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GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 7 Cooling 8A Audio/Video 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control Service Manual Comment Forms (Rear of Manual) Component and System Index
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VA INTRODUCTION 1 INTRODUCTION TABLE OF CONTENTS page page VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FASTENER USAGE DESCRIPTION - FASTENER USAGE . . . . . . . . . 5 THREADED HOLE REPAIR DESCRIPTION - THREADED HOLE REPAIR . . . . 5 METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
7 VEHICLE IDENTIFICATION NUMBER To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden- tification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta- tion. The formula to use the check digit is not released to the general public. DESCRIPTION The Vehicle Identification Number (VIN) plate is located on the lower windshield fence next to the left a-pillar. The VIN contains 17 characters that provide data concerning the vehicle.
Refer to the VIN DECODING INFORMATION table to determine the identification of a vehicle. VIN DECODING INFORMATION POSITION INTERPRETATION CODE = DESCRIPTION 1, 2 & 3 World Manufacturer Code WD2 = Truck WD5 = Multi-purpose vehicle 4 Model Y = Truck W = Multi-purpose vehicle D1 = Sprinter, 3000 mm (118 in.) wheelbase, 8,001 up to 9,000 lbs. class G D2 = Sprinter, 3550 mm (140 in.) wheelbase, 8,001 up to 9,000 lbs. class G D3 = Sprinter, 4025 mm (158 in.) wheelbase, 8,001 up to 9,000 lbs. class G D4 = Sprinter, 3550 mm (140 in.) wheelbase, Van 10,001 up to 14,000 lbs. Class 3 D5 = Sprinter, 4025 mm (158 in.) wheelbase, Van 10,001 up to 14,000 lbs.
Class 3 D6 = Sprinter, 3567 mm (140 in.) in connection with 16 9 wheels, Van 8,001 to 9,000 lbs. class G D7 = Sprinter, 4042 mm (159 in.) in connection with 16 9 wheels, Van 8,001 to 9,000 lbs. class G 5 & 6 Model, Cab, Weight 7 & 8 Engine 41 = 2.7L 5 cyl. Diesel 10 Model Year 3 = 2003 9 Check Digit 11 Assembly Plant 5 = Dьsseldorf Plant, Germany 12 Thru 17 Vehicle Build Sequence
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2 INTRODUCTION VA INTERNATIONAL SYMBOLS the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 2) and (Fig. 3).
DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 1) are used to identify various instrument con- trols. The symbols correspond to the controls and dis- plays that are located on the instrument panel. FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8.
The higher the grade number, the greater 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature 4 Turn Warning 16 Battery Charging Condition 5 Hazard Warning 17 Engine Oil 6 Windshield Washer 18 Seat Belt 7 Windshield Wiper 19 Brake Failure 8 Windshield Wiper and Washer 20 Parking Brake 9 Windscreen Demisting and Defrosting 21 Front Hood 10 Ventilating Fan 22 Rear hood (Decklid) 11 Rear Window Defogger 23 Horn 12 Rear Window Wiper 24 Lighter Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
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VA INTRODUCTION 5 FASTENER USAGE THREADED HOLE REPAIR DESCRIPTION - FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a Helicoil t . Follow the vehicle or Helicoil t recommen- dations for application and repair procedures. WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 = Meters M x 1.0936 = Yards mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph Kilometers/ Hr.
(Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h) COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 4).
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