Dodge Sprinter. Manual — part 311
(3) Install bracket onto check and install bracket
bolt/nut.
(4) Tighten bracket bolt/nut to 6 N·m (53 in. lbs.).
(5) Install check bracket onto a-pillar.
(6) Apply Loctite
t 243 sealant check strap bolts
and install bolts.
(7) Tighten the M8 bolts to 35 N·m (26 ft. lbs.) or
tighten the M6 bolts to 10 N·m (89 in. lbs.).
(8) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
(9) Connect battery negative cable.
DOOR
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - REMOVAL)
(3) Position aside the wiring boot and disconnect
the electrical connectors. (Fig. 3)
(4) Remove the bolts and disconnect the door check
from the a-pillar. (Fig. 4)
(5) Support door with a suitable device.
(6) Loosen the hinge set screws. (Fig. 5)
(7) Remove door by lifting off hinge pins.
INSTALLATION
(1) Slide door into hinges.
(2) Install set screws.
(3) Install check bracket onto a-pillar.
(4) Apply Loctite
t 243 sealant check strap bolts
and install bolts.
(5) Tighten the M8 bolts to 35 N·m (26 ft. lbs.) or
tighten the M6 bolts to 10 N·m (89 in. lbs.).
(6) Connect all door electrical connectors and posi-
tion boot back.
Fig. 3 ELECTRICAL CONNECTORS
1 - ELECTRICAL CONNECTORS
2 - BOOT
3 - DOOR
Fig. 4 FRONT DOOR CHECK - BODY
1 - DOOR
2 - A-PILLAR BOLTS
3 - DOOR CHECK
Fig. 5 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
23 - 14
DOOR - FRONT
VA
(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
VA
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
VA
(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
VA
DOOR - FRONT
23 - 17
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