Dodge VB Series Sprinter Body Builder Information Manual – PDF

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Dodge VB Series Sprinter Body Builder Information Manual – PDF DOWNLOAD

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Dodge VB Series Sprinter Body Builder Information Manual – PDF DOWNLOAD

Language : English
Pages : 123
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Dodge VB Series Sprinter Body Builder Information Manual – PDF DOWNLOAD

1.  .........................................................................  6
1. Introduction..............................................................  7
	1.1.  The aim of the Body Builder Information Book.......................  7
	1.2. Vehicle Safety   ...................................................  8
	1.3. Operating Safety....................................................  8
	1.4.  Regulatory Requirements:...........................................  9
	1.5.  Definitions........................................................ 10
	1.6. Warranty and Vehicle Safe Operation: ............................... 10
2.  General.................................................................. 11
	2.1. Emissions and safety information.................................... 11
		2.1.1. Vehicle noise emission control information.................... 11
		2.1.2.  Exhaust emission control information......................... 12
	2.2.  Vehicle safety standards information............................... 13
		2.2.1. FMVSS 101/CMVSS 101........................................... 13
		2.2.2. FMVSS 102/CMVSS 102........................................... 13
		2.2.3.  FMVSS 103/CMVSS 103.......................................... 13
		2.2.4. FMVSS 104/CMVSS 104........................................... 13
		2.2.5. FMVSS 105/CMVSS 105........................................... 13
		2.2.6. FMVSS 106/CMVSS 106........................................... 13
		2.2.7. FMVSS 108/CMVSS 108........................................... 13
		2.2.8. FMVSS 110/CMCSS 110........................................... 13
		2.2.9. FMVSS 111/CMVSS 111........................................... 14
		2.2.10. FMVSS 113/CMVSS 113.......................................... 14
		2.2.11. FMVSS 114/CMVSS 114.......................................... 14
		2.2.12. FMVSS 116/CMVSS 116.......................................... 14
		2.2.13. FMVSS 118/CMVSS 118.......................................... 14
		2.2.14. FMVSS 119/CMVSS 119.......................................... 14
		2.2.15. FMVSS 120/CMVSS 120.......................................... 14
		2.2.16. FMVSS 124/CMVSS 124.......................................... 14
		2.2.17. FMVSS 201/CMVSS 201.......................................... 14
		2.2.18. FMVSS 202/CMVSS 202.......................................... 14
		2.2.19.  FMVSS 203/CMVSS 203......................................... 15
		2.2.20. FMVSS 204/ CMVSS 204......................................... 15
		2.2.21. FMVSS 205/ CMVSS 205......................................... 15
		2.2.22. FMVSS 206/ CMVSS 206......................................... 15
		2.2.23. FMVSS 207/CMVSS 207.......................................... 15
		2.2.24.  FMVSS 208/ CMVSS 208........................................ 15
		2.2.25. FMVSS 209/ CMVSS 209......................................... 15
		2.2.26. FMVSS 210/ CMVSS 210......................................... 15
		2.2.27. FMVSS 212/ CMVSS 212......................................... 15
		2.2.28. FMVSS 214/CMVSS 214.......................................... 15
		2.2.29.  FMVSS 219/ CMVSS 219........................................ 16
		2.2.30. FMVSS 220/ CMVSS 220......................................... 16
		2.2.31. FMVSS 301/ CMVSS 301......................................... 16
		2.2.32. FMVSS 302/CMVSS 302.......................................... 16
	1.1.  ................................................................... 16
	2.3.  Vehicle and model designations..................................... 17
	2.4.  Vehicle and model designation...................................... 18
	2.5.  Vehicle Identification Number (VIN) Coding Summary................. 20
	2.6.  Labels............................................................. 22
	2.7.  Granting of body technical assistance.............................. 24
	2.8.  Body builder responsibilities...................................... 24
	2.9. Vehicle rollover stability information ............................. 25
3.  Planning of Bodies....................................................... 26
	3.1. Selecting the chassis............................................... 26
	3.2.  Vehicle modifications.............................................. 26
	3.3.  Dimensions and weights............................................. 27
	3.4.  Vehicle type identification date................................... 28
	3.5. Tires............................................................... 29
	3.6.  Bolted and welded connections...................................... 30
		3.6.1. Bolted connections............................................ 30
		3.6.2. Welded connections............................................ 30
	3.7.  Noise Insulation................................................... 33
	3.8. Maintenance and repairs............................................. 33
		3.8.1. Storing the vehicle........................................... 34
		3.8.2. Battery maintenance and storage............................... 34
		3.8.3.  Work before delivering the modified vehicle.................. 35
	3.9.  Optional Equipment................................................. 35
4.  Technical limiting values for planning................................... 36
	4.1. Limiting values of the basic vehicle ............................... 36
		4.1.1. Steerability.................................................. 36
		4.1.2.  Extreme permissible positions of center of gravity........... 36
		4.1.3. Center of gravity Chassis Cab................................. 36
		4.1.4. Vehicle dimensions Chassis Cab................................ 36
	4.2.  Chassis limiting values............................................ 37
		4.2.1. Permissible axle loads........................................ 37
		4.2.2. Approved tire sizes........................................... 37
		4.2.3.  Diameter of turning circle................................... 37
		4.2.4. Modifications to the Axles.................................... 37
		4.2.5. Modifications to the steering system.......................... 37
		4.2.6. Modifications to the brake system............................. 37
		4.2.7. Modifications to springs, spring mountings/shock absorbers.... 37
		4.2.8. Wheel alignment............................................... 37
	4.3.  Body shell limiting values......................................... 38
		4.3.1. Modifications to the body shell............................... 38
		4.3.2. Limiting values of the vehicle frame.......................... 38
		4.3.3. Vehicle overhang.............................................. 38
		4.3.4. Attachment points on the frame................................ 38
		4.3.5. Vehicle roof/roof load........................................ 38
	4.4.  Modifications of engine peripherals / drive train.................. 39
		4.4.1. Fuel system................................................... 39
		4.4.2. Modifications to the engine/drive train components............ 39
		4.4.3. Engine cooling system......................................... 39
	4.5.  Modification to the interior....................................... 39
		4.5.1. Modifications to airbags and belt tensions.................... 39
		4.5.2. Modifications to seats........................................ 39
	4.6.  Limits to Electrics / Electronics ................................. 40
		4.6.1. Vehicle Marker and Clearance lamps............................ 40
		4.6.2. Retrofitting electrical equipment............................. 40
		4.6.3. Mobile communication systems.................................. 40
		4.6.4. CAN bus....................................................... 40
		4.6.5. Electronic Stability Program.................................. 40
	4.7. Design Limits for additional equipment.............................. 40
	4.8. Design Limits for attachments....................................... 40
	4.9.  Design Limits for the body......................................... 41
		4.9.1. Design Limits of the mounting frame........................... 41
5.  Damage prevention ....................................................... 42
	5.1. Brake hoses / cables and lines...................................... 42
	5.2.  Welding Work....................................................... 42
	5.3.  Corrosion protection............................................... 44
	5.4.  Painting work...................................................... 46
	5.5.  Towing............................................................. 46
	5.6. Storing and handling over the vehicle............................... 46
6.  Electrics/Electronics.................................................... 47
	6.1. General Information................................................. 47
	6.2. Electromagnetic compatibility (EMC)................................. 47
	6.3.  Battery............................................................ 48
		6.3.1. Retrofitting a battery isolating switch....................... 48
		6.3.2. Retrofitting an additional battery............................ 48
		6.3.3. Battery maintenance and storage .............................. 48
	6.4. Interfaces.......................................................... 49
		6.4.1. CAN bus and networking........................................ 49
		6.4.2. Electric wiring/fuses......................................... 50
		6.4.3. Additional power circuits..................................... 50
		6.4.4. Control Switches.............................................. 50
		6.4.5.  Retrofitting electrical equipment............................ 51
		6.4.6. Retrofitting an alternator.................................... 51
		6.4.7. Power supply.................................................. 52
		6.4.8.  Speed Signal................................................. 53
		6.4.9. Ground Connections............................................ 53
	6.5.  Lighting........................................................... 54
		6.5.1. Adjusting the Headlamps....................................... 54
		6.5.2. Tail lamps.................................................... 54
		6.5.3.  Marker Lamps ................................................ 55
		6.5.4. Exterior lamps................................................ 55
		6.5.5.  Interior Lamps............................................... 56
		6.5.6.  Rain-light sensor............................................ 56
	6.6.  Mobile communication systems....................................... 57
		6.6.1. Equipment..................................................... 57
		6.6.2. Connecting and routing the wiring for the aerial (radio)...... 57
	6.7.  Electronic ignition switch (EZS)................................... 58
		6.7.1. General Information........................................... 58
		6.7.2. Central locking/rescue vehicle ............................... 58
	6.8. Windows and doors................................................... 59
		6.8.1. Power windows/window hinges................................... 59
		6.8.2. Load compartment sliding door................................. 59
		6.8.3.  Sliding sunroof.............................................. 59
		6.8.4. Windscreen wipers............................................. 60
		6.8.5. Exterior mirrors.............................................. 60
		6.8.6. Windscreen heating/rear window heating........................ 60
	6.9.  Electronic Stability Program (ESP)................................. 61
	6.10.  Programmable special module (PSM)................................. 62
		6.10.1. PSM Functions ............................................... 63
		6.10.2. Mini-SPS..................................................... 64
	6.11. Signal acquisition and actuation module (SAM)...................... 64
	6.12.  Tire pressure monitoring system................................... 65
	6.13.  Parktronic........................................................ 66
	6.14. Lifting platform connection........................................ 66
7. Modifications to the basic vehicle........................................ 67
	7.1.1.  General information on the suspension............................ 67
		7.1.2.  Springs/shock absorbers/anti-roll bars....................... 68
		7.1.3.  Brake system................................................. 68
		7.1.4.  Wheels and tires............................................. 70
		7.1.5.  Spare wheel.................................................. 70
	7.2.  Body shell / Body.................................................. 71
		7.2.1. General information on the body shell/body.................... 71
		7.2.2.  Attachment to the frame...................................... 74
		1.1.1.  ............................................................. 77
		7.2.3.  Chassis frame material....................................... 78
		7.2.4. Overhang extension............................................ 78
		7.2.5.   Side wall, windows, doors and flaps......................... 80
		7.2.6.  Mudguards and wheel jounce................................... 82
		7.2.7.  End frame cross member....................................... 83
	7.3.  Engine peripherals/drive train..................................... 84
		7.3.1. Fuel system................................................... 84
		7.3.2. Exhaust system................................................ 84
		7.3.3. Engine cooling system......................................... 85
		7.3.4. Engine air intake............................................. 85
		7.3.5.  Clearance for assemblies..................................... 86
		7.3.6. Engine speed regulation....................................... 86
	7.4.  Interior........................................................... 87
		7.4.1. General Information........................................... 87
		7.4.2.  Safety equipment............................................. 88
		7.4.3.  Reducing noise in the vehicle interior....................... 93
		7.4.4. Ventilation................................................... 93
	7.5.  Additional equipment............................................... 94
		7.5.1. Retrofitting an air-conditioning system....................... 94
		7.5.2. Auxiliary heating............................................. 94
		7.5.3. Power take-offs............................................... 94
	7.6.  Attachments........................................................ 96
		7.6.1. Wind deflectors............................................... 96
		7.6.2.  Attachment above cab......................................... 96
		7.6.3. Roof racks.................................................... 96
		7.6.4.  Fitted shelving/installations................................ 97
		7.6.5.  Loading cranes............................................... 98
		7.6.6.  Loading tailgate (lifting platform).......................... 99
		7.6.7.  Trailer hitch................................................100
		7.6.8. Underride guard...............................................101
8. Design of bodies..........................................................102
	8.1. Mounting frame......................................................102
		8.1.1. Material quality..............................................102
		8.1.2. Design........................................................102
		8.1.3. Section dimensions / dimensioning.............................103
		8.1.4. Attachment to the frame.......................................104
		8.1.5.  Mounting frame as floor assembly.............................107
	8.2.  Self-supporting bodies.............................................107
	8.3.  Modifications to the interior......................................108
		8.3.1. Retrofitting additional rear seats............................108
	8.4.  Modifications to Cargo vans........................................109
	8.5.  Platform bodies....................................................110
	8.6. Panel vans..........................................................110
	8.7.  Refrigerated vehicles..............................................110
	8.8. Dump bodies.........................................................110
	8.9.  Rescue vehicles....................................................111
	8.10. Torsional rigidity of body types...................................111
	8.11.  RV Conversion.....................................................111
9.  Calculating the center of gravity........................................113
10.  Programmable special module (PSM).......................................115
	10.1. General............................................................115
	10.2.  Signal concept and interfaces.....................................115
		10.2.1. Signal concept...............................................115
		10.2.2.  Inputs......................................................116
	10.3.  Outputs...........................................................117
		10.3.1.  Vehicle functions...........................................122

DESCRIPTION:

Dodge VB Series Sprinter Body Builder Information Manual – PDF DOWNLOAD

Introduction:

• Chrysler LLC and Chrysler Vans LLC Body Builder Information Book This is the 2007 -2008 Body Builders Information Book for Chrysler LLC (“CLLC”) and Chrysler Vans (“CVLLC”) Dodge Sprinter & Freightliner Sprinter vans and chassis cabs.
• This publication provides Body Builders who modify or install equipment in Dodge Sprinters & Freightliner Sprinters (“Sprinter”) Engineering specifications and assists them with their regulatory responsibilities.
• The specifications and descriptions contained in this book, including regulatory information, are believed to be accurate at time of publication. Nevertheless Body Builders should consult with legal counsel to ensure compliance of pertinent laws and regulations.
• Periodically, this book will be updated as new products are introduced and additional information regarding these products become available. Upon written requests CLLC and CVLLC’s designee set forth below will provide certain additional technical data.

VEHICLE SAFETY:

• We recommend that you only use parts, assemblies, conversion parts and accessories that have been recommended by CLLC & CVLLC for the type of vehicle concerned.
• Any modifications to the vehicle that change the the vehicle’s certification could endanger road users, or adversely affect exhaust emissions or noise.
• The use of parts, assemblies, conversion parts or accessories that have not been recommended may jeopardize the safety of the vehicle.
• Ensure that you comply with all applicable regulations as attachments, bodies, equipment on or modifications to the vehicle will change the vehicle and may invalidate the vehicle’s certification.

G.B 07/04/25