Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 483
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
VA
DOORS - REAR
23 - 27
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)
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.
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)
23 - 28
DOORS - REAR
VA
(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
VA
DOORS - REAR
23 - 29
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)
• Retaining magnet is too far forward relative to
mating plate. Turn in adjustment screw (2) at top
and bottom hinge.
• Retaining magnet is too far back relative to mat-
ing plate. Turn out adjustment screw (2) at top and
bottom hinge.
• Retaining magnet is too deep relative to mating
plate. Turn in adjustment screw (2) at top hinge,
turn out adjustment screw (2) at bottom hinge.
• Retaining magnet is too high relative to mating
plate. Turn out adjustment screw (2) at top hinge,
turn in adjustment screw (2) at bottom hinge.
• Retaining magnet strikes too hard against mat-
ing plate. Turn in adjustment screw (1) at top and
bottom hinge.
• Retaining magnet does not make contact with
mating plate. Turn out adjustment screw (1) at top
and bottom hinge.
• Door projects at corner paneling when closed.
Turn out adjustment screw (3) at hinge.
• Door 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. 10 STRIKER ADJUSTMENT
1 - STRIKER
2 - LOCK ROD HANDLE ASSEMBLY
3 - LEFT DOOR
Fig. 11 REAR HINGE ADJUSTMENT
1 - ADJUSTMENT SCREW
2 - ADJUSTMENT SCREW
3 - ADJUSTMENT SCREW
4 - CONTROL ARM
23 - 30
DOORS - REAR
VA
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