🏷️ Basic Information Identification Make: Dodge Model: Sprinter Cargo Van Year: 2004 Product Type: Owner's Manual 👋 Introduction Market Position Vehicle Segment: Light Commercial Vehicle (LCV), Full-size Cargo Van Target Audience: Businesses, tradespeople, delivery services, and individuals requiring substantial cargo capacity and versatility. Competitive Analysis Key Competitors: Ford E-Series, Chevrolet Express/GMC Savana, Ford Transit (later generations), Mercedes-Benz Sprinter (itself, but different configurations/markets). Key Features Cargo Capacity: Designed for maximum cargo volume and payload, configurable for various trade needs. Durability: Built for commercial use, emphasizing robust construction and reliability. Versatility: Platform suitable for various upfits and specialized applications. 📋 Manual Details Coverage Areas Primary Coverage: 2004 Dodge Sprinter Cargo Van Secondary Coverage: General Sprinter operation, maintenance, and features for the model year. Page Count Estimated Page Count: Variable (Factory original manual content, exact PDF page count depends on formatting but typically 300-500 pages for this vehicle type) Manual Type Manual Type: Owner's Manual Language Language: English Format Format: Digital PDF 📖 Manual Coverage Systems Covered Instrument Cluster: Detailed explanation of gauges, warning lamps, and indicator lights. Entertainment Systems: Operation of radio, CD player, and any auxiliary audio/video inputs. Climate Controls: Operation of HVAC system, including manual and automatic climate control functions, air conditioning, and heating. Lighting: Operation of headlights, taillights, interior lighting, hazard lights, and fog lights. Driver Controls: Explanation of steering wheel controls, gear selector, parking brake, and other primary driver interfaces. Locks And Security: Operation of door locks, remote keyless entry, central locking, and basic security features. Seating And Safety Restraints: Adjustment of seats, seat belt operation, SRS (Supplemental Restraint System) airbag information, and child seat installation guidelines. Driving: Basic driving techniques, starting and stopping the engine, shifting gears, and parking. Customer Assistance: Information on warranty, roadside assistance, and contacting the manufacturer. Reporting Safety Defects: Specific procedures for reporting safety defects in the U.S. Cleaning: Guidance on cleaning the interior and exterior of the vehicle, including recommended cleaning agents. Maintenance And Specifications: Overview of routine maintenance, recommended service intervals, and technical specifications. Engine Compartment: Identification of major engine components and fluid reservoirs. Engine Oil: Engine oil specifications, viscosity grades, checking oil level, and recommended oil change intervals. Battery: Battery specifications, maintenance, and jump-starting procedures. Fuel Information: Recommended fuel type, octane rating, and fuel system care. Air Filter: Information on the engine air filter, its replacement, and recommended service intervals. Part Numbers: Identification of some common maintenance part numbers (e.g., filters, fluids) as provided by the manufacturer. Refill Capacities: Capacities for engine oil, coolant, brake fluid, windshield washer fluid, etc. Lubricant Specifications: Specifications for various lubricants used in the vehicle, including transmission fluid, differential fluid, and grease. Accessories: Information on factory-installed accessories and their operation. Procedures Included Routine Maintenance: Guidance on checking fluid levels, tire pressure, lights, and other daily/weekly checks. Basic Troubleshooting: Guidance on common warning lights and basic issues the owner might encounter. Fluid Checks: Detailed instructions on how to check and top off essential vehicle fluids. Tire Maintenance: Information on tire pressure, rotation, and checking wear. Jump Starting: Safe and correct procedures for jump-starting the vehicle's battery. Wiper Blade Replacement: Instructions on how to replace windshield wiper blades. Fuse Replacement: Guidance on locating and replacing blown fuses. Technical Depth Depth: Owner-level information for understanding vehicle operation, basic maintenance, and safety features. Does not include in-depth diagnostic procedures or complete repair instructions typically found in service manuals. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Typically searchable text within the PDF, allowing for quick information retrieval. Print Quality Print Quality: High-resolution digital reproduction of the original factory manual. Binding Type Binding Type: N/A (Digital product) Paper Type Paper Type: N/A (Digital product) Compatibility Required Software: PDF Reader (e.g., Adobe Acrobat Reader, Foxit Reader) ⚙️ Engine Specifications Primary Engine Engine Type: Turbocharged Diesel (Commonly a 2.7L or 2.9L I4 diesel, or a larger 3.0L V6 diesel for some markets/configurations, though the 2004 model year is primarily associated with Mercedes-Benz sourced engines before full Dodge integration). Engine Displacement: Typically 2.7L (OM668) or 2.9L (OM611) CDI, or potentially 3.0L (OM647) CDI in some variants. Exact engine depends on specific market and sub-model. Horsepower Range: Approximately 100-150 hp (depending on engine variant). Torque Range: Approximately 180-250 lb-ft (depending on engine variant). Fuel System Fuel Type: Diesel Injection System: Common Rail Direct Injection (CDI) Cooling System Coolant Capacity: Approximately 10-12 Liters (subject to specific engine and configuration). Lubrication Engine Oil Capacity: Approximately 7.5-9.0 Liters (subject to specific engine and configuration). Recommended Oil Viscosity: Typically 5W-40 Synthetic Diesel Engine Oil meeting specific MB 229.51 or API CJ-4 specifications (check manual for precise MB approval). 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission (Common) Optional Transmission Type: 5-Speed or 6-Speed Automatic Transmission (Less common for 2004 models, but available on some variants). Features Transmission Fluid Type: Specific ATF (Automatic Transmission Fluid)...
Battery specifications, maintenance, and jump-starting procedures.
Fuel Information:
Recommended fuel type, octane rating, and fuel system care.
Air Filter:
Information on the engine air filter, its replacement, and recommended service intervals.
Part Numbers:
Identification of some common maintenance part numbers (e.g., filters, fluids) as provided by the manufacturer.
Refill Capacities:
Capacities for engine oil, coolant, brake fluid, windshield washer fluid, etc.
Lubricant Specifications:
Specifications for various lubricants used in the vehicle, including transmission fluid, differential fluid, and grease.
Accessories:
Information on factory-installed accessories and their operation.
Procedures Included
Routine Maintenance:
Guidance on checking fluid levels, tire pressure, lights, and other daily/weekly checks.
Basic Troubleshooting:
Guidance on common warning lights and basic issues the owner might encounter.
Fluid Checks:
Detailed instructions on how to check and top off essential vehicle fluids.
Tire Maintenance:
Information on tire pressure, rotation, and checking wear.
Jump Starting:
Safe and correct procedures for jump-starting the vehicle's battery.
Wiper Blade Replacement:
Instructions on how to replace windshield wiper blades.
Fuse Replacement:
Guidance on locating and replacing blown fuses.
Technical Depth
Depth:
Owner-level information for understanding vehicle operation, basic maintenance, and safety features. Does not include in-depth diagnostic procedures or complete repair instructions typically found in service manuals.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Searchability:
Typically searchable text within the PDF, allowing for quick information retrieval.
Print Quality
Print Quality:
High-resolution digital reproduction of the original factory manual.
Binding Type
Binding Type:
N/A (Digital product)
Paper Type
Paper Type:
N/A (Digital product)
Compatibility
Required Software:
PDF Reader (e.g., Adobe Acrobat Reader, Foxit Reader)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Turbocharged Diesel (Commonly a 2.7L or 2.9L I4 diesel, or a larger 3.0L V6 diesel for some markets/configurations, though the 2004 model year is primarily associated with Mercedes-Benz sourced engines before full Dodge integration).
Engine Displacement:
Typically 2.7L (OM668) or 2.9L (OM611) CDI, or potentially 3.0L (OM647) CDI in some variants. Exact engine depends on specific market and sub-model.
Horsepower Range:
Approximately 100-150 hp (depending on engine variant).
Torque Range:
Approximately 180-250 lb-ft (depending on engine variant).
Fuel System
Fuel Type:
Diesel
Injection System:
Common Rail Direct Injection (CDI)
Cooling System
Coolant Capacity:
Approximately 10-12 Liters (subject to specific engine and configuration).
Lubrication
Engine Oil Capacity:
Approximately 7.5-9.0 Liters (subject to specific engine and configuration).
Recommended Oil Viscosity:
Typically 5W-40 Synthetic Diesel Engine Oil meeting specific MB 229.51 or API CJ-4 specifications (check manual for precise MB approval).
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission (Common)
Optional
Transmission Type:
5-Speed or 6-Speed Automatic Transmission (Less common for 2004 models, but available on some variants).
Features
Transmission Fluid Type:
Specific ATF (Automatic Transmission Fluid) or manual transmission fluid as per manufacturer's specifications (e.g., MB 236.14 for automatics, GL-4/GL-5 for manuals).
📐 Dimensions
Exterior
Wheelbase:
Variable, common options include 118-inch and 140-inch.
Overall Length:
Variable, typically ranging from 194 inches to 236 inches depending on wheelbase and body style.
Cargo
Cargo Volume:
Significant, with various configurations available. Typically over 300 cubic feet, with longer wheelbase models offering more.
Weights
Curb Weight:
Typically 4,500 - 5,500 lbs, depending on configuration.
Gross Vehicle Weight Rating Gvwr:
Often in the 6,000 - 8,500 lbs range, depending on chassis and configuration.
Payload Capacity:
Typically 1,500 - 3,000 lbs, depending on GVWR and curb weight.
🛡️ Safety Features
Ratings
NHTSA Ratings:
As a commercial vehicle, specific NHTSA ratings may vary. Owner's manual will detail manufacturer's safety focus.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Often included, depending on trim and options.
Passive Features
Airbags:
Driver and front passenger airbags (SRS).
Seat Belts:
Three-point seat belts for all forward-facing occupants.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system where applicable, or standard seat belt methods for securing child seats.
💡 Technology Features
Infotainment
Radio System:
Factory AM/FM radio with CD player and potentially an auxiliary input (check specific configuration).
Speaker Configuration:
Typically 2 or 4 speakers, focused on cabin audio.
Driver Assistance
Cruise Control:
Available as an option on most models.
Connectivity
Power Outlets:
Standard 12V accessory power outlets for charging devices.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles or 12 months, depending on driving conditions and oil used. Diesel engines often have longer intervals. Consult manual for specific recommendations.
Air Filter Replacement Interval:
Recommended every 15,000 - 30,000 miles or as needed based on driving environment. Check manual for specific diesel air filter service.
Fuel Filter Replacement Interval:
Crucial for diesel engines. Typically recommended around 20,000 - 30,000 miles. Consult manual for precise diesel fuel filter replacement schedule.
Coolant Replacement Interval:
Initial service at 50,000 miles, then every 30,000 miles thereafter, or as per manufacturer's extended life coolant specifications.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (Check manual for precise specification and MB approval).
Power Steering Fluid Type:
Specific hydraulic fluid or ATF as per manufacturer's specifications.
Known Issues
Diesel Particulate Filter:
While less prevalent in 2004 models, early diesel emissions systems can be sensitive to fuel quality and driving style.
Body Rust:
Can be a concern in areas with road salt, particularly on undercarriage and wheel arches.
Transmission Shifting Issues:
While robust, like any commercial transmission, fluid changes are critical for longevity. Potential for solenoid issues in automatics.
Exhaust Gas Recirculation Egr:
Can become clogged in diesel engines with extensive city driving, affecting performance and emissions.
📚 Vehicle History
Brand Heritage
Dodge Commercial Lineage:
Dodge has a long history in commercial vehicles, with vans like the Ram Van and Tradesman. The Sprinter acquisition brought a European-designed, highly efficient commercial van into their lineup.
Model Evolution
Sprinter Origins:
The Sprinter platform originated with Mercedes-Benz (as the T1N Sprinter) before being rebadged and sold through Chrysler/Dodge in North America starting in 2003.
Production
Manufacturing Location:
Originally manufactured by Mercedes-Benz, with North American assembly often occurring in South Carolina (DaimlerChrysler plant).
Model Years Covered By Manual:
Specifically targets the 2004 model year, but information may be broadly applicable to closely related years (e.g., 2003-2006 T1N generation).
🏆 Awards & Recognition
Recognitions
Commercial Van Awards:
The Sprinter platform, in its Mercedes-Benz guise, has historically received numerous accolades as a leading commercial van for its efficiency, payload, and design.
Ratings
User Satisfaction:
Generally high among commercial operators due to its utility and operating costs.