MERCEDES-BENZ SPRINTER 2006 Service Manual

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)
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)
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

(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)(7) Using a trim stick C-4755 or equivalent, sepa-
rate window frame molding from door. (Fig. 20)
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

(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)
(5) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 23)
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

(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)
WINDOW REGULATOR - MAN-
UAL
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)
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

(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)
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) Remove glass support.
(5) Connect battery negative cable.
(6) Verify correct window operation.
(7) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
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
Fig. 29 MANUAL REGULATOR FASTENERS
1 - RIVETS (4)
2 - REGULATOR
3 - CARRIER PLATE
23 - 22 DOOR - FRONTVA

DOORS - REAR
TABLE OF CONTENTS
page page
CHECK
REMOVAL.............................23
INSTALLATION.........................23
DOOR
REMOVAL.............................23
DISASSEMBLY.........................25
ASSEMBLY............................27
INSTALLATION.........................28
ADJUSTMENTS
ADJUSTMENT........................29
DOOR GLASS
REMOVAL.............................30
INSTALLATION.........................30
EXTERIOR HANDLE
REMOVAL.............................31INSTALLATION.........................31
HINGE
REMOVAL.............................32
INSTALLATION.........................33
INSIDE HANDLE ACTUATOR
REMOVAL.............................33
INSTALLATION.........................33
LATCH
REMOVAL.............................33
INSTALLATION.........................34
TRIM PANEL
REMOVAL.............................34
INSTALLATION.........................34
CHECK
REMOVAL
(1) Open door and disengage check arm from
receiver. (Fig. 1)
(2) Remove the screws and remove the check arm.
(3) Remove the d-pillar trim, if equipped. (Refer to
23 - BODY/INTERIOR/D-PILLAR TRIM -
REMOVAL)
(4) Remove the rivets and remove the receiver.
INSTALLATION
(1) Install the receiver and replace the rivets.(2) Install d-pillar trim, if equipped. (Refer to 23 -
BODY/INTERIOR/D-PILLAR TRIM - INSTALLA-
TION)
(3) Install check arm and screws.
(4) Tighten the screws to 10 N´m (89 in. lbs.).
DOOR
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Open door and disengage check arm from
receiver. (Fig. 2)
(3) Using a grease pencil or equivalent, mark the
outline of the door hinges on the door to aid in instal-
lation.
(4) Support door with a suitable lifting device.
(5) Remove the bolts and remove the door. (Fig.
3)
Fig. 1 DOOR CHECK
1 - RECEIVER
2 - DOOR CHECK
3 - SCREWS
VADOORS - REAR 23 - 23

Fig. 2 CHECK STRAP
1 - RECEIVER
2 - DOOR CHECK
Fig. 3 DOOR HINGES
1 - DOOR
2 - TORX BOLTS (2 PER HINGE)
3 - ALLEN BOLTS (1 PER HINGE)
23 - 24 DOORS - REARVA

DISASSEMBLY
RIGHT DOOR
(1) Remove door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - REMOVAL)
(2) Remove trim panel (20) (Fig. 4). (Refer to 23 -
BODY/DOORS - REAR/TRIM PANEL - REMOVAL)
(3) Remove latch assembly (14). (Refer to 23 -
BODY/DOORS - REAR/LATCH - REMOVAL)
(4) Remove screws (21) from door handle (20).
(5) Slide door handle (20) to right and remove.
(6) Remove rivets (15) and remove closing wedge
(16).
(7) Remove bolts (2) and remove top closing wedge
(1).
(8) Remove bolts (9) and remove door check (10).
(Refer to 23 - BODY/DOORS - REAR/CHECK -
REMOVAL)
(9) Remove the bolts (3) and remove the door
hinges (4). (Refer to 23 - BODY/DOORS - REAR/
HINGE - INSTALLATION)
Fig. 4 RIGHT DOOR
1 - TOP CLOSING WEDGE 12 - DOOR LOCK LINKAGE
2 - BOLTS 13 - BOLTS (3)
3 - BOLTS (2) 14 - LATCH ASSEMBLY
4 - DOOR HINGE 15 - RIVETS (2)
5 - PANEL 16 - BOTTOM CLOSING WEDGE
6 - SCREW 17 - LOCKING ROD
7 - INNER ACTION 18 - GROMMET
8 - PANELING 19 - LOCKING KNOB
9 - BOLTS (2) 20 - EXTERIOR DOOR HANDLE
10 - DOOR CHECK 21 - SCREW
11 - THREADED PLATE
VADOORS - REAR 23 - 25

LEFT DOOR
(1) Remove door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - REMOVAL)
(2) Remove trim panel (20) (Fig. 5). (Refer to 23 -
BODY/DOORS - REAR/TRIM PANEL - REMOVAL)
(3) Disconnect electrical connectors and remove
license plate lighting (18, 19).
(4) Pull out switch and disconnect electrical con-
nector (17).
(5) Remove and discard roll pin (12) and remove
lock rod handle (11).
(6) Remove door check (23). (Refer to 23 - BODY/
DOORS - REAR/CHECK - REMOVAL)
(7) Remove door hinge (6). (Refer to 23 - BODY/
DOORS - REAR/HINGE - REMOVAL)
(8) Remove closing wedge (4).
(9) Remove rivets (22) and remove bottom closing
wedge (21).
(10) Remove rear door seal (8).(11) Remove the four screws (9, 14) from the lock
rod actuator.
(12) Using locking pliers, hold upper lock rod (2)
and remove lock rod actuator.
(13) Remove clips (15).
(14) Pull out lock rod guides (1, 16) and remove
lock rods (2, 13).
Fig. 5 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 - 26 DOORS - REARVA

ASSEMBLY
RIGHT DOOR
(1) Install the door hinges (4) and bolts (3) (Fig. 6).
(Refer to 23 - BODY/DOORS - REAR/HINGE -
INSTALLATION)
(2) Install the door check (10) and bolts (9). (Refer
to 23 - BODY/DOORS - REAR/CHECK - INSTALLA-
TION)
(3) Install the top closing wedge (1) and bolts (2).
(4) Install the bottom closing wedge (16) and
replace rivets (15).
(5) Install the exterior handle (20). (Refer to 23 -
BODY/DOORS - REAR/EXTERIOR HANDLE -
INSTALLATION)
(6) Install the latch assembly (14). (Refer to 23 -
BODY/DOORS - REAR/LATCH - INSTALLATION)
(7) Install trim panel (20). (Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - INSTALLATION)
(8) Install door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - INSTALLATION)
Fig. 6 RIGHT DOOR
1 - TOP CLOSING WEDGE 12 - DOOR LOCK LINKAGE
2 - BOLTS 13 - BOLTS (3)
3 - BOLTS (2) 14 - LATCH ASSEMBLY
4 - DOOR HINGE 15 - RIVETS (2)
5 - PANEL 16 - BOTTOM CLOSING WEDGE
6 - SCREW 17 - LOCKING ROD
7 - INNER ACTION 18 - GROMMET
8 - PANELING 19 - LOCKING KNOB
9 - BOLTS (2) 20 - EXTERIOR DOOR HANDLE
10 - DOOR CHECK 21 - SCREW
11 - THREADED PLATE
VADOORS - REAR 23 - 27