GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
7Cooling
8AAudio/Video
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION..........................1
INTERNATIONAL SYMBOLS
DESCRIPTION..........................2
FASTENER IDENTIFICATION
DESCRIPTION..........................2
FASTENER USAGE
DESCRIPTION - FASTENER USAGE.........5THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR....5
METRIC SYSTEM
DESCRIPTION..........................5
TORQUE REFERENCES
DESCRIPTION..........................7
VEHICLE IDENTIFICATION
NUMBER
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.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.
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1,2&3 World Manufacturer CodeWD2 = Truck
WD5 = Multi-purpose vehicle
4 ModelY = Truck
W = Multi-purpose vehicle
5 & 6 Model, Cab, WeightD1 = 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 169wheels, Van 8,001 to
9,000 lbs. class G
D7 = Sprinter, 4042 mm (159 in.) in connection with 169wheels, Van 8,001 to
9,000 lbs. class G
7 & 8 Engine 41 = 2.7L 5 cyl. Diesel
9 Check Digit
10 Model Year 3 = 2003
11 Assembly Plant 5 = Dîsseldorf Plant, Germany
12 Thru 17 Vehicle Build Sequence
VAINTRODUCTION 1
INTERNATIONAL SYMBOLS
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 greaterthe 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).
Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
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
2 INTRODUCTIONVA
FASTENER USAGE
DESCRIPTION - FASTENER USAGE
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.
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
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
(60É 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).
VAINTRODUCTION 5
