🏷️ Basic Information Identification Make: Dodge Model: Sprinter 2500 Year: 2004 Chassis Code: NCV3 (W906 platform, though commonly referred to by its Dodge era designation) 👋 Introduction Market Position Market Position: The 2004 Dodge Sprinter 2500 represents Dodge's entry into the full-size van market, offering a European-designed platform (originally Mercedes-Benz Sprinter) optimized for commercial and recreational use in North America. It competes with domestic vans like the Ford E-Series and Chevrolet Express, but differentiates itself with its taller roofline, cab-forward design, and fuel-efficient diesel engines, making it a premium choice for cargo hauling and van conversions. Competitive Analysis Competitive Analysis: The Sprinter 2500's key advantages over competitors were its superior fuel economy derived from its diesel powertrains, greater interior cargo volume due to its higher roof options, and more maneuverable driving dynamics for its size. Its drawbacks often included a higher initial purchase price and potentially more specialized maintenance requirements compared to its American counterparts. Key Features Key Features: Cab-forward design offering excellent visibility and maneuverability, choice of two powerful and efficient diesel engines, multiple body configurations (cargo van, passenger van, chassis cab), optional all-wheel drive, class-leading interior cargo height and volume, robust construction for commercial applications. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive coverage for all mechanical and electrical systems, bodywork, and diagnostics. Page Count Page Count: Estimated 1000+ pages (typical for full service manuals of this era) Manual Type Manual Type: Service & Repair Manual Software Language Language: English Format Format: Digital Software (likely PDF or proprietary executable) 📖 Manual Coverage Systems Covered Systems Covered: Engine (3.0L Diesel, 2.7L Diesel), Powertrain Control Module (PCM), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Automatic Transmission (5G-Tronic), Drivetrain (RWD, AWD options), Brakes (ABS, EBD), Suspension (Front/Rear), Steering, Electrical System (12V, wiring diagrams, fuses, relays), Body Control Module (BCM), Climate Control (HVAC), Lighting, Chassis Components, Interior/Exterior Trim, Diagnostic Trouble Codes (DTCs). Procedures Included Procedures Included: Routine maintenance (oil changes, filter replacements, inspections), engine repair and overhaul, transmission service and overhaul, brake system repair, suspension and steering component replacement, electrical system troubleshooting and repair, HVAC system diagnosis and repair, body panel repair and adjustment, diagnostic procedures for all major systems, component testing, torque specifications, special tool requirements. Technical Depth Technical Depth: Extensive, covering everything from basic fluid checks and filter replacements to complete engine and transmission rebuilds, advanced electrical diagnostics using wiring schematics, and body repair. 📊 Manual Specifications File Format File Format: Digital Software, likely searchable PDF or interactive executable. Print Quality Print Quality: High resolution, suitable for digital viewing and printing of individual pages. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Primary Engine: 2.7L DOHC Inline-5 Turbo Diesel (OM612 engine family) Primary Engine Details Displacement: 2.7 Liters (2687 cc) Horsepower: 154 hp @ 3800 rpm Torque: 243 lb-ft @ 1400-2200 rpm Secondary Engine Secondary Engine: 3.0L DOHC Inline-5 Turbo Diesel (OM647 engine family - introduced later in the generation or as an option) Secondary Engine Details Displacement: 3.0 Liters (2987 cc) Horsepower: 156 hp @ 3400 rpm Torque: 280 lb-ft @ 1400-2400 rpm Fuel System Fuel System: Common Rail Direct Injection (CDI) with turbocharging and intercooling. Emissions Control Emissions Control: Exhaust Gas Recirculation (EGR), Diesel Oxidation Catalyst (DOC), likely with Diesel Particulate Filter (DPF) depending on market and specific configuration. 🔧 Transmission Standard Transmission: 5-speed Automatic Transmission (Mercedes-Benz 5G-Tronic / NAG1) Optional Transmission Options: Manual transmission was an option in some markets, but the 5-speed automatic was far more common, especially in North America. Features Features: Tiptronic shifting, electronically controlled, robust design suitable for commercial use. Fluid Type Fluid Type: MB Spec 236.12 (ATF) 📐 Dimensions Exterior Wheelbase Wheelbase: Common wheelbases include 140.6 inches (3570 mm) and 170.1 inches (4320 mm). Exterior Length Length: Varies by wheelbase and body configuration, typically ranging from approximately 236 inches to 277 inches. Exterior Height Height: Offered in standard and high-roof options, with high-roof variants exceeding 90 inches (approx. 2300 mm) internal standing height. Interior Cargo Volume Cargo Volume: Exceptional for its class, with configurations offering over 400 cubic feet (approx. 11300 liters) of cargo space in high-roof, long-wheelbase versions. Weights Gvwr Gross Vehicle Weight Rating: Typically around 8,550 lbs (3878 kg) to 9,990 lbs (4531 kg) for the 2500 model, depending on configuration. Weights Curb Curb Weight: Approximately 5,000 - 6,000 lbs (2268 - 2722 kg), varying by body style and equipment. 🛡️ Safety Features Ratings Ratings: While specific NHTSA or IIHS ratings for this model year are not as readily available as for passenger cars, the Sprinter's robust chassis and cab-forward design contribute to good structural integrity. Cargo van configurations often focus on occupant protection and load security. Active Features Active Features: Anti-lock Braking System (ABS), Electronic Stability Program (ESP - standard on most models), Traction Control...