2005 MERCEDES-BENZ SPRINTER Service Repair Manual

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

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. 29 MANUAL REGULATOR FASTENERS
1 - RIVETS (4)
2 - REGULATOR
3 - CARRIER PLATE
VADOOR - FRONT 23 - 23
WINDOW REGULATOR - MANUAL (Continued)

DOORS - REAR
TABLE OF CONTENTS
page page
CHECK
REMOVAL.............................24
INSTALLATION.........................24
DOOR
REMOVAL.............................25
DISASSEMBLY.........................26
ASSEMBLY............................28
INSTALLATION.........................30
ADJUSTMENTS
ADJUSTMENT........................30
DOOR GLASS
REMOVAL.............................31
INSTALLATION.........................31
EXTERIOR HANDLE
REMOVAL.............................32INSTALLATION.........................33
HINGE
REMOVAL.............................34
INSTALLATION.........................34
INSIDE HANDLE ACTUATOR
REMOVAL.............................34
INSTALLATION.........................34
LATCH
REMOVAL.............................34
INSTALLATION.........................35
TRIM PANEL
REMOVAL.............................35
INSTALLATION.........................35
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 idn. lbs.).
Fig. 1 DOOR CHECK
1 - RECEIVER
2 - DOOR CHECK
3 - SCREWS
23 - 24 DOORS - REARVA

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. 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)
VADOORS - REAR 23 - 25

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
23 - 26 DOORS - REARVA
DOOR (Continued)