Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 480
(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.
•
During 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.
•
A 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
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DOOR - FRONT
23 - 15
(4) Tighten the reinforcement bolts to 21 N·m (18
ft. lbs.).
(5) Install the regulator. (Refer to 23 - BODY/
DOOR - FRONT/WINDOW REGULATOR - POWER
or MANUAL - INSTALLATION)
EXTERIOR HANDLE
REMOVAL
(1) Remove handle bolt. (Fig. 8)
(2) Slide handle assembly towards front of door.
(Fig. 9)
(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.
INSTALLATION
(1) Position front of handle into front slot in door.
(Fig. 10)
(2) Position rear of handle into latch opening and
engage lock and latch actuation levers with the latch
levers. (Fig. 11)
(3) Slide exterior handle towards rear of door and
install bolt. (Fig. 12)
Fig. 8 LATCH/HANDLE FASTENERS
1 - EXTERIOR HANDLE BOLT
2 - LATCH
3 - LATCH BOLTS (3)
Fig. 9 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - DOOR
Fig. 10 EXTERIOR HANDLE INSTALLATION
1 - DOOR LATCH OPENING
2 - LOCK ACTUATION LEVER
3 - LATCH ACTUATION LEVER
4 - EXTERIOR HANDLE
Fig. 11 LATCH LEVERS
1 - LATCH LEVER
2 - LATCH OPENING
3 - LOCK LEVER
23 - 16
DOOR - FRONT
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(4) Tighten bolt to 10 N·m (89 in. lbs.).
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 side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - REMOVAL)
(3) Loosen hinge set bolts. (Fig. 13)
(4) Remove hinge bolts and remove hinge. (Fig.
14)
INSTALLATION
(1) Install hinge and install bolts.
(2) Tighten bolts to 25 N·m (18 ft. lbs.).
(3) Tighten hinge set bolts.
(4) Install side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE
VIEW
MIRROR
-
INSTALLA-
TION)
(5) Adjust door if necessary. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
Fig. 12 EXTERIOR HANDLE
1 - EXTERIOR HANDLE BOLT
2 - LATCH
3 - LATCH BOLTS (3)
Fig. 13 FRONT DOOR
1 - UPPER CHECK BOLT
2 - DOOR CHECK
3 - UPPER HINGE SET SCREW
4 - LOWER HINGE SET SCREW
5 - HINGE RECEIVERS
6 - DOOR
7 - LOWER CHECK BOLT
Fig. 14 HINGE
1 - HINGE BOLTS
2 - DOOR HINGE
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DOOR - FRONT
23 - 17
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 - FRONT
VA
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