Maintenance service

AP00.20-M-0011A

Maintenance service

7.9.06

Customer: Order number: License number:

Confirm that work has been completed by signing Fitter: Date:

Completed 



Initial condition 

Not OK 

Operation

item no.



Service sheet for special equipment

Model 903.6, 904.6 with engine 111.984 with code MZ7 Liquified Petrol Gas (LPG) powerplant

Model 903.6, 904.6 with engine 111.984 with code MS7 NGT (Natural Gas Transporter) Sprinter

AP00.20-D-1209A

Check by customer service adviser



Check due date for tachograph inspection (§57B); authorize inspection if necessary

Date: 



Check due date for main inspection; authorize inspection if necessary

Date: 



Check due date for safety inspection; authorize inspection if necessary

Date: 



Check due date for exhaust emissions inspection; authorize inspection if necessary

Date: 



Check vehicle for damage to paintwork, corrosion and accident damage



Test bench



Brake testing on test stand



Enter braking values in N:

Left Right

Front

Rear

Parking brake

AP42.00-D-4290A

Engine compartment



Engine:
Oil and filter change

Engine 611.983

Engine 111.984, 611.981/987, 612

AP18.00-D-0101A

Check fluid level, correct
If fluid has been lost, determine cause and remedy - against separate job



Check engine cooling system
corrosion/frost protection and correct



______°C

Correct subject to a separate repair order.

AP20.00-M-2010A



Hydraulic brake system



AP42.50-D-4210A



Power steering



AP46.00-D-4611A



Battery



AP54.10-D-5410A



Windshield washer system



AP82.35-D-8210A



Air conditioning system:
check refrigerant level

except roof air conditioning 

Sütrak AC 111

Correct subject to a separate repair order.

AR83.30-M-1760A

Engine:



Replace spark plugs

Engine 111.984

AP15.10-D-1580A



Replace fuel filter

(filter with water separator)

Engine 611.981/983/987, 612

AP47.20-D-0780E



Air filter element: Check contamination
(Air filter with maintenance indicator)



Inspect and replace, if necessary
- subject to separate repair order.

 Replace at least every 3 years
(note installation date!).

Paper element replaced  Yes  No

AP09.10-D-0951A

Chassis and body



Replace dust filter for heating/air conditioning

AP83.00-D-8381A

Wheels, brakes



Adjust tire inflation pressure to correct pressure, including spare tire



AP40.15-D-4060A



Check brake lining thickness

Model 903, 904 

AP42.10-D-4253A

Model 905 

AP42.10-D-4253B

Underside of vehicle

Check, correct fluid level
In the event of fluid loss, determine and eliminate cause

- subject to a separate repair order



Transfer case

Model 904.663 Minibus Sprinter 

low floor, model 905.613 Minibus Sprinter low floor 6 t

AP28.80-M-2811A

Check for leaks and condition
Pay attention to chafing points and line routing!



All major assemblies:
Engine, transmission, transfer case, reversing gear, front axle, rear axle, steering, power steering pump



AP00.20-M-0050B



All lines and hoses, sensor cables



AP00.20-M-0051B



Rubber boots of front axle supporting joints, rubber boots of front axle drive shafts, shock absorbers, load-sensitive brake force regulator



AP00.20-D-0052A

Chassis and body



Rubber auxiliary springs: visual inspection



AP32.00-D-3250A



Retarder: Check gap

Telma CC 35 retarder 

AP43.40-M-4356A



Checking condition of steering mechanism



AP46.00-D-4650A



Compressed-air reservoir:

Drain condensation

Model 905.613 

AP42.60-D-4390A

Tighten screws and nuts:

Observe official torque specifications.



Chassis, body, retarder

AP00.20-M-0073A

Vehicle interior



Reset ASSYST maintenance computer

 After completing the maintenance work.

AP00.20-D-0040A

Function test



Signaling system, indicator lamps



AP54.00-D-5451A



Headlamps, exterior lamps



AP82.10-D-8251A



Windshield wipers, windshield washer system



AP82.30-D-8252A



Air conditioning



AP83.00-M-8352A



Door and reversing system



AP72.40-M-7250A



Straight-line lift



AP86.20-M-8653A

climate control



Air conditioning system:
check refrigerant level

Roof air conditioning, Sütrak AC 111 

Correct subject to a separate repair order.

AP83.30-M-8312A



Air conditioning: Clean air filter, inspect and replace, if necessary

Roof air conditioning, Sütrak AC 111 

AP83.00-M-8330A

except roof air conditioning 

Sütrak AC 111

AP83.00-M-8330B



Clean dust filter of additional heat exchanger, inspect and replace, if necessary

Heat exchangers in passenger compartment 

AP83.20-M-8334A

Additional work at each maintenance service

Lubricating work



Doors, trailer hitch, propeller shafts

AP00.20-M-0020A



Retarder

Telma CC 35 retarder

AP43.40-M-4320A

Chassis and body



Trailer hitch:
check function, play and attachment



AP31.10-D-3151A

Additional operations at every
2nd maintenance service

Oil change



Manual transmission

Transmission 711.60 /62

AP26.00-D-2601A

Transmission 716.6

 Once at 2nd maintenance service.

AP26.00-D-2601B



Transfer case

Model 903.6, 904.6 with code ZG1 Engageable all-wheel drive

Model 903.6, 904.6 with code ZG2 Permanent all-wheel drive

Model 903.6, 904.6 with code ZG3 Gear reduction for all-wheel drive

AP28.00-D-2801A



Front axle

Model 903.6, 904.6 with code ZG1 Engageable all-wheel drive

Model 903.6, 904.6 with code ZG2 Permanent all-wheel drive

Model 903.6, 904.6 with code ZG3 Gear reduction for all-wheel drive

AP33.00-D-3301A



Transfer case

Model 904.663 Minibus Sprinter low floor

Model 905.613 Minibus Sprinter low floor
6 t

AP28.80-M-2802A



Air compressor

Model 905.613 Minibus Sprinter low floor
6 t

AP13.10-M-1301A

Engine:



Replace air filter element
(Air filter without maintenance indicator)

 Replace at least every 3 years (note installation date!).

AP09.10-D-0980A



Replace fuel filter

(filter without water separator)

Engine 111.984

AP47.20-D-0780A

Engines 611, 612

AP47.20-D-0780D



Inspect poly V-belt for wear and damage



AP13.22-D-1351A

Additional operations at each
6th maintenance service

Oil change



Rear axle

Rear axle 741.411

Rear axle 741.130/408/980

AP35.00-D-3501A

Maintenance operations once a year



Air compressor: Clean cooling fins

Model 905.613 Minibus Sprinter low floor
6 t

Model 905.613 Minibus Sprinter Classic 6 t

AP13.10-M-1330A



Air compressor: Clean intake air filter

Model 905.613 Minibus Sprinter low floor
6 t

Model 905.613 Minibus Sprinter Classic 6 t

AP13.10-M-1331A



Air conditioning: Clean condenser

Roof air conditioning, Sütrak AC 111

AP83.00-M-8335A



Air conditioning: Clean, check condenser

Rear air conditioning SC3-11 with 

additional condenser

AP83.00-M-8337A



Clean dust filter of roof air conditioning, inspect and replace, if necessary

Roof air conditioning, Sütrak AC 111 

AP83.00-M-8387A



Floor heaters: Clean heat exchanger

Heat exchangers in passenger compartment

AP83.20-M-8333A

Convector heater, control via "Heatmatic"

AP83.20-M-8333B

Maintenance work every 2 years



Hydraulic brake system:
replace brake fluid

AP42.50-D-4280A



Compressed air drier:

Replace granulate cartridge

Model 905.613 Minibus Sprinter low floor
6 t

AP42.60-M-4381A

Model 905.613 Minibus Sprinter Classic 6 t

AP42.60-M-4381B

Maintenance work
every 10 years/300,000 km



Manual transmission:

Oil change

Transmission 716.6

AP26.00-D-2601B

Maintenance work every
15 years/250,000 km



Replace coolant

 Observe coolant composition

AP20.00-M-2080A

Final inspection



Visual inspection/road test