2005 MERCEDES-BENZ SPRINTER Service Repair Manual

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)
VADOORS - REAR 23 - 27
DOOR (Continued)

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
23 - 28 DOORS - REARVA
DOOR (Continued)

LEFT DOOR
(1) Install lock rods (2, 13) and install lock rod
guides (1, 16). (Fig. 7)
(2) Using locking pliers, hold upper lock rod (2) in
place.
(3) Install clips (15).
(4) Install the lock rod actuator (10). The bolts
should reach into the holes (arrows) of the lock rods
(2, 13). Place and o-ring (dia. 6 mm) on each of the
lock rod actuator bolts to prevent the lock rods from
chattering against the lock.
(5) Install rear door seal.
(6) Install bottom closing wedge (21) and replace
rivets (22).
(7) Install closing wedge (4).
(8) Install door hinge (6). (Refer to 23 - BODY/
DOORS - REAR/HINGE - INSTALLATION)(9) Install door check (23). (Refer to 23 - BODY/
DOORS - REAR/CHECK - INSTALLATION)
(10) Install lock rod handle (11) and replace roll
pin (12).
(11) Connect the electrical connector and install
switches (17).
(12) Connect electrical connectors and install
license plate lighting (18, 19).
(13) Install trim panel (20). (Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - INSTALLATION)
(14) Install door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - INSTALLATION)
Fig. 7 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)
VADOORS - REAR 23 - 29
DOOR (Continued)

INSTALLATION
CAUTION: If the door is being replaced a suitable
seam sealer must be used prior to painting.
(1) Support the door with a suitable lifting device,
install door and install the hinge bolts.
(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
Fig. 10 STRIKER ADJUSTMENT
1 - STRIKER
2 - LOCK ROD HANDLE ASSEMBLY
3 - LEFT DOOR
23 - 30 DOORS - REARVA
DOOR (Continued)

CAUTION: Since the rear doors are components
with static functions it is very important that they
are fastened while driving. This prevents excessive
torsion of the vehicle and leaky rear doors. The rear
doors are fastened by adjusting the closing
wedges.
(9) Closing wedges at bottom must be resting free
of play on plastic closing plates when rear doors are
closed. To adjust, loosen door hinges and raise or
lower complete doors.
(10) Loosen upper closing wedge screws and move
top closing wedge up against plastic closing plate free
of play with rear door closed and tighten screws to 10
N´m (89 in. lbs.).
(11) Check and adjust the hinges. On rear doors,
the retaining magnets should run up to the middle of
the mating plate at the side wall. If this is not the
case, correct as listed. (Fig. 11)
CAUTION: Adjustment range of screw (3) maximum
1 turn (risk of control cam breaking, 4)
²Retaining magnet is too far forward relative to
mating plate. Turn in adjustment screw (2) at top
and bottom hinge.
²Retaining magnet is too far back relative to mat-
ing plate. Turn out adjustment screw (2) at top and
bottom hinge.
²Retaining magnet is too deep relative to mating
plate. Turn in adjustment screw (2) at top hinge,
turn out adjustment screw (2) at bottom hinge.
²Retaining magnet is too high relative to mating
plate. Turn out adjustment screw (2) at top hinge,
turn in adjustment screw (2) at bottom hinge.
²Retaining magnet strikes too hard against mat-
ing plate. Turn in adjustment screw (1) at top and
bottom hinge.
²Retaining magnet does not make contact with
mating plate. Turn out adjustment screw (1) at top
and bottom hinge.
²Door projects at corner paneling when closed.
Turn out adjustment screw (3) at hinge.
²Door is too far recessed at corner paneling when
closed. Turn in adjustment screw (3) at hinge.
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. 11 REAR HINGE ADJUSTMENT
1 - ADJUSTMENT SCREW
2 - ADJUSTMENT SCREW
3 - ADJUSTMENT SCREW
4 - CONTROL ARM
VADOORS - REAR 23 - 31
DOOR (Continued)

NOTE: Remove any mineral spirits with a clean
cloth after glass installation.
(6) Verify that the seal is seated in the window
opening (Fig. 12).
(7) Test the window for water leaks. (Refer to 23 -
BODY - DIAGNOSIS AND TESTING - WATER
LEAKS)
EXTERIOR HANDLE
REMOVAL
(1) Remove handle bolt. (Fig. 13)
NOTE: Front door shown, rear door similar.
(2) Slide handle assembly towards front of door.
(Fig. 14)
NOTE: Front door shown, rear door similar.
(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.
Fig. 12 Glass & Weatherstrip Seal Installation
1 - BODY PANEL
2 - WEATHERSTRIP SEAL
3 - INSTALLATION CORD
4 - WINDOW OPENING
Fig. 13 EXTERIOR HANDLE
1 - EXTERIOR HANDLE BOLT
2-LATCH
3 - LATCH BOLTS (3)
Fig. 14 LATCH/HANDLE FASTENERS
1 - EXTERIOR HANDLE
2 - DOOR
23 - 32 DOORS - REARVA
DOOR GLASS (Continued)

INSTALLATION
(1) Position front of handle into front slot in door.
(Fig. 15)
NOTE: Front door shown, rear door similar.
(2) Position rear of handle into latch opening and
engage lock and latch actuation levers with the latch
levers. (Fig. 16)
NOTE: Front door shown, rear door similar.(3) Slide exterior handle towards rear of door and
install bolt. (Fig. 17)
NOTE: Front door shown, rear door similar.
(4) Tighten bolt to 10 N´m (89 in. lbs.).
Fig. 15 EXTERIOR HANDLE INSTALLATION
1 - DOOR LATCH OPENING
2 - LOCK ACTUATION LEVER
3 - LATCH ACTUATION LEVER
4 - EXTERIOR HANDLE
Fig. 16 LATCH LEVERS
1 - LATCH LEVER
2 - LATCH OPENING
3 - LOCK LEVER
Fig. 17 EXTERIOR HANDLE
1 - EXTERIOR HANDLE BOLT
2-LATCH
3 - LATCH BOLTS (3)
VADOORS - REAR 23 - 33
EXTERIOR HANDLE (Continued)

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 the bolts and remove the hinge. (Fig. 18)
INSTALLATION
(1) Install hinge and install bolts.
(2) Tighten bolts to 25 N´m (18 ft. lbs.).
(3) Adjust door if necessary. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the handle trim cover. (Fig. 19)
(2) Remove the screws and handle.
(3) Disconnect the latch cable.
INSTALLATION
(1) Connect the latch cable.
(2) Install handle and screws.
(3) Install trim cover.
LATCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove right side trim panel. (Refer to 23 -
BODY/DOORS - REAR/TRIM PANEL - REMOVAL)(3) Disconnect lock rod. (Fig. 20)
(4)
Remove the screws and pull out latch from door.
(5) Disconnect cable and electrical connectors.
Fig. 18 REAR DOOR HINGE
1 - TORX BOLTS BODY SIDE
2 - TORX BOLTS DOOR SIDE
3 - HINGE
4 - ALLEN BOLT
Fig. 19 TRIM PANEL
1 - TRIM
2 - INSIDE HANDLE ACTUATOR
3 - TRIM PANEL
4 - CONTROL CABLE
Fig. 20 LATCH
1 - DOOR LOCK KNOB
2 - ELECTRIC
3 - CABLE
4 - LOCK ROD
5 - LATCH ASSEMBLY
6 - ELECTRICAL CONNECTORS ROUTING
7 - SCREWS (3)
23 - 34 DOORS - REARVA