2004 Dodge-Mercedes Sprinter Parts Manual – PDF DOWNLOAD

Description

2004 Dodge-Mercedes Sprinter Parts Manual – PDF DOWNLOAD

FILE DETAILS:

2004 Dodge-Mercedes Sprinter Parts Manual – PDF DOWNLOAD

Language : English
Pages : 675
Downloadable : Yes
File Type : PDF
Size: 6.42 MB

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

2004 Dodge-Mercedes Sprinter Parts Manual – PDF DOWNLOAD

2004VA 1
VIN PLATE DECODING INFORMATION 1
Group – 2 Front Suspension & Drive 2
Front Suspension 2
Fig 2-110 –> Front Control Arms, Knuckles, Bearings and Hubs 3
Fig 2-120 –> Front Shocks 5
Fig 2-130 –> Front Stabilzer Bar 7
Fig 2-140 –> Front Spring 9
Group – 3 Rear Axle 13
Rear Axle 13
Fig 3-110 –> Differential Assembly,Rear 14
Differential and Housing 0
Fig 3-210 –> Internal Differential Parts,Rear 15
Fig 3-220 –> Differential Housing,Rear 18
Fig 3-230 –> Axle Shaft and Wheel Bearings,Single Rear Wheels 20
Fig 3-240 –> Axle Shaft and Wheel Bearings,Dual Rear Wheels 21
Rear Axle Vent 0
Fig 3-310 –> Vent,Rear Axle 22
Group – 4 Parking Brake 23
Parking Brake Lever and Cables 23
Fig 4-110 –> Parking Brake Lever Assembly 24
Fig 4-120 –> Parking Brake Assembly 30
Group – 5 Service Brakes 31
Front Brakes 31
Fig 5-110 –> Brakes, Front 32
Rear Brakes 0
Fig 5-210 –> Brakes,Rear,272MM 34
Fig 5-220 –> Brakes,Rear,285MM 36
Power Brake Booster 0
Fig 5-310 –> Booster 37
Fig 5-320 –> Vacuum Lines 38
Fig 5-330 –> Vacuum Reservoir 40
Brake Master Cylinder 0
Fig 5-410 –> Master Cylinder 41
Fig 5-420 –> Hydraulic Control Unit and ABS Module 44
Brake Lines and Hoses 46
Fig 5-510 –> Lines,Brake,With ABS,2500/3500 Series 47
Fig 5-520 –> Brake, Power Regulator 54
Brake Pedals 56
Fig 5-610 –> Pedal Brake 57
Group – 7 Cooling 60
Radiator and Related Parts 60
Fig 7-110 –> Radiator And Related parts 61
Fig 7-120 –> Charge Air Intercooler 65
Water Pump and Related Parts 0
Fig 7-210 –> Water Pump And Related Parts 68
Pulleys and Related Parts 0
Fig 7-410 –> Drive pulleys 71
Drive Belts 72
Fig 7-510 –> Drive Belts 73
Lines, Transmission Oil Cooler 73
Fig 7-610 –> Oil Cooler Lines 74
Grilles 76
Fig 7-710 –> Grille And Related Parts 77
Group – 8 Electrical 78
Starters 79
Fig 8-105 –> Starters & Mounting 80
Alternators 0
Fig 8-205 –> Alternators (Generator) 81
Modules 0
Fig 8-405 –> Modules Seating Area 83
Fig 8-410 –> Modules and Related Parts 86
Fig 8-415 –> Module Back Up 91
Relays 91
Fig 8-505 –> Under Seat – Relays & Fuses 92
Fig 8-510 –> Instrument Panel – Relays & Fuses 98
Sensors 103
Fig 8-605 –> Sensors Engine 104
Fig 8-610 –> Sensors – Drivetrain 107
Fig 8-615 –> Sensors – Brakes 110
Fig 8-620 –> Sensor Ambient Temperature 112
Single Board Engine Controllers 112
Fig 8-715 –> Single Board Engine Controller (S B E C ) 113
Switches 0
Fig 8-805 –> Switches – Instrument Panel 114
Fig 8-810 –> Switches -Steering Column 121
Fig 8-815 –> Switches – Door 123
Fig 8-820 –> Switch Brake 125
Horns 126
Fig 8-905 –> Horns & Alarm 127
Battery Tray and Cables 0
Fig 8-1005 –> Battery Tray & Cables 128
Lamps – Front, Rear and Courtesy 0
Fig 8-1105 –> Lamps – Front End 137
Fig 8-1110 –> Lamps – Rear End 143
Fig 8-1115 –> Lamps Rear End Cab and Chassis Vehicles 148
Fig 8-1120 –> Lamps Interior Passenger Van 150
Fig 8-1125 –> Lamps Interior Cargo Van 152
Fig 8-1130 –> Lamp – Bulbs 157
Wiring-Engine & Related Parts 158
Fig 8-1210 –> Wiring – Engine 159
Wiring-Headlamp to Dash 0
Fig 8-1305 –> Wiring – Headlamp & Dash 161
Wiring-Instrument Panel 164
Fig 8-1405 –> Wiring – Instrument Panel 165
Wiring-Body & Accessories 0
Fig 8-1505 –> Wiring – Body & Accessories 168
Wiring Repair 173
Fig 8-1605 –> Connectors Engine Compartment 174
Fig 8-1610 –> Connectors Body 177
Fig 8-1615 –> Connectors Roof 181
Fig 8-1620 –> Connectors Front Doors 183
Fig 8-1625 –> Connectors Rear Doors 186
Fig 8-1630 –> Connectors Seating Area 188
Air Bag Systems 189
Fig 8-1705 –> Air Bag System Drivers Side 190
Fig 8-1710 –> Air Bag System Passenger Side 193
Spark Plugs-Cables-Coils 194
Fig 8-1910 –> Glow Plugs 195
Group – 08A Instrument Panel and Radios and Consoles 196
Instrument Panel 196
Fig 08A-105 –> Instrument Panel 197
Fig 08A-110 –> Instrument Panel Bezel and Related Parts 202
Fig 08A-115 –> Ash Reciever and Glove Box 208
Fig 08A-120 –> Instrument Panel Cover and Related Parts 211
Fig 08A-125 –> Instrument Panel Reinforcement 216
Instrument Panel Cluster 217
Fig 08A-205 –> Instrument Panel Cluster 218
Radio, Antenna, and Speakers 219
Fig 08A-305 –> Radio 220
Fig 08A-310 –> Antenna 221
Fig 08A-315 –> Speakers 223
Consoles 224
Fig 08A-405 –> Console Cup Holder 225
Group – 9 Engine Mounting 227
Engine Mounting 227
Fig 9-110 –> Engine Mounting 228
Fig 9-120 –> Transmission Mounting 229
Group – 2 7LD-HO 2 7L Diesel – Mercedes Benz [EX8] 231
Engine Identification 232
Fig 2 7LD-HO-110 –> Engine Assemblies 233
Cylinder Head 0
Fig 2 7LD-HO-210 –> Cylinder Head, 2 7LD – H/O 234
Fig 2 7LD-HO-220 –> Cylinder Head Cover, 2 7LD – H/O 235
Cylinder Block 0
Fig 2 7LD-HO-310 –> Cylinder Block and Related Parts, 2 7L – H 236
Crankshaft, Piston and Drive Plate 0
Fig 2 7LD-HO-410 –> Crankshaft and Pistons, 2 7L – H/O 237
Camshafts and Valves 0
Fig 2 7LD-HO-510 –> Camshaft and Valves 239
Timing Belt and Cover 0
Fig 2 7LD-HO-610 –> Timing Cover and Chain 240
Fig 2 7LD-HO-620 –> Vaccum Pump 242
Engine Oiling 0
Fig 2 7LD-HO-710 –> Oil Pump 243
Fig 2 7LD-HO-720 –> Oil Cooler & Filter 244
Fig 2 7LD-HO-730 –> Oil Pan 245
Fig 2 7LD-HO-740 –> Turbo, Oil Feed & Return Lines 246
Manifolds 0
Fig 2 7LD-HO-810 –> Intake Manifold 247
Fig 2 7LD-HO-820 –> Exhaust Manifold 248
Crankcase Ventilation 0
Fig 2 7LD-HO-910 –> Crankcase Ventilation 249
Group – 11 Exhaust 250
Exhaust System 250
Fig 11-110 –> Exhaust System 251
Heat Shields 0
Fig 11-210 –> Heat Shields Exhaust 255
Group – 13 Frames and Bumpers 256
Frames 256
Fig 13-105 –> Front Frame Rails 257
Fig 13-110 –> Side Frame Rails and Crossmembers 2500 263
Fig 13-120 –> Side Frame Rails and Crossmembers 3500 267
Fig 13-130 –> Brackets, Frame To Body Supports 270
Front Bumper and Fascia 271
Fig 13-230 –> Bumper, Front 272
Rear Bumper and Fascia 0
Fig 13-320 –> Bumper, Rear 275
Trailer Tow 0
Fig 13-610 –> Rear Hitch 277
Fig 13-620 –> Trailer Tow 279
Group – 14 Fuel 281
Tank, Fuel 281
Fig 14-110 –> Fuel Tank 282
Fuel Tank Filler Tube 282
Fig 14-210 –> Fuel Tank Filler Tube 283
Fuel Lines 285
Fig 14-310 –> Fuel Lines 286
Fig 14-320 –> Fuel Line and Filter 291
Fuel Rail 0
Fig 14-410 –> Injection System [EX8] 292
Fuel Pump and Sending Unit 0
Fig 14-510 –> Fuel Module 293
Fuel Injection Pump & Turbo Charger 294
Fig 14-610 –> Fuel Injection Pump [EX8] 295
Fig 14-630 –> Turbo Charger 296
Fig 14-635 –> Turbo Charger Heat Shield 297
Air Cleaner 298
Fig 14-810 –> Air Cleaner 299
Accelerator Pedal 303
Fig 14-1110 –> Accelerator Pedal 304
Group – 16 Propeller Shafts and U-Joints 305
Propeller Shaft 305
Fig 16-120 –> Shaft,Propeller,Rear,2 Piece 306
Fig 16-130 –> Shaft,Propeller,Rear,3 Piece 309
Group – 17 Rear Suspension 312
Rear Suspension 312
Fig 17-110 –> Rear Shocks 313
Fig 17-120 –> Rear Springs, 2500 Series 317
Fig 17-130 –> Rear Springs, 3500 Series 322
Rear Stabilizer 0
Fig 17-210 –> Stabilizer Bar,Rear 323
Group – 19 Steering 325
Steering Wheel 325
Fig 19-110 –> Steering Wheel and Related 326
Steering Column 329
Fig 19-210 –> Column Steering and Related 330
Steering Gear 333
Fig 19-310 –> Gear – Steering 334
Power Steering Pump 335
Fig 19-510 –> Pump and Pulley, Steering 336
Power Steering Hoses 0
Fig 19-710 –> Hoses Steering and Related 337
Group – NAG1 Automatic Transmission 5 Speed [DGJ] 342
Transmission Assembly 342
Fig NAG1-110 –> Automatic Transmission 343
Case and Extension 343
Fig NAG1-210 –> Case and Related Parts 344
Oil Pump 0
Fig NAG1-310 –> Pump, Oil 346
Gear Train 0
Fig NAG1-410 –> Laminated Brake and Front Support – [B1] 347
Fig NAG1-420 –> Gear Train, Front Planetary Clutch – [K-1] 348
Fig NAG1-430 –> Carrier, Planetary – [K1] – [VPLS] 349
Fig NAG1-440 –> Clutch – Output Shaft – [K2] 350
Fig NAG1-450 –> Center & Rear Planetary Set – Output Shaft – [ 351
Fig NAG1-460 –> Clutch – [K3] 352
Fig NAG1-470 –> Multiple Disc Brake – [B2 & B3] 353
Fig NAG1-480 –> Multiple Disc Brake – [B2 & B3] 354
Fig NAG1-490 –> Multiple Disc Brake – [B2 & B3] 355
Valve Body 0
Fig NAG1-710 –> Electronic – Hydraulic Control 356
Gearshift Controls 0
Fig NAG1-1210 –> Gear Shift Control 357
Group – 22 Wheels, Covers and Jacks 360
Wheels and Hardware 360
Fig 22-120 –> Wheels And Hardware 361
Jack Stowage 0
Fig 22-340 –> Jack and Stowage 364
Spare Tire Stowage 0
Fig 22-430 –> Wheel, Spare 367
Group – 23D Wiper/Lock Cylinder and Keys 368
Lock Cylinders and Keys 368
Fig 23D-105 –> Lock Cylinders & Components 369
Windshield Wiper and Washer Systems 0
Fig 23D-205 –> Windshield Wiper & Washer 372
Group – 24 Air Conditioning & Heater 383
Air Conditioner and Heater Units 383
Fig 24-130 –> Hevac Unit, Front 384
Air Conditioner and Heater Plumbing 393
Fig 24-250 –> Heat Exchanger and Plumbing 394
Fig 24-260 –> Plumbing, Heater 400
Fig 24-265 –> Plumbing, Heater with Auxiliary warm water Heate 404
Fig 24-270 –> Plumbing, Air Conditioning 408
Fig 24-280 –> Condenser, Fan Front 415
Fig 24-285 –> Condenser, Fan Roof 418
Fig 24-290 –> Auxiliary Warm Water Heater 420
Air Conditioner and Heater Controls 427
Fig 24-320 –> Control 428
Air Conditioning Compressor 428
Fig 24-420 –> Compressor and Mounting 429
Air Ducts and Outlets 430
Fig 24-630 –> Air Ducts And Outlets, Front 431
Fig 24-640 –> Air Ducts And Outlets, Rear 435
Fig 24-650 –> Ventilator, Roof Mounted 437
Group – DVA Doors and Related Parts 438
Front Door 438
Fig DVA-110 –> Door, Front Shell And Hinges 439
Fig DVA-120 –> Door, Front Glass And Regulator Handle 443
Fig DVA-130 –> Door, Front Exterior Handle And Links 448
Door, Sliding Cargo 451
Fig DVA-320 –> Door, Sliding Cargo Glass 452
Fig DVA-330 –> Door, Sliding Cargo Lock And Controls 454
Door, Dual and Single Cargo 458
Fig DVA-410 –> Door, Cargo Shell And Hinges 459
Fig DVA-420 –> Door, Cargo Glass And Hardware 465
Fig DVA-430 –> Door, Cargo Lock And Control 470
Exterior Mirror 474
Fig DVA-520 –> Mirrors, Exterior 475
Group – EVA Exterior Ornamentation 482
Nameplates 482
Fig EVA-120 –> Nameplates And Decals 483
Moldings and Ornamentation 0
Fig EVA-210 –> Exterior Moldings 486
Group – IVA Interior Trim 487
Headliner and Visor 487
Fig IVA-110 –> Headliner, Low Roof 488
Fig IVA-115 –> Headliner, High Roof 492
Fig IVA-120 –> Sunvisors, Grabhandles, Shelf and Attaching Par 497
Moldings, Scuff Plates 501
Fig IVA-210 –> Inner Panels – Fabric 502
Fig IVA-215 –> Inner Panels – Cab 504
Fig IVA-220 –> Inner Panels – Plywood 508
Fig IVA-221 –> Inner Panel, Hard Fiber 509
Fig IVA-225 –> Inner Panels 510
Fig IVA-230 –> Inner Paneling Window – Pillar In Cab 512
Fig IVA-235 –> Cargo Retainers – Without Windows 515
Fig IVA-240 –> Cargo Retainers – With Windows 517
Fig IVA-245 –> Rear Pillar Inner Panel 519
Fig IVA-250 –> Cowl Panel – Silencer 522
Fig IVA-255 –> Partition Panel 523
Fig IVA-260 –> Partition Wall and Sliding Door 524
Carpet 528
Fig IVA-310 –> Carpet – Floor 529
Fig IVA-315 –> Floor Lining, Entry Paneling & Footrest 532
Fig IVA-320 –> Floor – Rubber 535
Fig IVA-330 –> Floor – Wooden 539
Fig IVA-340 –> Insulation – Carpet 544
Fig IVA-350 –> Insulation Floor 546
Door Trim Panels-Front and Sliding 0
Fig IVA-410 –> Front Door Trim 549
Fig IVA-420 –> Sliding Door Trim 555
Fig IVA-430 –> Rear Dual Door Trim 558
Front Seats and Attaching Parts 559
Fig IVA-510 –> Front Seat – Venice 560
Fig IVA-515 –> Front Seat – Santos 563
Fig IVA-520 –> Front Seat – Catano 566
Fig IVA-525 –> Front Seat – Attaching Parts 568
Fig IVA-530 –> Front Seat – Attaching Parts – Riser 575
Fig IVA-535 –> Front Seat – Attaching Parts 577
Rear Seats 578
Fig IVA-610 –> Rear Seat – 2 Passenger 579
Fig IVA-615 –> Rear Seat – 3 Passenger 581
Fig IVA-620 –> Attaching Parts – 3rd Passenger Seat 583
Seat Belts-Front and Rear 0
Fig IVA-710 –> Seat Belt – Front 587
Fig IVA-720 –> Seat Belt – Second Row 590
Group – SVA Body Sheet Metal Except Doors 591
Floor Pans 592
Fig SVA-210 –> Front Floor Pan 593
Fig SVA-220 –> Rear Floor Pan 595
Plugs 597
Fig SVA-310 –> Plugs 598
Front Fenders 602
Fig SVA-410 –> Front Fender 603
Fig SVA-420 –> Fender Splash Guards 606
Hood and Hood Release 607
Fig SVA-510 –> Hood and Hood Release 608
Cowl and Dash Panel 612
Fig SVA-610 –> Cowl and Dash 613
Fig SVA-620 –> Inner Paneling in Cab, Cowl 615
Glass and Rear View MIrror 617
Fig SVA-710 –> Windshield, Backlite and Rear View Mirror 618
Fig SVA-720 –> Front Right Side Sliding Glass 621
Fig SVA-730 –> Side Glass, Fixed 623
Aperture Panel 624
Fig SVA-810 –> Front Aperture, Inner, Left 625
Fig SVA-820 –> Front Aperture, Outer, Left 627
Fig SVA-830 –> Front Aperture, Inner, Right 629
Fig SVA-840 –> Front Aperture, Outer, Right 632
Quarter Panel and Pillars 0
Fig SVA-910 –> Right Side Cargo Door Pillars & Wheelhouse 633
Fig SVA-920 –> Right Side Panels, Cargo 636
Fig SVA-930 –> Right Side Panels, Wagon 640
Fig SVA-940 –> Left Side Cargo Door Pillars & Wheelhouse 642
Fig SVA-950 –> Left Side Panels, Cargo 645
Fig SVA-960 –> Left Side Panels, Wagon 647
Fig SVA-970 –> Rear Splash Shield 651
Fig SVA-980 –> Rear Step Panel 653
Fig SVA-990 –> Partition Wall & Load Protection Grill 655
Roof Panels 0
Fig SVA-1110 –> Low Roof Panel 657
Fig SVA-1120 –> High Roof Panel 661
Sunroof 0
Fig SVA-1210 –> Manual Sunroof 665
Fig SVA-1220 –> Fixed Sunroof 668
Group – LBLS Labels All Vehicle Locations 669
Interior 669
Fig LBLS-105 –> Instrument Panel / Visors & Interior 670
Under Hood 671
Fig LBLS-205 –> Engine Compartment 672
Doors 673
Fig LBLS-305 –> Front / Side & Cargo 674
Exterior 0
Fig LBLS-410 –> Fuel Door & Filler 675

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