket bolt/nut to 6 N´m (53 in. lbs.).
(5) Install check bracket onto a-pillar.
(6) Apply Loctitet243 sealant check strap bolts
and install bolts.
(7) Tighten the M8 bolts to 35 N´m (26 ft. lbs.) or
tighten the M6 bolts to 10 N´m (89 in. lbs.).
(8) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
(9) Connect battery negative cable.
DOOR
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - REMOVAL)
(3) Position aside the wiring boot and disconnect
the electrical connectors. (Fig. 3)
(4) Remove the bolts and disconnect the door check
from the a-pillar. (Fig. 4)
(5) Support door with a suitable device.
(6) Loosen the hinge set screws. (Fig. 5)
(7) Remove door by lifting off hinge pins.
INSTALLATION
(1) Slide door into hinges.
(2) Install set screws.
(3) Install check bracket onto a-pillar.
(4) Apply Loctitet243 sealant check strap bolts
and install bolts.(5) Tighten the M8 bolts to 35 N´m (26 ft. lbs.) or
tighten the M6 bolts to 10 N´m (89 in. lbs.).
(6) Connect all door electrical connectors and posi-
tion boot back.
(7) Install mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - INSTALLATION)
(8) Adjust door if required. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
(9) Connect battery negative cable.
Fig. 3 ELECTRICAL CONNECTORS
1 - ELECTRICAL CONNECTORS
2 - BOOT
3 - DOOR
Fig. 4 FRONT DOOR CHECK - BODY
1 - DOOR
2 - A-PILLAR BOLTS
3 - DOOR CHECK
Fig. 5 FRONT DOOR
1 - UPPER CHECK BOLT
2 - DOOR CHECK
3 - UPPER HINGE SET SCREW
4 - LOWER HINGE SET SCREW
5 - HINGE RECEIVERS
6 - DOOR
7 - LOWER CHECK BOLT
23 - 14 DOOR - FRONTVA
CHECK (Continued)

ADJUSTMENTS
ADJUSTMENT
NOTE: Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
²During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper bolts to hold the door
with final torque of the fasteners occurring after
correct door positioning is achieved.
²A suitable body sealant should be used when
removing or moving the hinges.
(1) Check door alignment. (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS)
(2) If adjustment is required, remove latch striker.
(Refer to 23 - BODY/DOOR - FRONT/LATCH
STRIKER - REMOVAL)
(3) Remove side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - REMOVAL)
(4) Loosen hinge bolts and adjust door gap and
align ridge pattern as necessary.
(5) Tighten hinge bolts to 25 N´m (18 ft. lbs.).
(6) Install latch striker and adjust flush measure-
ment as necessary. (Refer to 23 - BODY/DOOR -
FRONT/LATCH STRIKER - INSTALLATION)
(7) Install side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - INSTALLA-
TION)
DOOR GLASS
REMOVAL
(1) Remove the regulator. (Refer to 23 - BODY/
DOOR - FRONT/WINDOW REGULATOR - POWER
or MANUAL - REMOVAL)
(2) Remove reinforcement bolts. (Fig. 6)
(3) Carefully lower glass into door and out of run
channel.
(4) Remove glass from door.
INSTALLATION
(1) Carefully place glass into door and slide up
into run channel.
(2) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 7)
(3) Install reinforcement and install the bolts.
(4) Tighten the reinforcement bolts to 21 N´m (18
ft. lbs.).(5) Install the regulator. (Refer to 23 - BODY/
DOOR - FRONT/WINDOW REGULATOR - POWER
or MANUAL - INSTALLATION)
Fig. 6 FRONT DOOR GLASS
1 - DOOR RUN CHANNEL
2 - DOOR GLASS
3 - REINFORCEMENT BOLTS
Fig. 7 GLASS SUPPORT
1 - WOOD WEDGE (or equivalent)
2 - WINDOW GLASS
VADOOR - FRONT 23 - 15
DOOR (Continued)

EXTERIOR HANDLE
REMOVAL
(1) Remove handle bolt. (Fig. 8)
(2) Slide handle assembly towards front of door.
(Fig. 9)
(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. 10)
(2) Position rear of handle into latch opening and
engage lock and latch actuation levers with the latch
levers. (Fig. 11)
Fig. 8 LATCH/HANDLE FASTENERS
1 - EXTERIOR HANDLE BOLT
2-LATCH
3 - LATCH BOLTS (3)
Fig. 9 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - DOOR
Fig. 10 EXTERIOR HANDLE INSTALLATION
1 - DOOR LATCH OPENING
2 - LOCK ACTUATION LEVER
3 - LATCH ACTUATION LEVER
4 - EXTERIOR HANDLE
Fig. 11 LATCH LEVERS
1 - LATCH LEVER
2 - LATCH OPENING
3 - LOCK LEVER
23 - 16 DOOR - FRONTVA

(3) Slide exterior handle towards rear of door and
install bolt. (Fig. 12)
(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 side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - REMOVAL)
(3) Loosen hinge set bolts. (Fig. 13)
(4) Remove hinge bolts and remove hinge. (Fig. 14)
INSTALLATION
(1) Install hinge and install bolts.
(2) Tighten bolts to 25 N´m (18 ft. lbs.).
(3) Tighten hinge set bolts.
(4) Install side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - INSTALLA-
TION)
(5) Adjust door if necessary. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
Fig. 12 EXTERIOR HANDLE
1 - EXTERIOR HANDLE BOLT
2-LATCH
3 - LATCH BOLTS (3)
Fig. 13 FRONT DOOR
1 - UPPER CHECK BOLT
2 - DOOR CHECK
3 - UPPER HINGE SET SCREW
4 - LOWER HINGE SET SCREW
5 - HINGE RECEIVERS
6 - DOOR
7 - LOWER CHECK BOLT
Fig. 14 HINGE
1 - HINGE BOLTS
2 - DOOR HINGE
VADOOR - FRONT 23 - 17
EXTERIOR HANDLE (Continued)

LATCH
REMOVAL
(1) Remove trim panel. (Refer to 23 - BODY/DOOR
- FRONT/TRIM PANEL - REMOVAL)
(2) Remove exterior handle. (Refer to 23 - BODY/
DOOR - FRONT/EXTERIOR HANDLE - REMOVAL)
(3) Remove screws and remove latch assembly.
(4) Disconnect electrical connector and control
cable. (Fig. 15)
INSTALLATION
(1) Connect electrical connectors and control cable.
(2) Install latch and install bolts.
(3) Tighten bolts to 10 N´m (89 in. lbs.).
(4) Install exterior handle. (Refer to 23 - BODY/
DOOR - FRONT/EXTERIOR HANDLE - INSTALLA-
TION)
(5) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
LATCH STRIKER
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the striker to aid installation.
(2) Remove the bolts and remove the striker. (Fig.
16)
INSTALLATION
(1) Install striker and install bolts.
(2) Tighten bolts to 25 N´m (18 ft. lbs.).
(3) Check door for flush and adjust the striker hor-
izontally if necessary. (Refer to 23 - BODY/BODY
STRUCTURE/GAP AND FLUSH - SPECIFICA-
TIONS)
LOCK CYLINDER
REMOVAL
(1) Remove exterior door handle. (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
REMOVAL)
(2) Remove lock cylinder from handle.
INSTALLATION
(1) Install lock cylinder into exterior handle.
(2) Install exterior handle. (Refer to 23 - BODY/
DOOR - FRONT/EXTERIOR HANDLE - INSTALLA-
TION)
Fig. 15 FRONT DOOR LATCH
1 - CONTROL CABLE
2 - LATCH LEVER
3 - LATCH BOLTS (3)
4 - WIRE HARNESS
5 - LATCH ASSEMBLY
Fig. 16 LATCH STRIKER
1 - BOLTS
2 - STRIKER
23 - 18 DOOR - FRONTVA

TRIM PANEL
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Using a small flat bladed tool or equivalent,
press retaining clip upward through cutout in handle
cover and remove cover. (Fig. 17)
(3) Remove switch bezel and disconnect electrical
connectors.
(4) Remove the screws. (Fig. 18)(5) Remove mounting ring and remove window
crank, if equipped.
(6) Open pocket door. (Fig. 19)
Fig. 17 TRIM PANEL HANDLE
1 - SWITCH BEZEL
2 - HANDLE COVER
Fig. 18 TRIM PANEL FASTENERS
1 - UPPER SCREW
2 - WINDOW CRANK MOUNTING RING
3 - WINDOW CRANK
4 - LOWER SCREW
Fig. 19 TRIM PANEL
1 - TRIM PANEL
2 - DOOR POCKET
VADOOR - FRONT 23 - 19

(7) Using a trim stick C-4755 or equivalent, sepa-
rate window frame molding from door. (Fig. 20)
(8) Slightly pull door trim upward and swing away
slightly.
(9) Unlock retainer clip and disconnect control
cable. (Fig. 21)
(10) Remove trim panel.INSTALLATION
(1) Position trim panel and connect control cable.
(2) Install trim panel.
(3) Position window frame molding and seat clips
fully.
(4) Close pocket door.
(5) Install window crank and mounting ring, if
equipped.
(6) Install handle screws.
(7) Connect electrical connectors and install switch
bezel.
(8) Install handle cover.
(9) Connect battery negative cable.
WINDOW REGULATOR -
POWER
REMOVAL
(1) Lower front window approximately 2 cm (3/4
in.).
(2) Disconnect and isolate battery negative cable.
(3) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(4) Disconnect electrical connector. (Fig. 22)
Fig. 20 MANUAL REGULATOR ASSEMBLY
1 - DOOR
2 - CARRIER PLATE BOLTS
3 - CARRIER PLATE
4 - REGULATOR ASSEMBLY
5 - SEALING STRIP
6 - REGULATOR RIVETS (4)
7 - WINDOW CRANK/TRIM RING
8 - TRIM PANEL
9 - CLIPS
10 - WINDOW FRAME MOLDING
11 - REGULATOR
Fig. 21 CONTROL CABLE
1 - RETAINER CLIP
2 - CONTROL CABLE MOUNTING
Fig. 22 ELECTRICAL CONNECTOR
1 - ELECTRICAL CONNECTOR
2 - REGULATOR MOTOR
3 - WIRE TIE
23 - 20 DOOR - FRONTVA
TRIM PANEL (Continued)

(5) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 23)
(6) Remove tape securing wire harness to regula-
tor assembly. (Fig. 24)(7) Remove carrier plate bolts.
(8) Disengage lift arm from glass guide rail and
remove regulator assembly. (Fig. 25)
(9) Remove four rivets attaching regulator to car-
rier plate and remove regulator.
INSTALLATION
(1) Install regulator onto carrier plate and install
new rivets.
(2) Install regulator lift arm into glass guide rail
and install regulator assembly.
(3) Install carrier bolts and tighten to 10 N´m (89
in. lbs.).
(4) Replace tape securing wire harness to regulator
assembly.
(5) Remove glass support.
(6) Connect the electrical connector.
(7) Connect battery negative cable.
(8) Verify correct window operation.
(9) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
Fig. 23 GLASS SUPPORT
1 - WOOD WEDGE (or equivalent)
2 - WINDOW GLASS
Fig. 24 REGULATOR ASSEMBLY MOUNTING
1 - CARRIER PLATE BOLTS (3)
2 - CARRIER PLATE
3 - REGULATOR MOTOR
4 - TAPE
Fig. 25 REGULATOR ASSEMBLY
1 - GUIDE RAIL
2 - REGULATOR
3 - CARRIER PLATE
4 - RIVETS (4)
5 - CARRIER PLATE BOLTS (3)
6 - WINDOW GLASS
VADOOR - FRONT 23 - 21
WINDOW REGULATOR - POWER (Continued)

WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 26)
(4) Remove carrier plate bolts. (Fig. 27)
(5) Disengage lift arm from glass guide rail and
remove regulator assembly. (Fig. 28)
(6) Remove four rivets attaching regulator to car-
rier plate and remove regulator. (Fig. 29)
Fig. 26 GLASS SUPPORT
1 - WOOD WEDGE (or equivalent)
2 - WINDOW GLASS
Fig. 27 MANUAL REGULATOR ASSEMBLY
1 - DOOR
2 - CARRIER PLATE BOLTS
3 - CARRIER PLATE
4 - REGULATOR ASSEMBLY
5 - SEALING STRIP
6 - REGULATOR RIVETS (4)
7 - WINDOW CRANK/TRIM RING
8 - TRIM PANEL
9 - CLIPS
10 - WINDOW FRAME MOLDING
11 - REGULATOR
Fig. 28 LIFT ARM
1 - GLASS GUIDE RAIL
2 - LIFT ARM
23 - 22 DOOR - FRONTVA