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2004 dodge-mercedes Sprinter Parts Manual 2004 dodge-mercedes Sprinter Parts Manual
2004 dodge-mercedes Sprinter Parts Manual
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2004 dodge-mercedes Sprinter Parts Manual – PDF DOWNLOAD
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Description
2004 dodge-mercedes Sprinter Parts Manual – PDF DOWNLOAD
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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
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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