US Edition F 09/05 BODY BUILDER’S INFORMATION BOOK Some specifications and features shown or mentioned in this brochure are optional and only available on request at extra cost. Specifications are subject to change without notice. © 2005, DaimlerChrysler Manufacturing International LLC, Huntersville, NC 28078. All rights reserved.
Introduction DaimlerChrysler Motors Corporation and DaimlerChrysler Vans Body Builders Information Book This is the 2005 - 2006 Body Builders Information Book for DaimlerChrysler Motors Corporation (DCMC) and DaimlerChrysler Vans (DCV) Sprinter vans and cab chassis. Prior to making any modification to or installing any equipment in or on a Sprinter, read this Information Book, and if necessary, consult with DaimlerChrysler Manufacturing International LLC’s Engineering and Compliance Department (DCMI).
Introduction Definitions Body Builders include Final-Stage Manufacturers, Intermediate Manufacturers, Incomplete Vehicle Manufacturers, Vehicle Alterers and component suppliers. Complete Vehicle means a vehicle that requires no further manufacturing operations to perform its intended function, other than the addition of readily attachable components, such as mirrors, tires or tire and rim assemblies, or finishing operations such as painting.
Introduction Important Information Regulatory Requirements: The U.S. and Canadian Governments have established emission standards and motor vehicle safety standards for new engines and/or new vehicles and equipment, under the provisions of the Clean Air Act, the Noise Control Act and the National Traffic and Motor Vehicle Safety Act in the U.S., and the Canadian Motor Vehicle Safety Act in Canada (“Acts”).
Introduction by a fine of up to $25,000 (Federal) and $5,000 (California) per vehicle for emissions non-compliance, $1,000 per vehicle for safety non-compliance, plus a recall and other sanctions. 2. The Body Builder is responsible for certifying the altered vehicle persuant to Title 49 of the Code of Federal Regulations S567.7 and S568.8 in the United States or to Section 9 of the Canada Motor Vehicle Safety Regulations in Canada. 3.
Introduction Warranty and Vehicle Safe Operation: DCAG requires the use of Genuine DCG parts and DCG replacement & conversion Parts, or replacement & conversion Parts and accessories expressly approved by the Sprinter van manufacturer in order for Body Builders to maintain regulatory compliance of these components or equipment, as well as the durable and safe operation of Sprinters.
Introduction
Contents Chapter Page General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Body Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Frame and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Cab . . . . . . . . . . . . . . . . . . . . . .
1 1General Information Vehicle and Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Sprinter Vehicle Identification Number (VIN) Code Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Emissions and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Labels . . . . . . . . . . . . .
General Information 1.1 Vehicle and Model Designations This Body Information Book covers the following vehicles: Vehicle Name Type Wheel Base Roof Height Sprinter Passenger Van 2500 118” Standard 140” Standard 118” High 140” High 158” High 118” Standard 140” Standard 118” High 140” High 158” High 140” Standard 140” High 158” High Sprinter Cargo Van 2500 3500 Note: All 3500 Sprinters come with Dual Rear Wheels as standard 1.
General Information Vehicle Name Type Wheel Base Roof Height Sprinter Cab-Chassis 2500 140” --- 158” --- 140” --- 158” --- 3500 Note: All 3500 Sprinters come with Dual Rear Wheels as standard 1.
General Information 1.2 Sprinter Vehicle Identification Number (VIN) Code Sample WD 8 B D1 44 4 5 5 999999 Sequentially Assigned Vehicle Serial Number by the Plant of Manufacture Vehicle Manufacture Plant: 5 = Duesseldorf, Germany Model Year Designation: 5 = 2005, 6 = 2006, 7 = 2007 Check Digit for VIN Verification Engine/Fuel/Displacement/Configuration/Brake: 44 = MB OM647LA(50-State)/Diesel/2.7L/I-5/Hydraulic Model/Wheelbase/Wheelsize/GVWR/Class: D1 = C2,500;P2,500/3000 mm/15”/8,001 to 9,000lbs.
General Information 1.3 Emissions and Safety Information A Complete Sprinter Van "As Delivered"or a cab chassis, i.e., an incomplete vehicle, delivered by DCMC or DCV to Dealers or Body Builders is certified for by DCAG for compliance with the U.S. and Canadian emissions and safety standards at the time of manufacture. If this vehicle is altered, after delivery by DCMC or DCV, Body Builders and/or Dealers assume the regulatory responsibility for certification.
General Information engine calibrations, such as fuel output settings, injection timings, emission control device calibration and location, charge air and cooling system calibration and location are prohibited from any alterations from the certified configurations.
General Information CMVSS, identify certain requirements and certification responsibilities for the various stages of vehicle manufacturing. Therefore, Body Builders and Dealers need to review all regulatory requirements carefully to ensure compliance with applicable standards. Please consult with an attorney to ensure compliance with applicable laws or standards. 1.3.3.
General Information 1.3.3.6 FMVSS 106 / CMVSS 106 This vehicle, when completed, will conform to Standard 106, Brake Hoses, if no alterations are made to the hydraulic brake hoses, brake hose assemblies, or the brake hose fittings including the labeling on these components. 1.3.3.7 FMVSS 108 / CMVSS 108 obstructions are installed which limits the full function of these mirrors. 1.3.3.
General Information compliance with the Standard 118 is necessary, if subsequent alterations or installations are made. 1.3.3.14 FMVSS 119 /CMVSS 119 armrests, sun visors, seats and armrests, or other interior trims. Vehicles ordered with a D62 option, must be retrofitted with a partition wall to comply with this Safety Standard.
General Information door hinges, door locks, door latch posts, door hinge posts, other attachments or supporting cab structure. 1.3.3.22 FMVSS 207 / CMVSS 207 This vehicle, when completed, will conform to Standard 207, Seating Systems, if no alterations are made to the seats, seat tracks, seat adjusters, restraining devices, release and adjustment controls, seat risers and supports, or the cab floor and supporting structure. 1.3.3.
General Information 1.3.3.29 FMVSS 220 / CMVSS 220 1.4 Labels This vehicle when completed, will conform to Standard 220, School Bus Rollover Protection, if no alterations are made to the roof panel and its supporting structure, including roof rails, front header, roof bows or roof pillars, the door window frames, the windshield or its mounting system or any window frame, subsequent to the delivery by DCAG.
General Information VIN Plate Vehicle Safety Certification Label and Type Plate 1. Vehicle identification number 1. Incomplete vehicle certification label for chassis-cab. Location: lower edge of windshield) 2. Type plate (vehicle identification number, permissible weights) Location: below the driver´s seat on an outward facing position of the seat pedestal. 1.
General Information Exhaust Emission Control Information Label (Sample) Complete Vehicle Certification Label (Sample) Important Engine Information This is a LOW EMISSION VEHICLE engine and meets all applicable requirements of US EPA CFFV as "ILEV" per 40 CFR 88 and CARB as "ULEV" per CCR 1956.8 DaimlerChrysler AG, Stuttgart, Germany Mercedes-Benz Engine, Model Engine Family / Engine Code Exhaust Emission Control System Date of engine manufacture Advertised output (SAE gr.) Fuel rate at adv.
General Information Incomplete Vehicle Certification Label (Sample) Air Bag Warning Label (Sample) Location: below the driver’s seat on an outwardfacing position of the mounting pillar. Location: on sun riser. 1.
General Information Tire and Loading Information Label Tire and Loading Information Label (Sample) Location: on the driver’s door B-pillar. NOTE: Data shown on label are for illustration purposes only. Load limit data and seating data are specific to each vehicle and may vary from data shown in the illustration. Refer to label on vehicle for actual data specific to your vehicle. For tire and loading information, see Chapter 12. 1.
General Information 1.5 Granting of Body Approval / Technical Assistance To obtain technical assistance or information, please contact DCMC and DCV’s designee: Modification by Body Builders must not affect safety of the Sprinter. DCMC and DCV, through their designee, DCMI, will offer technical assistance concerning DCMC and DCV Sprinter vans, including technical data & drawing and product info brochures, but it is the responsibility of Body Builders to ensure modifications do not affect safety of vehicle.
General Information 1.6 Body Builder Responsibilities Each completed Sprinter “As Delivered” in the U.S. is certified for the U.S. EPA or CARB exhaust emissions in accordance with 40 CFR Part 86, or Title 13 of CCR, and an exhaust emission control information label is affixed thereto. While the complete Sprinter van “As Delivered” is certified to comply with the applicable FMVSS safety regulations in accordance with 49 CFR Section 567.
General Information 5. Do not impair the operational reliability, roadworthiness and driveability of the Sprinter by body or accessory equipment installation or modification. 1.7 Vehicle Rollover Stability Information Body Builder is responsible for ensuring that modification or equipment installation does not affect the safety of the Sprinter.
General Information 1.8 Center of Gravity Center of Gravity of Sprinter Vans as delivered without optional Equipment: Vehicle Rim Diameter (*1 Passenger Van 15" 2500 GVWR 16" 8,550 lbs HR HR WB [inch] FA [lbs] RA [lbs] CW [lbs] 118 118 140 140 159 1,918 1,954 2,108 2,150 2,342 4,657 4,705 4,999 5,058 5,305 2,739 2,752 2,891 2,908 2,964 Center of Gravity [inch] (*2 x y z 48.66 -0.472 32.09 49.06 -0.472 32.09 59.21 -0.472 34.06 59.68 -0.472 34.06 70.24 -0.472 34.06 1.
General Information Vehicle Rim Diameter (*1 Cargo Van 2500 GVWR 8,550 lbs 15" HR 16" HR Cargo Van 3500 GVWR 9,990 lbs 1.19 15" HR WB [inch] FA [lbs] RA [lbs] CW [lbs] 118 118 140 140 159 140 140 158 1,868 1,903 2,068 2,108 2,309 2,267 2,302 2,498 4,600 4,648 4,935 4,990 5,241 5,166 5,221 5,460 2,732 2,745 2,867 2,882 2,933 2,900 2,919 2,961 Center of Gravity [inch] (*2 x y z 47.95 -0.472 32.09 48.35 -0.472 32.09 59.33 -0.472 34.06 59.33 -0.472 34.06 70.08 -0.472 34.06 61.34 -0.472 32.09 61.
General Information Center of Gravity [inch] (*2 x y z Sprinter Cab Chassis as delivered is certified with an maximum unloaded vehicle wheight, when completed, of 4,900 lbs. Cab Chassis 118 2,778 1,228 4,002 36.10 -0.472 25.00 15"(*3 (*3 2500, GVWR 15" 140 2,860 1,173 4,033 40.67 -0.472 25.00 8,550 lbs 15"(*3 158 2,961 1,136 4,097 43.94 -0.472 25.00 16" 140 2,913 1,226 4,139 41.61 -0.472 26.97 16" 159 3,014 1,188 4,203 45.00 -0.472 26.
General Information 1.8.1 Extreme Permissible Positions of Center of Gravity Vehicles with ESP x direction: < 2,400 mm referred to the front axle y direction: When the vehicle is laden, the wheel load (1/2 of the axle load) may only be exceeded by 4%. Height of center of gravity, z-direction Gross vehicle weight [t] / Rim Diameter Unladen with body [mm] Laden [mm] 3.88/15" 815 1,100 3.88/16" 865 1,100 1.
General Information 1.8.2 Calculating the Center of Gravity Measurement 1 After installation or modification of the equipment, vehicles must be weighed on a weighbridge in two different positions. The axle loads must be weighed when the vehicle is horizontal (Gv1 and Gh1) and when one axle is raised by amount "a" (Gv2 and Gh2; we recommend a = 500 mm). The wheelbase RS1 (3,000 mm, 3,550 mm or 4,025 mm) is defined by the vehicle model series (see Ordering) or must be measured using a rule.
General Information Measurement 2 xv1, xv2... distance from centre to front axle, measurement 1/2 xh1, xh2... distance from centre to rear axle, measurement 1/2 N00.00-2689-00 1.
General Information The sum of all moments about a point is zero.
General Information The values for xh1 and xh2 are already known from equations (2) and (4). The required u is calculated using: a - = -------u - (9) and results in the following equation: --------RS 2 xh 2 a∗ xh 2 u = --------------RS 2 If equations (7) and (10) are used in equation (5) and are referred back to the given/measured values a, RS1, Gv1, Gh1, Gv2 and Gh2, the result for the height of the center of gravity z is: z = tan cos 1.
General Information 1.9 Conversion Tables 1.
General Information 1.
2 2Body Installation Chassis Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Installation Dimensions and weight of the Sprinter are based on the standard vehicle equipment: 2.1 Chassis Dimensions Note weight tolerances allow up to + 5 % in production ISO 1176. Observe all specifications in the offer drawings! 2.2 Cab Dimensions Observe all specifications in the offer drawings! Do not exceed permissible axle loads and gross vehicle weights. The permissible load and weights are listed on vehicle certification label, see section 2.4 of this manual.
Body Installation 2.5 Body Mounting Methods 2.6 Shelf support 2.5.1 Bolted Connections Floor attachment If the factory installed bolts have to be replaced with longer bolts, use only bolts with – the same diameter – the same strength class and – the same thread pitch. 2.5.2 Welded Connections Do not perform any welding work on assemblies, including but not limited to the engine, the transmission, the axles and the chassis frame.
Body Installation 2.7 Tire Envelope Clearance designee, DaimlerChrysler Manufacturing International LLC. 2.7.1 Snow Tires 2.8 Chain Clearance (Rear Axle) Following any modification to the Sprinter body, Body Builder must ensure that only tires of the size approved for the Sprinter are installed. Allow at least tire envelope clearance, taking into consideration snow tires, anti-skid chains, as well as potential frame distortion.
Body Installation 2.9 Turning Radius Wheelbase Turning Radius 15” Tires Turning Radius 16” Tires 2500 SWB 118” 36.7 feet not available 2500 MWB 140” 42.0 feet 44.6 feet 2500 LWB 158” 47.0 feet 49.5 feet 3500 MWB 140” 42.0 feet 44.6 feet 3500 LWB 158” 46.9 feet 49.5 feet 2.
Body Installation 2.10 Paint Work To prevent discoloration when painting the body, check the suitability and compatibility of paint prior to performing any paintwork on the Sprinter. Contact DCMC and DCV’s designee, DaimlerChrysler Manufacturing International LLC, to inquire about color code for primer and paint.
Body Installation Width and Location of the Body to be Installed onto the Cab Chassis 2.
Body Installation 2.11.2 Location of the Clearance Lamps If the width of the body installed is 80 “ or greater, Body Builders must install at minimum, 2 yellow clearance lamps/ 1 yellow identification lamp upfront, and 2 red clearance lamps/ 1 red identification lamp on the rear of the box to comply with FMVSS 108 and 49 CFR Part 568. It is recommended that Body Builders install the front lamps on the roof of the chassis cab within the shaded area as shown in Drawing YY. 4" 2.
3 3Frame and Chassis Frame Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Drilling Holes in Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Detachable Parts and Auxiliary Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.
Frame and Chassis 3.1 Frame Specifications 3.2 Drilling Holes in Frame Never drill holes in the following areas of the Sprinter: Do not alter the wheel base or lengthen the frame of the Sprinter Cargo Van or Passenger Van. Due to the vehicle's self- carrying structure, any such alteration may seriously harm its structural integrity, its road worthiness and the safety of the vehicle. – In the top or bottom of the chassis frame. (Exceptions are holes at the rear and of the frame.
Frame and Chassis For Cab Chassis only: In special cases holes can be drilled in the web of the longitudinal frame member. – Distance ”a”: at least 20% of frame height – Distance between holes ”b”: at least 50 mm – Maximum hole diameter ”d”: 15 mm 3.3 Detachable Parts and Auxiliary Assemblies 3.3.1 Mounting on the Sprinter Chassis Frame – All auxiliary assemblies must be secured to mounting brackets. – If using bolted connections, spacer must be weldable. 3.3.
Frame and Chassis 3.4 Mounting Frame The specified sectional models and channel dimensions assume that the longitudinal frame members are loaded uniformly on both sides. – A mounting frame or structure with the function of a mounting frame is required for all 2ND bodies for proper connection between the chassis and body (exception: self-supporting bodies and mounting frames as floor assembly). If a number of bodies are installed on one chassis (e.g.
Frame and Chassis 3.4.1 Material Quality 3.4.2 Design Material qualities for specified steel mounting frames: The transition of the channel at the front ends of the longitudinal members should be a gradual one.
Frame and Chassis I II 1 2 3 4 3.
Frame and Chassis 3.4.3 Channel Dimensions Channel dimensions for 2ND Body longitudinal frame members (open channel). Mounting frames and chassis frames should have approximately the same material thickness and flange width. h: WX Channel height in mm Moment of resistance in cm3 3.
Frame and Chassis 3.4.4 Mounting The mounting of the body to the chassis depends on the model, intended body, and the intended use of the vehicle. With prefabricated mounting frames take construction tolerances for chassis frame width into consideration (max. +6/-3 mm). Use shims to compensate for frame distortions (max. 6 mm) resulting from the manufacturing. Plan a sufficient number of mounts to take up the forces of braking and cornering. With rigid bodies, provide for resilient mounts in the cab (e.
Frame and Chassis 3.4.4.1 Friction-locking – Bracket mounting – Limit movement of the longitudinal member in relation to the longitudinal chassis member whenever possible. – Perform strength calculation separately for each longitudinal member. – Distribute bending moment in accordance with moments of inertia. – Secure the 2ND Body frame on the mounting brackets of the chassis frame. If additional securing points are required, use a shackle mount. 3.
Frame and Chassis 1. 3.
Frame and Chassis 3.4.5 Mounting Frame as Floor Assembly A mounting frame with continuous longitudinal members is not required when the floor assembly of the body can assume the function of the mounting frame. Front 3.
Frame and Chassis 3.5 Types of Bodies members if the cross members are installed at maximum intervals of 600 mm. 3.5.1 Self-Supporting Bodies Self-supporting van or box-type bodies do not require mounting frames with continuous longitudinal Front 3.
Frame and Chassis If required the maximum interval of 23 inches may be exceeded in the area of the rear axle. 1. Floor frame Self-supporting van or box bodies can be mounted directly to the mounting bracket on the chassis frame using a floor frame. 3. Bolt 2. Mounting bracket 4. Chassis frame Attach each mounting bracket with 2 bolts ensuring that the strength of the bolts is adequate to secure the body to the frame. 3.
Frame and Chassis 3.5.2 Platform, Van and Box-Type Bodies – Park vehicle on a level, horizontal surface to install the body. – The body must be mounted with a mounting frame (C-Section longitudinal members) to ensure that the chassis frame is loaded uniformly. – The body must be in contact with the longitudinal chassis-frame members without distortion.
Frame and Chassis 3.5.3 Loading Cranes for platform bodies and dump truck bodies on page 3.17. The crane size must be matched to the chassis size. Ensure that the vehicle is stable when crane is in use. Limit sewing range of crane as required. – To prevent vehicle tipping, install outriggers for each crane. We recommend hydraulic outriggers. – To prevent frame damage do not lift vehicle with outriggers. Disregarding these directions may cause the vehicle to tip over.
Frame and Chassis 3.5.4 Dump Truck Bodies Articulated bearings: – On 3-way and rear dump truck bodies, position the rear articulated bearing as close as possible to the rear axle. Disregarding these directions reduces the operational safety of the vehicle. This can lead to an accident, and, as consequence, serious injury or death. – The lowered tailgate must not strike the end of the frame, the lighting equipment nor the trailer towing hitch.
Frame and Chassis Vehicle Moment of resistance (WX) per longitudinal member in cm3 2500 45 3500 60 3.5.5 Roll-Off and Removable Dump Truck Bodies These guidelines apply similarly to roll-off removable dump bodies. – To avoid damage to frame do not allow the front axle to lift when mounting or removing. – Attach supports at end of vehicle. Channel dimensions and mounting frame sectional modules: – Ensure the stability of the vehicle during the loading and unloading procedures.
Frame and Chassis 3.5.6 Longitudinal Reinforcement with Unladen Front Axle When working with a lifting hoist, the entire vehicle may be lifted on 4 hydraulic pillars: The wheels lose all contact with the ground. Due to heavy weight of the front of the vehicle, this causes impermissibly high tension in the longitudinal frame members in the area of the front support. A reinforcement of the chassis frame is essential for applications.
4 4Cab Seat Belts and Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Modifications of Cab other than Seat Belts or Airbag or Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.
Cab 4.1 Seat Belts and Airbag Compliance with Vehicle Safety Standards for Seat Belts Note: The Sprinter, when completed by DCAG, conforms with all applicable national standards, including but not limited to FMVSS/CMVSS 208, FMVSS/CMVSS 209, FMVSS/CMVSS 210. Any alteration of the seat location, seat belts, seat belt anchorage points, seats, seat anchorage point, cab and support structure as well as cab underbody may void this certification. Alterations may require certification. Please see section 1.3.
Cab Do not pass belts over sharp edges. Do not seat children less than 5 feet tall or 12 years and under in the front seats. Do not remove labels regarding placement of children less than 5 feet tall or 12 years and under in the front. Do not modify the components or electrical wiring of the restraint systems, including the installation of additional trim material, badges, etc.
Cab Safety Precautions for the Airbag Airbags can cause serious injury or death. Do not position the seat closer than designed by DCAG. Do not move the seat anchorage points. Do not position objects on the airbag or between the airbag and the vehicle´s occupants. Do not touch any hot parts after the airbag has inflated. Covering the padded steering wheel or attaching labels or stickers to the padded steering wheel may reduce the functionality of airbags.
Cab 4.2 Modifications of Cab other than Seat Belts or Airbag or Restraint System Depiction of zones relevant for FMVSS 201: 4.
Cab 4.
5 5Electrical System Electrical Center/Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Box Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 5.1 Electrical Center/Expansion General guidelines: • Never loosen or move the battery connection terminals while the engine is still running. • Quick charge battery only after disconnecting it from the vehicle’s electrical system. Both positive and negative terminal must be disconnected. • Please see section 5.4 for notes on the installation of additional electrical equipment/devices. • Only use cables with fire-proof jackets in the vicinity of the exhaust systems.
Electrical System 5.2 Wiring System Always observe the following points and guidelines when extending the electrical wiring: • Only use wires with reduced insulation gauge and wires with the same cross-section and same color code as the standard wires supplied by DCAG. Disregarding these directions can lead to electrical malfunctions. This can cause an accident, and, as a consequence, serious injury or death. • The wires must be jacketed with an insulating sheath.
Electrical System 5.3 Battery Box Location An additional battery may only be installed in conjunction with a D + relay. This battery may only be used to power defined auxiliary devices such as auxiliary heating or air conditioning, a loading tailgate, etc. If the auxiliary battery is located in the passenger compartment, it is essential that the breather venting is fed into the open air through a central vent hose. 5.
Electrical System Improper work on or incorrect installations in the vehicle electrics/electronics could lead to electrical malfunctions. This could lead to an accident, and, as consequence, serious injury or death. Note: Improper work on or incorrect installations in the vehicle electrics/electronics could endanger the vehicle´s operating safety and / or invalidate the vehicle´s warranty. 5.5 Electrical Installation of Mobile Communication Systems When mobile communication systems, e.g.
Electrical System 5.5.3 Connection and Routing of Equipment Wiring Always connect the equipment directly to terminal 30 via an additional fuse. When routing lines, keep them as short as possible and avoid loops. Do not twist cables. Always ensure that the aerial and electrical equipment have good ground connection to the vehicle body. Aerial cables connecting lines between the transmitter, receiver and operating panel must be separated from the body ground with a wiring harness.
Electrical System 5.7 Connection of the Clearance Lamps Operating cell phones or other radio telecommunications equipment with an aerial inside the vehicle can interfere with the operation of the vehicle and cause a safety hazard. Note: If a cell phone or a two-way radio has been retrofitted without complying with the manufacturer’s installation requirements, the vehicles warranty may be voided. The clearance lamps must be connected to the end connector J16 by a cable 6mm2, rd and an additional fuse 10A.
Electrical System Connection of the Clearance Lamps J16 1,5 gr/gnrd 6 rd 10 A additional fuse 1,5 gr/gnrd 1,5 rd 86 87 87a K140 (existing) 85 additional relay 30 1,5 br seat pedestal W5.1 to the clearance lamps 5.
Electrical System To install the clearance lamps, DCMC and DCV recommend only the following parts released by DCAG: End connector A 001 546 87 41 Relay A002 542 14 19 Socket A006 545 07 28 Plug housing, 1-pole A 002 545 10 28 Plug socket housing, 1-pole A 002 545 10 28 Fixing parts A 002 545 10 28 Fuse N 072581 000304 5.8 Connection of the Third Brake Lamp The third brake lamp must be connected to the end connector J8 by a cable 1.5mm2, bk/rd.
Electrical System 5.
6 6Brake System Modifications to Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
Brake System 6.1 Modifications to Brake System Caution! The Sprinter, "as delivered" by DCMC and DCV complies with all applicable national standards, including but not limited to FMVSS/CMVSS 105/106/116. Any alteration of the brake system may void this certification and cause a safety hazard. Recertification may be necessary! Please contact DCMC and DCV’s designee, DaimlerChrysler Manufacturing International LLC Engineering and Compliance Department for additional information.
7 7Fuel System Fuel Tank Specification and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Modifications of Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.
Fuel System 7.1 Fuel Tank Specification and Location See offer drawings of the passenger Van for the fuel tank location. 7.2 Modifications of Fuel System Do not move or replace the fuel system. Movement or replacement of the fuel system may lead to fire, serious injury or death. The Sprinter, "as delivered" by DCMC and DCV conforms with all applicable national standards, including but not limited to FMVSS/CMVSS 301. Any alteration of the fuel system may void this certification.
8 8Exhaust System System Layout/Location/Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Oxidation, Catalytic Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Modifications of Exhaust Systems Other Than Catalytic Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.
Exhaust System 8.1 System Layout/Location/ Specifications 8.
Exhaust System 8.
Exhaust System 8.
Exhaust System 8.2 Oxidation, Catalytic Converters The material /...../ (see installation pages 8.1-8.3) bracketry of the exhaust type, type of exhaust, connector system from turbocharger outlet to the oxidation catalytic converters, including the converters and muffler themselves, must not be altered. Any alterations will invalidate EPA exhaust emission certification. 8.3 Modifications of Exhaust Systems Other Than Catalytic Converters – Bending radii must be > 2.5 d.
Exhaust System Bending radii 8.
9 9Engine System Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine System 9.1 Engine Specifications Designation/Engine Number/arrangement of cylinders Engine type Injection Number of valves per cylinder OM612LA / OM647LA 5 cylinders in line turbocharged engine with charge air cooling Common Rail Direct Injection with valve-covered orifice injection nozzles 4 (2 intake/2 exhaust) Bore (in.) 3.46 Stroke (in.) 3.48 Piston displacement (cu. in.) 164 Compression ratio Engine output (hp) * @ rpm Torque (lb.
Engine System 9.2 Engine Air Intake 9.3 Engine Cooling System Note: The Sprinter, "as delivered" by DCMC and DCV conforms with the EPA Emission Standards, relating to air intake manifold temperature, air intake system pressure drop, etc. Do not modify the engine cooling system, radiator, radiator grill, air ducts, cooling circuits, etc. Any alteration of the air intake and air cooling system may void this certification. Recertification may be necessary.
Engine System 9.
10 10Axles Front Axles Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Track and Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axles 10.1 Front Axles Specifications Front axle with individual wheel suspension, transversal leaf parabolic springs, shock absorber and stabilizer bar. 10.2 Rear Axle Specifications Rear axle with standard rear axle ratio i = 3,727 (optional i = 4,111), parabolic springs and stabilizer bar as standard (reinforced stabilizer bar as an option on vehicles with 9,990 GVW) 10.3 Axle Track and Overall Width Observe all specifications in the offer technical drawings. See Diagram. 10.
11 11Rear Suspension Modifications of Leaf and Coil Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.
Rear Suspension 11.1 Modifications of Leaf and Coil Springs Only use original leaf and coil springs approved by DCAG. Do not damage the surface or corrosion protection of the spring leaf. Before welding always cover the springs to protect against welding spatter. Never touch the springs with welding electrodes and welding tongues. Installing additional spring leaf is not permitted. Damaged springs must be replaced. 11.
12 12Tires and Wheels Tire and Wheel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.
Tires and Wheels 12.1 Tire and Wheel Specifications Model Tires Wheels 2500 225/70 R 15 C 6J X 15 H2 225/75 R 16 LT (140" and 158" wheelbases) 6J X 16 H2 195/70 R 15 C 5 1/2J X 15 H2 (rear axle with dual wheels) 225/75 R 16 LT (Cab - Chassis) 6J X 16 H2 3500 12.
Tires and Wheels 12.2 Loading the Vehicle 12.2.1 Tire and Loading Information Two labels on the vehicle show how much weight it may properly carry. – The Tire and Loading Information Label can be found on the driver’s door B-pillar. This label tells you important information about the number of people that can be in the vehicle and the total weight that can be carried in the vehicle.
Tires and Wheels Tire and Loading Information Label Seating Capacity The seating capacity (1) gives you important information on the number of occupants that can be in the vehicle. Observe front and rear seating capacity. Never let more people ride in the vehicle than there are designated seating positions and seat belts available. Be sure everyone riding in the vehicle is correctly restrained with a separate seat belt. Load Limit Information 1. Seating capacity 2.
Tires and Wheels Steps for Determining Correct Load Limit Step 5 The following steps have been developed as required of all manufacturers under Title 49, Code of U.S. Federal Regulations, Part 575 pursuant to the "National Traffic and Motor Vehicle Safety Act of 1966". – Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage load capacity calculated in step 4.
Tires and Wheels Example Combined weight limit of occupants and cargo from label Occupants weight Combined Number of Seating weight of all occupants configuraoccupants (driver and tion passengers) Available cargo/luggage and trailer tongue weight (total load limit from label minus combined weight of all occupants) 1 5 1500 lbs front: 2 rear: 3 Occupant 1: 150 lbs Occupant 2: 180 lbs Occupant 3: 160 lbs Occupant 4: 140 lbs Occupant 5: 120 lbs 750 lbs 1500 lbs – 750 lbs = 750 lbs 2 1500 lbs 3 fro
Tires and Wheels Certification Label Gross Vehicle Weight Rating (GVWR): Even after careful determination of the combined weight of all occupants, cargo and the trailer tongue load (if applicable) as to not exceed the permissible load limit, you must make sure that your vehicle never exceeds the Gross Vehicle Weight Rating (GVWR) and the Gross Axle Weight Rating (GAWR) for either the front or rear axle.
Tires and Wheels Trailer Tongue Load The tongue load (tongue weight at the hitch ball) of any trailer is an important weight to measure because it affects the load you can carry in your vehicle. If a trailer is towed, the tongue load must be added to the weight of all occupants riding and any cargo you are carrying in the vehicle to prevent exceeding your Sprinter tow vehicle’s rear GAWR. The tongue load typically is between 10 % and 15 % of the trailer weight and everything loaded in it.
13 13Other Additional Information Special Notes on Loading Tail Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Special Notes on Trailer Coupling and Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Special Notes on Wind Deflectors and Wind Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.
Other Additional Information 13.1 Special Notes on Loading Tail Gates Observe the following instructions when installing loading tail gates to the Sprinter: – Loading tail gates must conform with all national accident prevention regulations and guidelines. – When installing tail gates, ensure that the permissible rear axle load is not exceeded. – Comply with the front minimum axle load. – Test the loading tail gate stability only when the vehicle is stationary.
Other Additional Information Ball head coupling MAX. 8" MAX. 2" MAX. 2" MAX. 2" N31.10-2095-20 N31.10-2094-20 The assembly of a trailer coupling may take place only at, the frame-lateral fastening spots prescribed by DCMC or DCV’s designee, DCMI Engineering. The hitch ball adapter used should not exceed the maximum dimensions described in diagram above. 13.
Other Additional Information The bumpers on Sprinter are not designed for use with clamp-type hitches. Do not install/attach rental hitches or other bumper-type hitches to the Sprinter. Installation of hitches, which have not been approved by DCAG, may result in loss of trailer and as consequence serious injury or death. N31.10-2096-20 Only install a trailer hitch receiver approved by DCAG for use on Sprinter. For Information on availability and installation please see your authorized Sprinter Dealer.
Other Additional Information IMPORTANT: Trailer tow hitch ball head coupling: Operation instructions must be included with the vehicle indicating the special features and operation of the coupling. To avoid jackknifing, serious injury or death. An unladen vehicle may only be used to tow an unladen trailer. Always observe the trailer coupling manufacturer’s instructions.
Other Additional Information 13.5 Special Notes on Noise Reduction Avoid any contact of the ark welder ground clamp with any of the drive train assemblies, including but not limited to, engine, transmission, and axles! – Do not touch electronic component housings, such as airbag control modules or electric lines with welding electrodes or ground contact clamps for ark welders. – On Sprinter cabs with insulating mountings, connect the welding equipment’s earth terminal to the cab.
Other Additional Information 13.5.2 Cab Platform The cab platform including the doorway, should be isolated with a soft, flexible insulating material (weight 10 to 12 kg/m2) and with carpet including foam padding. 13.5.3 Flooring To insulate and sound proof the floor structure, follow diagram regarding flooring structure. An additional covering with heavy insulating material may be provided in the area of the wheel wells.
Other Additional Information 13.5.4 Seals Carefully seal ducts, joints and slots between the engine compartment, the underside of the vehicle, and the splashboard to the vehicle interior with resilient material. Do not position airing and ventilation openings in the immediate vicinity of sources of noise. Always consult with suppliers of soundproofing materials to ensure compliance with national safety laws and regulations.
Other Additional Information 13.7 Special Notes on Modifications to Passenger and Cargo Vans The Sprinter body and chassis form a single, self supporting unit. Any modification to the vehicles body or chassis, which are not described in these guidelines, could adversely affect the vehicles structural integrity and road-worthiness.
Other Additional Information 13.7.4 Creating an Opening in the Roof When creating an opening in a Sprinter roof, reinforce the opening using a profiled frame. If utilizing a profiled frame is not feasible, additional roof bows must be installed. Height of roof Moment of inertia IX for each roof bow 250 mm 40,000 mm4 400 mm 65,000 mm4 550 mm 86,000 mm4 13.9 Above specifications are based on a plastic roof with an elasticity modulus of 7,000 N/mm2/psi and a wall thickness of 4 mm/inches.
Other Additional Information 13.8 Special Notes on Damage Prevention 13.8.1 Special Notes on the Prevention of Damage to Brake Hoses Before welding, drilling, grinding or working with cutting disks always cover the plastic brake hoses and brake lines. Remove the brake hoses and brake lines if necessary. Check systems for pressure loss after the brake hoses and brake lines have been reinstalled.
Other Additional Information 13.8.2 Welding Work When welding with electrical equipment, the following guide lines have to be observed: – Only trained personal may perform welding on the chassis frame. – The positive and negative terminals of the battery cover have to be disconnected. – The ground clamp for an arc welder may only be connected directly to the part which is welded.
US Edition F 09/05 Aussenti.fm Seite 1 Donnerstag, 22. September 2005 13:35 BODY BUILDER’S INFORMATION BOOK Some specifications and features shown or mentioned in this brochure are optional and only available on request at extra cost. Specifications are subject to change without notice. © 2005, DaimlerChrysler Manufacturing International LLC, Huntersville, NC 28078. All rights reserved.
US Edition F 09/05 Aussenti.fm Seite 1 Donnerstag, 22. September 2005 13:35 BODY BUILDER’S INFORMATION BOOK Some specifications and features shown or mentioned in this brochure are optional and only available on request at extra cost. Specifications are subject to change without notice. © 2005, DaimlerChrysler Manufacturing International LLC, Huntersville, NC 28078. All rights reserved.
