roof MERCEDES-BENZ SPRINTER 2006 Owner's Guide

Fig. 30 AJAR SWITHES, LIGHTER, ROOF FAN
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43

Fig. 38 ROOF INLINE CONNECTORS
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 51

Fig. 39 ROOF A/C UNIT
8W - 91 - 52 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

Fig. 40 ROOF A/C RELAYS AND MODULE
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 53

Fig. 41 ROOF A/C FUSES
8W - 91 - 54 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

(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.
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.
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

(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

(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

(9) Disconnect the rear liquid line from the rear
refrigerant reservoir outlet and remove and discard
the O-ring seal.
(10) Install plugs into, or tape over the rear refrig-
erant line fittings and condenser and reservoir ports.
(11) Remove the eight nuts and washers that
secure the rear A/C condenser housing to the roof
panel.
(12) Carefully separate the body sealer between
the rear A/C condenser housing and the roof panel
and with help from an assistant, remove the con-
denser housing.
(13) Remove any shims and trim the body sealer
on top of the roof panel down to a thickness of 2 mm
(0.078 in.).
VADISTRIBUTION - REAR 24 - 53

INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
A/C condenser is being replaced. The refrigerant oil
must be drained from the old condenser and mea-
sured to determine the amount of refrigerant oil to
add to the new condenser. Use only refrigerant oil
of the type recommended for the rear A/C compres-
sor in the vehicle.
(1) If the rear A/C condenser is being replaced,
install the correct amount and type of refrigerant oil
into the new rear A/C condenser. Drain the old con-
denser and measure the refrigerant oil. Fill the new
condenser with the same amount of new refrigerant
oil that was drained out of the old condenser.
(2) Install new body sealant and any removed
shims onto the top of the roof panel.
(3) With help from an assistant, position the rear
A/C condenser housing onto the top of the roof panel.
(4) Install the eight nuts and washers that secure
the rear A/C condenser housing to the roof panel.
Tighten the nuts to 25 N´m (18 ft. lbs.).
(5) Remove the tape or plugs from the rear liquid
line fitting and rear refrigerant reservoir port.
(6) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the rear liquid line fit-
ting. Use only the specified O-ring seal as it is madeof a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(7) Connect the rear liquid line to the rear refrig-
erant reservoir outlet. Tighten the liquid line nut to
35 N´m (26 ft. lbs.).
(8) Remove the tape or plugs from the rear dis-
charge line fitting and rear condenser port.
(9) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the rear discharge line
fitting. Use only the specified O-ring seal as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(10) Connect the rear discharge line to the rear
A/C condenser. Tighten the discharge line nut to 35
N´m (26 ft. lbs.).
(11) Install the bracket and screw that secures the
rear discharge line to the right side of the rear con-
denser housing. Tighten the screw securely.
(12) Connect the rear A/C wire harness to the rear
blower motor suppression filter and to the rear A/C
high pressure switch.
(13) Install new retaining straps to secure the rear
A/C wire harness to the rear liquid line.
(14) Install a new rear receiver/drier (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
REAR RECEIVER/DRIER - INSTALLATION).
Fig. 2 Rear A/C Condenser Housing
1 - REAR A/C CONDENSER HOUSING
2 - LIQUID LINE
3 - REAR REFRIGERANT RESERVOIR
4 - REAR A/C HIGH PRESSURE SWITCH
5 - REAR CONDENSER OUTLET TUBE6 - SUCTION LINE
7 - NUT AND WASHER (8)
8 - REAR A/C WIRE HARNESS
9 - REAR BLOWER MOTOR SUPPRESSION FILTER
24 - 54 DISTRIBUTION - REARVA