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and driving style must therefore be adapted to suit road conditions. In winter, install M+S radial tires. Below a tread depth of 1/8 inch (3 mm), tire grip begins to decrease rapidly on wet roads. Hydroplaning Depending on the depth of the water layer on the road, hydroplaning may occur, even at low speeds and with new tires. Reduce vehicle speed, avoid grooves in the road, and apply brakes cautiously in the rain.
STARTING AND OPERATING 175
TIRE PRESSURES
WARNING!
If tire pressures are too low, there is a risk of the tire’s tread deteriorating and sudden loss of pres- sure due to the excessive temperature of the tire. This has an adverse effect on road safety and in- creases the risk of an accident. The limiting speed for the tires (tires and tire pressure) must not be exceeded. Exceeding the permissible maximum speed causes tire damage, which can lead to loss of control of the vehicle. Do not overinflate tires. Overinflating tires can result in sudden deflation (blowout) because they are more likely to become punctured or damaged by road debris, potholes, etc. Follow recommended inflation pressures. Do not overload the tires by exceeding the specified vehicle capacity weight as indicated by the label on the base of the driver’s seat. Overloading the tires can overheat them, possibly causing a blowout, which could cause an accident resulting in severe personal injuries, death and property damage.
176 STARTING AND OPERATING
The vehicle’s safety on the road depends to a great extent on tire condition and correct tire pressure. If tire pressures are too high or too low, handling characteristics will be adversely affected and fuel consumption and tire wear will increase. Check tire pressures regularly (each time the vehicle is refueled). Check tire pressures (including the spare wheel) with the tires cold. The pressure difference between the tires on a single axle should not exceed 1.5 psi (10 kPa). If tire pressure in individual tires is too low: check the valves, wheels and tires for signs of leaks. After a period of fast driving, or in hot weather, tire pressures can increase by as much as 14.5 psi (100 kPa). Never release air from a warm tire or else the tire pressure will be too low.
WARNING!
Correct the tire pressures before loading the vehicle fully. If the tire pressure is too low driving safety and tire mileage are decreased.
NOTE: Tire pressure changes by about 1.5 psi (10 kPa) for every 18 °F (+10 °C) change in air temperature. For this reason, do not release pressure from tires when they are warm. Remember to allow for this when checking tire pressures indoors, particularly in winter. Example: Room temperature: about 68 °F (+20 °C) Outside temperature: about 32 °F (0 °C) Required tire pressure, specified tire pressure 3 psi (20 kPa). Information on tires can be obtained from any authorized Sprinter Dealer.
STARTING AND OPERATING 177
Tire Pressures of Loaded Vehicle in PSI (kPa) Vehicle type 2500 C/HC/SHC Tire pressures for size 225/70 R 15 C 115 N – Front axle with max. axle load
Vehicle type 3500 C/HC/SHC Tire pressures for size 195/70 R 15 C 104/102 R – Front axle with max. axle load
3,858 lbs (1,750 kg)
65 psi (450 kPa)
3,858 lbs (1,750 kg)
51 psi (350 kPa)
– Rear axle with max. axle load
– Rear axle with max. axle load
5,357 lbs (2,430 kg)
70 psi (480 kPa)
Tire pressures for size LT225/75 R 16 115 N – Front axle with max. axle load
7,054 lbs (3,200 kg)
65 psi (450 kPa)
Tire pressures for size LT225/75 R 16 115/112
– Front axle with max. axle load3,858 lbs (1,750 kg)
58 psi (400 kPa)
3,858 lbs (1,750 kg)
55 psi (380 kPa)
– Rear axle with max. axle load
– Rear axle with max. axle load
5,357 lbs (2,430 kg)
80 psi (550 kPa)
7,054 lbs (3,200 kg)
57 psi (390 kPa)
Comfort Tire Pressures in PSI (kPa)
Rear Axle
Axle loads in lbs (kg), see type plate
1,764
(800)2,205
(1,000) 36
(250)2,646
(1,200)3,307
(1,500)3,748
(1,700)–
–
–
Double –
Single 33
(225)
33
(225)36
(250)43
(300)47
(325)178 STARTING AND OPERATING
Comfort Tire Pressures in PSI (kPa) For reasons of comfort, we recommend setting the tire pressures according to the table below, depending on axle loads, on longer journeys with an unloaded or only partially loaded vehicle.
Front Axle
Size
Appli- cation
Size
Application
195/70 R 15 C 104/102 R 225/70 R 15 C 112/110 R (115 N)
Single
Single
Axle loads in lbs (kg), see
type plate 2,976
(1,350) 47
(325)2,646
1,200) 40
(275)2,315
(1,050) 36
(250)3,219
(1,460) 51
(350)33
(225)36
(250)36
(250)36
(250)195/70 R 15 C 104/102 R 225/70 R 15 C 112/110 R (115 N)
WARNING!
Correct the tire pressures before loading the vehicle fully. If the tire pressure is too low driving safety and tire mileage are decreased.
SNOW CHAINS Install snow chains on rear wheels only. Install snow chains on exterior wheel in vehicles with double tires. Comply with installation instructions. NOTE: Vehicles with snow chains installed are only to be driven on a snow-covered surface. The snow chains must be removed on road surfaces free of snow.
the manufacturer’s
FUEL REQUIREMENTS Use only commercially available vehicular diesel fuels No. 2 or No. 1 (ASTM D 975 No. 2-D or No. 1-D). NOTE: Because of its better quality the manufacturer recommends the use of commercially available vehicular diesel fuel No. 2. For information on cold weather operation, contact your authorized Sprinter Dealer.
STARTING AND OPERATING 179
WARNING!
Marine diesel fuel, Bio diesel fuel, heating oil or the like must not be used. Do not blend diesel fuel with marine diesel fuel, Bio diesel fuel or heating oil. The use of such non-approved fuels or blending diesel fuel may result in malfunction or cause engine damage. Damage or malfunctions resulting from poor fuel quality or from blending specific fuel additives are not covered by the Sprinter Warranty.
If diesel fuels are used with a sulphur content exceeding 0.5 % by weight, engine oil change intervals must be shortened. Please contact your Sprinter Dealer to obtain the necessary information. Refueling from drums or canisters may lead to the fuel becoming contaminated. This in turn can cause faults in the fuel system. Always filter the fuel before adding it to the vehicle’s tank.
180 STARTING AND OPERATING
WARNING!
Under no circumstances should gasoline be mixed with diesel fuel. Due to the high pressure and high temperature in the injection system, there is a risk of fire and explosion. In addition, there is a risk of engine damage. Always follow basic safety rules when working with any combustible material.
Fuel Filter with Water Separator Check the water separator when the fuel indicator lamp does not go out or comes on while the engine is running. For more information on the indicator lamp The interval for changing the fuel filter is reduced to 10,000 miles (about 15,000 km).
insufficient due
Diesel Fuels for Use at Very Low Temperatures At very low temperatures the fluidity of No. 2 diesel fuel may become to parraffin separation. For this reason the vehicle comes equipped with a fuel preheater. It permits a troublefree engine operation to a temperature of approximately 14 °F (– 10 °C) when using No. 2 diesel fuel. To avoid malfunctions, No. 2 diesel fuel of a lowered cloud point is marketed during the cold season. At temperatures below 14 °F (–10 °C) use winterized or No. 1 diesel fuel only. If not available, a certain quantity of kerosene or fuel flow improver may be added. Mixing only to be done within the vehicle’s fuel tank. Kerosene has to be filled in before the diesel fuel. Engine power may drop according to the proportion of kerosene. For this reason, keep percentage of kerosene added to the minimum necessitated by the ambient temperature.
The following information can be used as a reference, if adding of kerosene becomes necessary. The mixing ratios shown refer to the total mixture. Ambient temperature: 14 °F to –4 °F (–10 °C to –20 °C) No. 2 Diesel Fuel: 70% Kerosene: 30% Ambient temperature: below –4 °F to (–20 °C) No. 2 Diesel Fuel: 50 % Kerosene: 50 % Even in extreme climatic conditions, the maximum mixture ratio should not exceed 50 %. Adding of kerosene to No. 1 diesel fuel is not recommended even at low temperatures. Do not blend other specific fuel additives with diesel fuel except for fuel flow improver. They only result in unnecessary cost, and may be harmful to the engine operation.
CAUTION!
Damage or malfunctions resulting from poor fuel quality or from blending specific fuel additives are not covered by the Sprinter Warranty.
STARTING AND OPERATING 181
REFUELING
1. Fuel filler neck 2. Fuel filler cap The fuel filler neck (1) is located behind the fuel filler flap next to the driver’s door. The fuel filler flap can be opened when the driver’s door is open. Turn the fuel filler cap (2) on the fuel filler neck (1) counterclockwise and take it off. For cargo/passenger vans, place the fuel filler cap (2) in the holder on the inside of the fuel filler flap. When you have finished refueling, install the fuel filler cap (2).
182 STARTING AND OPERATING
NOTE: Only fill the fuel tank until the fill nozzle cuts off, do not overfill. NOTE: Holder on the inside of the fuel filler flap only for cargo/passenger vans.
WARNING! Always handle fuel with great care. Shut off the engine and the auxiliary heater before refueling. Fuel is flammable and explosive. Keep open flames away from the fuel. Refrain from smoking as well as use of any electrical equipment (such as cell phones). This also applies to places where the characteristic smell of fuel is evident. If diesel fumes are noticed inside the vehicle, have the cause traced and rectified immediately by an authorized Sprinter Dealer.
Capacity Fuel tank including reserve fuel about 26.4 US gal (100 l).
PROGRAMMED TOP SPEED (OPTIONAL) NOTE: The top speed of this vehicle can be electronically limited to a speed between 19 mph (30 km/h) and 82 mph (132 km/h). The vehicle’s electronic speed controller should be programmed only by a qualified technician by an authorized Sprinter Dealer. When programming the electronic speed controller, the circumference of the specific tires actually mounted on that circumference must be correctly programmed into the vehicle’s electronic speed controller. It is critical that tire circumference be programmed the correct accurately speed controller. Accurate tire circumference information should be confirmed each time the electronic speed controller is programmed and each time new wheels or tires are mounted on the vehicle.
the vehicle must be determined and
the vehicle’s electronic
into
WARNING!
Possible tire damage resulting in serious personal injury or death may occur if the vehicle’s electron- ic speed controller is programmed at a speed above the maximum speed allowed by the manu- facturer of the specific tires mounted on the vehi- cle. The maximum speed of the tires prescribed by the tire manufacturer must be determined and ac- curately programmed into the electronic speed controller. The electronic speed controller must never be programmed at a speed greater than the maximum allowable tire speed as prescribed by the manufacturer of the specific tires mounted on the vehicle.
STARTING AND OPERATING 183
BLEEDING DIESEL FUEL SYSTEM If the fuel tank was run empty, the diesel fuel system must be bled after refueling before starting the engine. – Turn the key in the ignition lock to position 2 for at least 30 seconds. – Return the key to position 0. – Start the engine three to four times. The malfunction indicator light (MIL) ± must go out. NOTE: Too many attempts to start the engine could drain the battery. If the engine does not start after several attempts, consult an authorized Sprinter Dealer.
184 STARTING AND OPERATING
DRAINING FUEL FILTER WITH WATER SEPARATOR 1. Fuel filter 2. Drain hose 3. Water drain screw The fuel filter (1) is located in the engine compartment. NOTE: The fuel filter must be drained as soon as the water in fuel indicator lamp
lights up.
CAUTION!
Delaying draining of the fuel filter for a considerable time after the indicator lamp lights up may lead to engine damage.
NOTE: Prior to opening water drain screw (3), place a suitable receptacle underneath the drain hose (2). Turn water drain screw (3) on and off only by hand. Diesel fuels and diesel fuel mixtures must be disposed of properly; we recommend water be drained from fuel filters by an authorized Sprinter Dealer. Draining Fuel Filter (cid:127) Stop the engine. (cid:127) Shift gear selector lever to ‘‘P’’ position. (cid:127) Open the hood. (cid:127) Place a suitable receptacle underneath the drain
hose (2).
(cid:127) Turn the key in the ignition lock to position 2.
(cid:127) Open immediately the water drain screw (3) about 1
turn (counterclockwise) until fluid emerges. Ensure that the fluid is collected in the receptacle.(cid:127) Close the water drain screw (3) as soon as about 0.25
US qt (0.2 liters) are emerged.
Bleeding the Diesel Fuel System The diesel fuel system must be bled before starting the engine. (cid:127) Turn the key in the ignition lock position 2 for at
least 30 seconds.
STARTING AND OPERATING 185
(cid:127) After draining, return the key in the ignition lock to
position 0.
(cid:127) Dispose of the collected fluid in an environmentally
responsible manner.
(cid:127) If the filter is still saturated, drain the filter once
more.
After draining, the engine may run briefly but stall for lack of fuel. If this occurs, bleed the system. NOTE: Should the water in the fuel indicator lamp still not go out after the fuel filter has been drained twice, the cause should be examined by an authorized Sprinter Dealer.
(cid:127) Return the key to position 0. (cid:127) Start the engine three to four times. The engine
control unit indicator lamp ± must go out.
NOTE: Too many attempts to start the engine could drain the battery. If the engine does not start after several attempts, consult an authorized Sprinter Dealer.
186 STARTING AND OPERATING
PERMISSIBLE ROOF LOAD The maximum permissible roof load is: (cid:127) Vehicles with low roof 660 lbs (300 kg) (cid:127) Vehicles with high roof 330 lbs (150 kg) (cid:127) The weight of any load carried on the roof, including the roof rack, must not exceed the maximum permissible roof load.
TRAILER TOWING
WARNING!
towing or failure
Failure to use proper equipment and driving tech- nique can result in a loss of vehicle control when towing a trailer. Improper the instructions contained in this guide can result in serious injury. Follow the guidelines below carefully to assure safe trailer operation. Ask your authorized Sprinter Dealer, if you require an explanation of information contained in this guide.
to follow
Trailer Hitches (Optional) Only install a trailer hitch receiver approved for your vehicle. For information on availability and installation, please see your authorized Sprinter Dealer. The bumpers on your vehicle are not designed for use with clamp-type hitches. Do not attach rental hitches or other bumper-type hitches to them. To reduce the possibility of damage, remove the hitch ball adaptor from the receiver when not in use. Electrical Connections (Optional) The Sprinter is available with a variety of pre-installed conditions (lines and turn signal indicator and brake module installed and/or not installed). Make sure that the correct trailer hitch receiver kit is used. For further information, please see your authorized Sprinter Dealer. In order to prevent possible damage to the vehicle’s electrical system by incorrectly installing the trailer wiring plug, we recommend having the harness connected at an authorized Sprinter Dealer.
Vehicle and Trailer Weights and Ratings Gross Vehicle Weight Rating (GVWR) is the maximum permissible vehicle weight: 8,550 lbs (3,878 kgs), 9,990 lbs (4,531 kgs) or 10,200 lbs (4,627 kgs). NOTE: The weight of your Sprinter is indicated on the type plate. For type plate, see Identification Labels. Gross Vehicle Weight (GVW): comprises weight of vehicle including fuel, tools, spare wheel, installed accessories, passengers, cargo and trailer tongue. It must never exceed the GVWR. Gross Axle Weight Rating (GAWR) is the maximum permissible axle weight:
Type
GVWR
GAWR (FA) GAWR (RA)
2500
C/HC/
SHC
3500
C/HC/
SHC
8,550 lbs 3,878 kgs
3,860 lbs (1,751 kgs)
5,360 lbs (2,431 kgs)
9,990 lbs 4,531 kgs
3,860 lbs (1,751 kgs)
7,060 lbs (3,202 kgs)
10,200 lbs 4,627 kgs
3,860 lbs (1,751 kgs)
7,060 lbs (3,202 kgs)
STARTING AND OPERATING 187
be
is to
the maximum towed:
(GTW) trailer weight
Gross Trailer Weight permissible 5,000 lbs. (2,260 kgs) Trailer Tongue Weight Rating (TWR) is the maximum permissible weight of the trailer tongue: 500 lbs. (225 kgs) limit for Sprinter approved hitch receiver. Loading a Trailer When loading a trailer, you should observe that neither the permissible GTW, nor the GVWR are exceeded. Maximum permissible values are listed on the safety compliance certification labels for the vehicle and for the trailer to be towed. The lowest value listed must be selected when determining how the vehicle and trailer are loaded. We recommend loading the trailer in such a manner that it has a tongue weight (TW) between 10% and 15% of the GTW. The tongue weight at the hitch ball must be added to the GVW to prevent exceeding your Sprinter tow vehicle’s rear GAWR.
188 STARTING AND OPERATING
Checking Weights of Vehicle and Trailer To assure that the tow vehicle and trailer are in compliance with the maximum permissible weight limits, and to know the actual weights, have the loaded vehicle-trailer combination (tow vehicle including driver, passengers and cargo, trailer fully loaded) weighed on a commercial scale. Check the vehicle’s front and rear Gross Axle Weight (GAW), the GTW and TW. The values as measured must not be exceeded, according to the weight listed under “Vehicle and trailer weight and ratings”. Attaching a Trailer Please observe maximum permitted trailer dimensions (width and length). Most states and all Canadian provinces require safety chains between your tow vehicle and the trailer. The chains should be crisscrossed under the trailer tongue. They must be attached to the hitch receiver, and not to the vehicle’s bumper or axle. Be sure to leave enough slack in the chains to permit turning corners. Most states and all Canadian provinces require a separate brake system at various trailer weights.
WARNING!
Do not connect a trailer brake system (if trailer is so equipped) directly to the vehicle’s hydraulic brake system as your vehicle is equipped with an- tilock brakes. If you do, neither the vehicle’s brakes nor the trailer’s brakes will function prop- erly. This could cause an accident resulting in property damage, injury or death to you or others. The provided vehicle electrical wiring harness for trailer towing has a brake signal wire for hook-up to a brake controller. Most states and all Canadian provinces require a break-away switch on trailers with a separate brake system. The switch activates the trailer brakes in the possible event that the trailer might separate from the tow vehicle. You should consider using a trailer sway control system. For information see your authorized Sprinter Dealer.
further
STARTING AND OPERATING 189
Take into consideration that when towing a trailer, the handling characteristics are different and less stable from those when operating the vehicle without a trailer. It is important to avoid sudden maneuvers. The vehicle and trailer combination is heavier, and therefore is limited in acceleration and climbing ability, and requires longer stopping distances. It is more prone to reacting to side wind gusts, and requires more sensitive steering input. In order to gain skill and an understanding of the vehicle’s behavior, you should practice turning, stopping and backing up in an area which is free from traffic. If possible, do not brake abruptly, but rather engage the brake slightly at first to permit the trailer to activate its brake. Then increase the braking force.
Towing a Trailer There are many different laws, including speed limit restrictions, having to do with trailer towing. Make sure that your vehicle-trailer combination will be legal, not only for where you reside, but also for where you will be driving. A good source for this information can be the police or local authorities. Before you start driving with the trailer, check the trailer hitch, break-away switch, safety chains, electrical connections, lighting and tires. Also adjust the mirrors to permit unobstructed view beyond rear of trailer. If the trailer has electric brakes, start your vehicle and trailer moving slowly, and then apply only the trailer brake controller by hand to be sure the brakes are working properly. When towing a trailer, check occasionally to be sure that the load is secure, and that lighting and trailer brakes (if so equipped) are functioning properly. Always secure items in the trailer to prevent load shifts while driving.
190 STARTING AND OPERATING
WARNING!
Take into consideration that when towing a trail- er, the handling characteristics are different and less stable from those when operating the vehicle without a trailer. It is important to avoid sudden maneuvers. Sudden maneuvers may lead to loss of control over the vehicle-trailer combination. This could cause an accident resulting in property damage or injury to you or others.
CAUTION!
If the transmission hunts between gears on inclines, manually shift to a lower gear (select "4", "3", "2" or "1"). A lower gear and reduction of speed reduces the chance of engine overloading and/or overheating. When going down a long hill, shift into a lower gear and use the engine’s braking effect. Avoid riding the brakes, thus overheating the vehicle and trailer brakes. If the engine coolant rises to an extremely high needle temperature approaching the air conditioner is on, turn off the air conditioner. Engine coolant heat can be additionally vented by opening the windows, switching the climate control fan speed to high and setting the temperature control to the maximum hot position.
temperature red zone) when
(coolant the
CAUTION!
Extreme care must be exercised since your vehicle with a trailer will require additional passing distance ahead than when driving without a trailer. Because your vehicle and trailer is longer than your vehicle alone, you will also need to go much farther ahead of the passed vehicle before you can return to your lane.
STARTING AND OPERATING 191
Parking a Trailer
WARNING!
To reduce the risk of personal injury, or damage to the vehicle powertrain, as a result of vehicle/trail- er movement, always: Keep right foot on brake pedal. Shift gear selector lever to position "N". Have a second person place wheel chocks on downhill side of left and right trailer wheels. Slowly release brake pedal and let vehicle and trailer roll into chocks until stopped. Firmly depress parking brake pedal. Move gear selector lever to position "P". On inclines turn front wheels towards the road curb.
FORDING (WADING CAPABILITY) Avoid fording flooded roads or passing through water unless you are certain as to how deep it is. Driving through deep water can cause damage to the vehicle, including but not limited to the electrical components, engine, transmission, etc. This type of damage is not covered under the Warranty.
192 STARTING AND OPERATING
EMISSIONS CONTROL SYSTEM (CATALYTIC CONVERTER)
WARNING!
When driving or parking the vehicle, make sure that its exhaust system does not come into contact with flammable material (such as dry leaves) as these materials may otherwise catch fire.
INHALATION OF EXHAUST GAS WARNING!
Inhalation of exhaust gas is hazardous to your health. All exhaust gas contains carbon monoxide and inhaling it can cause unconsciousness and lead to death. Do not run the engine in confined areas (such as a garage) which are not properly ventilated. If you think that exhaust gas fumes are entering the vehicle while driving, have the cause determined and corrected immediately. If you must drive under these conditions, drive only with at least one window fully open.
BODY BUILDER GUIDELINE If you intend on making any alterations to the vehicle, we strongly recommend that you select one of the following options in order to obtain all necessary information: 1. Contact the authorized Sprinter Dealer nearest you to obtain a copy of the Sprinter Body Builder Guideline.
2. Call DaimlerChrysler Vans LLC at telephone (800) 992-1997 to request a copy of the Sprinter Body Builder Guideline (there may be a charge).
3. Write to the following address and order the Sprinter Body Builder Guideline (there may be a charge). DaimlerChrysler Vans LLC P.O. Box 21-8004
Auburn Hills, MI 48321-8004
United States of AmericaSTARTING AND OPERATING 193
WARNING!
Any modifications or alterations of the Sprinter vehicle not in compliance with the Sprinter Body Builder Guideline and the Sprinter Operator’s Manual may seriously inhibit its roadworthiness and safety and may lead to an accident resulting in serious personal injury or death. Consult the Sprinter Body Builder Guideline and the Sprinter Operator’s Manual prior to initiating any alter- ations or modifications.
Body Builders and Dealers who makes any modifications which may affect the final certification of the engine, vehicle or equipment assume the sole responsibility for the vehicle, including labeling and documentation, affected by their modifications. It is their responsibility to certify that the altered vehicle conforms to all applicable standards and regulations affected by the vehicle alteration or continues to comply with the Motor Vehicle Safety standards and Emissions regulations.
194 STARTING AND OPERATING
They are responsible for ensuring that modifications or equipment installation does not affect the safety of the vehicle. A Special Note Concerning Vehicle Alteration
WARNING!
Any modifications or alterations of the Sprinter vehicle not in compliance with the Sprinter Body Builder Guideline and the Sprinter Operator’s Manual may seriously inhibit its roadworthiness and safety and may lead to an accident resulting in serious personal injury or death. Consult the Sprinter Body Builder Guideline and the Sprinter Operator’s Manual prior to initiating any alter- ations or modifications.
The Manufacturer is not responsible for any final certification or claims sounding in product liability, or warranty claims, which result from any component, assembly, or system being altered, or which cause non- compliance with any of the emission control standards or motor vehicle safety standards, or which would otherwise cause the vehicle to be or become defective or unsafe. The Manufacturer does not assume the responsibility as the final stage manufacturer or the consequential product liability.
WHAT TO DO IN EMERGENCIES
CONTENTS
3 Hazard Warning Flasher Switch . . . . . . . . . . . . . 196
3 Fire Extinguisher (Optional) . . . . . . . . . . . . . . . . . 197
3 Vehicle Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3 Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . 198
U Spare Wheel Location . . . . . . . . . . . . . . . . . . . . 200
3 Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
U Using the Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . 2033 Removing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 206
3 Installing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3 Jump Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3 Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 211
U If the Engine is Damaged . . . . . . . . . . . . . . . . . 212
U If the Transmission is Damaged . . . . . . . . . . . . 212
U If the Front Axle is Damaged . . . . . . . . . . . . . . 212
U If the Rear Axle is Damaged . . . . . . . . . . . . . . . 212196 WHAT TO DO IN EMERGENCIES
HAZARD WARNING FLASHER SWITCH
The switch is located on top of the steering column housing. When the hazard warning flasher switch is switched on, the indicator lamp in the switch and the turn signal indicator lamp in the instrument cluster both flash.
WARNING!
If the rear cargo doors are opened to 90° (detent position), the rear lights will be concealed. The vehicle is then not sufficiently safeguarded at the rear and may only be seen by other road users when they are close to the vehicle. This could lead to an accident. The vehicle must then be clearly marked in accordance with state and local laws, e.g., with a warning triangle.
FIRE EXTINGUISHER (OPTIONAL)
WHAT TO DO IN EMERGENCIES 197
NOTE: Read the manufacturer’s instructions on the fire extinguisher carefully and make yourself familiar with the operation of the fire extinguisher.
VEHICLE TOOL KIT
1. Fire extinguisher 2. Locking mechanism The fire extinguisher is located in the driver’s side entrance area. Pull locking mechanism (2) on the side marked with an arrow to release the tether. Take the fire extinguisher (1) from the holder with an upward movement.
1. Locked 2. Unlocked The vehicle tool kit and the jack are located under the hatch in the front passenger footwell.
198 WHAT TO DO IN EMERGENCIES
CHANGING THE TIRE If you get a flat tire while driving, gradually decrease your speed. Hold the steering wheel firmly and slowly move to a safe place on the side of the road. The pressure of the spare wheel always has to be checked regularly (at least after every tenth time at the filling station).
WARNING!
Only certain tires meeting the tire size/load/speed rating specifications contained in the Tire Pres- sure Tables are certified to conform to FMVSS 120
for the Sprinter vehicle at this time. Please check your side walls of your originally equipped tires for specific makes/sizes, and speed load ratings when you need to replace your tires. To prevent accident, injury or possible death, use only the correct tires for your tire replacement.WARNING!
The jack is designed exclusively for jacking up the vehicle at the jack take-up brackets built into ei- ther side of the vehicle. To help avoid personal in- jury, use the jack only to lift the vehicle during a wheel change. Never get beneath the vehicle while it is supported by the jack only. Keep hands and feet away from the area under the lifted vehicle. Always firmly set parking brake and block wheels before raising vehicle with jack. Do not disengage parking brake while the vehicle is raised. Always use the jack on a level surface. Do not change wheels on either steep uphill or downhill grades. Be sure that the jack arm end is fully seated in the jack take-up bracket. The vehicle may begin to move and fall from the jack which could cause serious or fatal personal injury and property damage. Always lower the vehicle onto sufficient capacity jack stands before working under the vehicle.
Do not jack the vehicle up more than 1.2 in (30
mm) between the tire and the surface. Otherwise, the vehicle may tip over and may cause serious injury or death to you or others. Precautions when changing a wheel: For the torque, refer to "Installing a wheel"; Do not damage, grease or oil wheel bolts or their threads.Procedure: 1. Park the vehicle on a firm, level, non-slippery
surface.
2. Switch on the hazard warning flasher switch, apply the parking brake, and place the transmission selector in "P".
3. Everyone must leave the vehicle before you jack it
up.
4. Everyone must leave the danger zone, before
jacking the vehicle.
WHAT TO DO IN EMERGENCIES 199
5. The vehicle must be safeguarded in accordance with legal regulations (such as using a warning triangle).
6. Prevent vehicle from rolling away by blocking wheels with wheel chocks (not supplied with vehicle) or sizable wood block or stone. On a level road, place one chock in front of and one behind the wheel that is diagonally opposite to the wheel being changed. When changing a wheel on mild uphill or downhill grades, place chocks on the downhill side blocking both wheels of the other axle.
WARNING!
Do not change wheels on either steep uphill or downhill grades. The vehicle may begin to move and fall from the jack which could cause personal injury and property damage.
200 WHAT TO DO IN EMERGENCIES
Spare Wheel Location
WARNING!
If the rear cargo doors are opened to 90° (detent position), the rear lights will be concealed. The ve- hicle is then not sufficiently safeguarded at the rear and may only be seen by other road users when they are close to the vehicle. This could lead to an accident. The vehicle must then be clearly marked in accordance with state and local laws, e.g., with a warning triangle.
WARNING!
The spare wheel holder should be reattached once the wheel has been changed. Regularly check the spare wheel fastening. A loose spare wheel or spare wheel holder could be loosen or could move around the vehicle interior uncontrollably in the event of sudden braking, a rapid change in direction or an accident. This increases the risk of injury to vehicle occupants and other road users in these situations. Do not use retreaded/remolded tires. This process does not always permit previous damage to be detected. Therefore vehicle safety cannot be guaranteed if retreaded/remolded tires are fitted.
NOTE: Lug wrench and jack, refer to "Vehicle Tool Kit". For reasons of safety, check at regular intervals that the spare wheel is properly secured.
Spare Wheel Beneath the End of the Frame
Spare Wheel in Cargo Area (Optional)
WHAT TO DO IN EMERGENCIES 201
1. Open the rear cargo doors.
Retaining screws for the spare wheel structural member (1) Hook (2) 1. Open the cargo doors and remove the retaining screws (1) with the lug wrench from the vehicle tool kit.
2. Lift the spare wheel structural member, unhinge the hooks (2), and lower the spare wheel structural member. Remove the spare wheel.
202 WHAT TO DO IN EMERGENCIES
Spare Wheel Location for Chassis
2. Turn spare wheel holder to loosen. 3. Remove the spare wheel.
1. Loosen thumb nuts by hand and remove. 2. Use wrench to loosen fixing nut to the thread end. 3. Lift spare wheel holder. 4. Turn hooks to the side and lower spare wheel
holder. Remove the spare wheel.
WHAT TO DO IN EMERGENCIES 203
Using the Jack The jack is located together with the vehicle tool kit under the hatch in the front passenger footwell, refer to "Vehicle Tool Kit". 1. Loosen the wheel bolts before raising the vehicle. 2. Close the release valve on the jack. 3. Assemble the pump lever provided and insert it
into the socket on the jack.
4. Secure the lever by turning it clockwise in the
socket.
Position the jack under the appropriate jack point and raise the vehicle by pumping the lever.
JACK
WARNING!
To avoid the risk of serious or fatal injuries or vehicle damage, please bear the following points in mind: (cid:127) The jack is intended only for raising the vehicle briefly, for instance, when changing a wheel. If it is not designed to enable work to be carried out underneath the vehicle.
Do not crawl under the jacked-up vehicle. For work under the vehicle, stands must be used. (cid:127) The jack must be placed on a firm, flat surface only. (cid:127) Do not change wheels on uphill or downhill
gradients under any circumstances.
(cid:127) Make sure that no persons are present in the vehicle
when jacking up the vehicle.
(cid:127) Do not start the engine while the vehicle is raised. (cid:127) Make sure that the distance between the underside of the tires and the ground does not exceed 1.2 in (30
mm). Otherwise the vehicle may tip over.204 WHAT TO DO IN EMERGENCIES
Front Axle Jack Point (All Vehicles)
Rear Axle Jack Point for 8,550 lbs (3,880 kgs) (Vehicle type 2500 HC/SHC)
The vehicle longitudinal member in front of the front axle.
jacking point is located under the
The vehicle longitudinal member in front of the rear axle.
jacking point is located under the
CAUTION!
Do not position the jack at the leaf spring or the differential housing.
Rear Axle Jack Point for 9,990 lbs (4,530 kgs) (Vehicle type 3500 HC/SHC)
Rear Axle Jack Point for Chassis (Vehicle type 2500 C and 3500 C)
WHAT TO DO IN EMERGENCIES 205
The vehicle longitudinal member in front of the rear axle.
jacking point is located under the
The vehicle jacking point is locked next to the front recess for the leaf spring.
CAUTION!
CAUTION!
Do not position the jack at the leaf spring or the differential housing.
Do not position the jack at the leaf spring or the differential housing.
INSTALLING A WHEEL
206 WHAT TO DO IN EMERGENCIES
REMOVING A WHEEL 1. Loosen the wheel bolts. 2.
Jack up the vehicle until the wheel is clear of the ground.
3. Unscrew the wheel bolts and remove the wheel
(keep the wheel bolts clean).
NOTE: If the vehicle moves forwards or backwards while it is being jacked-up, lower it again and reposition the jack. When the vehicle is jacked-up, the jack must stand vertically (plumb-line).
Wheel bolts for pressed steel wheels (1) Wheel bolts for light-alloy wheels (Optional) (2)
WARNING!
WARNING!
WHAT TO DO IN EMERGENCIES 207
Incorrect mounting bolts or improperly tightened mounting bolts can cause the wheel to come off. To avoid the risk of serious or fatal injuries or ve- hicle damage, please bear the following points in mind: • Always replace wheel bolts that are damaged or rusted. • Never apply oil or grease to wheel bolts • If a wheel hub thread is damaged, you must not drive the vehicle. Consult a qualified specialist workshop.
Different wheel bolts are required for pressed steel and light-alloy wheels. Incorrect wheel lug bolts for the wheels could work loose, thereby causing you to lose control of the vehicle. This could cause an accident resulting in severe personal injuries and and property damage.
NOTE: The optional light alloy wheels are supplied with 5 short wheel lug bolts enclosed for the steel spare wheel in the vehicle tool kit. (cid:127) Before fitting the spare wheel, clean rust and dirt off the contact surfaces of the wheel and the wheel hub, and from the wheel bolts.
(cid:127) Note the specified wheel and tire size, tire load
capacity and speed code.
(cid:127) Do not change the tire’s direction of rotation. (cid:127) Do not damage, grease or oil wheel bolts or their
threads.
208 WHAT TO DO IN EMERGENCIES
Centering wheels with wheel bolts (cid:127) If dual assemblies are used, before placement the inner wheel should be inspected to ensure that all ball bearing rings are in proper position.
(cid:127) Install the wheel and snug the wheel bolts. (cid:127) Slightly tighten wheel bolts. (cid:127) Slowly open jack release valve to lower vehicle until
tire is resting on ground.
WARNING!
Do not tighten the wheel bolts and wheel nuts completely while the vehicle is still jacked up. The vehicle could tip.
(cid:127) Tighten the wheel bolts in a crosswise pattern to the
specified torque with a torque wrench. Tightening torque for 8,550 lbs (3,880 kgs) (vehicle type 2500 C/HC/SHC): Steel wheel – 177 lbf.ft ±7 lbf.ft (240 N.m ±10 N.m) Light alloy wheel – 138 lbf.ft ±14 lbf.ft (190 N.m ±20 N.m)
Tightening torque for 9,990 lbs (4,530 kgs) (vehicle type 3500 C/HC/SHC): Steel wheel – 138 lbf.ft ±14 lbf.ft (190 N.m ±20 N.m)
(cid:127) Remove jack and stow it in the vehicle tool kit. (cid:127) Check the tire pressure. (cid:127) Re-tighten the wheel bolts to the specified torque with a torque wrench after a distance of 30 miles (about 50 km).
WARNING!
After changing a wheel, you must, for safety reasons, (cid:127) have the specified tightening torque checked. The
wheels could otherwise work loose.
(cid:127) check the tire pressure and correct it if necessary. (cid:127) retighten the wheel bolts and wheel nuts to the specified tightening torque once the vehicle has been driven for 30 miles (50 km).
(cid:127) have a reversed direction of tire rotation corrected as soon as possible at a qualified specialist workshop. The vehicle handling characteristics could otherwise be affected.
WHAT TO DO IN EMERGENCIES 209
WARNING!
Battery fluid contains sulfuric acid. Do not allow this fluid to come in contact with eyes, skin or clothing. In case it does, immediately flush affect- ed area with water, and seek medical help. The battery housing could be damaged. Never lean over batteries while connecting or jump- starting. You might get injured. Read all instructions before proceeding.
JUMP STARTING If the battery is dead, the engine can be started with jumper cables from another vehicle’s battery.
WARNING!
A battery will produce hydrogen gas, which is flammable and very explosive. Avoid open flames and the formation of sparks in the vicinity of the batteries. Refrain from smoking or cell phone use. Avoid improper connection of jumper cables. Observe safety precautions when handling batteries. Exercise care near moving engine components and electrical cables. Failure to follow these directions will cause damage to the electronic components and can lead to a battery explosion and severe injury or death.
210 WHAT TO DO IN EMERGENCIES
(cid:127) A dead battery can freeze at a temperature of 14 °F (–10 °C). Never try to start the engine if the battery is frozen. Thaw the battery out first.
(cid:127) Only use a battery of the same rated voltage and of approximately the same capacity for jump-starting.
(cid:127) The two vehicles must not touch. (cid:127) Switch off all electrical accessories. (cid:127) Run the vehicle with the booster battery at idle. (cid:127) Connect the jumper cables in the sequence given in
the illustration.
1. First connect the positive terminals of the two batteries (see illustration, Items 1 + 2). Start with the booster battery.
2. Then connect the negative terminal of the vehicle with the booster battery to a vehicle ground point of the vehicle with the discharged battery, such as to the engine block (see illustration, Items 3 + 4). Start with the booster battery.
3. Start the engine in the customary manner. 4. Allow the engine to run for a short time. 5. Before disconnecting the jumper cables from the vehicle with the booster battery, switch on an electrical consumer (e.g. the blower, but not the lamps).
6. Disconnect the jumper cables in the reverse order to
that in which they were connected.
7. Disconnect
the
jumper cable
from negative terminal and vehicle ground point first (see illustration, items 3 + 4), then from positive terminals of the batteries (see illustration 1 + 2).
NOTE: Never try to start the engine with the aid of a battery quick-charge unit.
TOWING THE VEHICLE
WHAT TO DO IN EMERGENCIES 211
WARNING!
Do not tow the vehicle if the key cannot be turned in the ignition lock. If the key cannot be turned, the ignition lock re- mains locked and the vehicle cannot be steered. With the engine not running there is no power assistance for the braking and steering systems. In this case, it is important to keep in mind that a considerably higher degree of effort is necessary to brake and steer the vehicle. The vehicle must not be towed with the front axle raised and the key in position 2 in the ignition lock as the drive wheels could then lock due to the acceleration skid control (ASR) or the optional Electronic Stability Program (ESP)*.
*Vehicle Type 2500 only
212 WHAT TO DO IN EMERGENCIES
If the Engine is Damaged For towing distances up to 30 miles (about 50 km) (cid:127) Shift gear selector lever to "N" position. (cid:127) Do not exceed a towing speed of 30 mph (50 km/h). For towing distances greater than 30 miles (about 50 km) (cid:127) Remove the propeller shafts leading to the drive
axles. The vehicle can be towed without restriction.
If the Transmission is Damaged (cid:127) Remove the propeller shafts leading to the drive
axles.
If the Front Axle is Damaged (cid:127) Raise the front axle. (cid:127) Observe the same towing restrictions as for engine
damage.
If the Rear Axle is Damaged (cid:127) Raise the rear axle. NOTE: Comply with local legal regulations regarding towing vehicles.
MAINTAINING YOUR VEHICLE
CONTENTS
3 Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . 215
3 Sprinter Original Parts . . . . . . . . . . . . . . . . . . . . . . 217
3 Service Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
U Disposal of Service Products . . . . . . . . . . . . . . 2183 Emission Related Component Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3 Regular Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
U Windshield Washer System Fluid Reservoir . 219
U Air Filter Restriction Indicator (Optional) . . . 219
U Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
U Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 221
U Ribbed V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
U Hydraulic Brake System, ClutchMechanism Fluid Level . . . . . . . . . . . . . . . . . . . 222
U Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
U Engine Cooling System . . . . . . . . . . . . . . . . . . . 223U Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 223
U Checking Coolant Level . . . . . . . . . . . . . . . . . . 224
3 Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
U Disconnecting the Battery . . . . . . . . . . . . . . . . . 227
U Reconnecting the Battery . . . . . . . . . . . . . . . . . . 228
U Charging the Battery . . . . . . . . . . . . . . . . . . . . . 228
3 Replacing Wiper Blades . . . . . . . . . . . . . . . . . . . . . 230
U Appearance Care and Corrosion Protection . 231
U Power Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
U Automatic Car Wash . . . . . . . . . . . . . . . . . . . . . 233
U Tar Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
U Paintwork, Painted Body Components . . . . . . 233
U Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 233
U Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . 234
U Ornamental Moldings . . . . . . . . . . . . . . . . . . . . 234214 MAINTAINING YOUR VEHICLE
U Headlamps, Taillamps, Identification Lamps,
Turn Signal Lenses . . . . . . . . . . . . . . . . . . . . . . . 234
U Reversing Aid Sensors . . . . . . . . . . . . . . . . . . . . 235
U Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . 235
U Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
U Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . 236
U Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 236
U Steering Wheel and Gear Selector Lever . . . . 236
U Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
U Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
U Headliner and Shelf Below Rear Window . . . 237
U Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
U Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . 237
U Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . 238
3 Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
U Standard Fuse and Relay Equipment . . . . . . . 239
U Relay Assignment, Standard Equipment . . . . 242
U Fuse and Relay Optional Equipment . . . . . . . 2423 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 245
U Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . 245
U Taillamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
U License Plate Lamps(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252
U Additional Brake Lamp
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252
U Side-Mounted Turn Signals . . . . . . . . . . . . . . . 253
U Side-Marker Lamps,Standing Lamps (Optional) . . . . . . . . . . . . . . . . 253
U Identification Lamps (Cargo/
passenger vans only) . . . . . . . . . . . . . . . . . . . . . 254
U Interior Lighting in Passenger Compartment
and Load Compartment . . . . . . . . . . . . . . . . . . 254
U Interior Lighting with Reading Lamp . . . . . . . 255
U Interior Lighting with Interior SensorProtection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
U Exit Lamps (Optional) . . . . . . . . . . . . . . . . . . . . 256
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
U Recommended Fluids and Lubricants . . . . . . 258ENGINE COMPARTMENT
MAINTAINING YOUR VEHICLE 215
216 MAINTAINING YOUR VEHICLE
Legend For Engine Compartment 1. Windshield washer system fluid reservoir. 2. Maintenance indicator for air cleaner element
(Optional). 3. Oil dipstick. 4. Oil filler neck. 5. Ribbed V-belt.
Auxiliary drive (Optional) refer to “Auxiliary drive“.
6. Fuel filter with water separator. 7. Hydraulic brake fluid reservoir. 8. Coolant reservoir. 9. Battery
The auxiliary battery is located underneath the front passenger seat (optional equipment).
10. Fuse box
(These special fuses should only be replaced at by an authorized Sprinter Dealer).
SPRINTER ORIGINAL PARTS Every authorized Sprinter Dealer maintains a stock of Sprinter original parts for maintenance and repair work. Over 6,000 retailers around the world guarantee that you can be supplied with Sprinter original parts wherever you are. Over 300,000 different parts and assemblies, including parts for older vehicle models, are distributed from a central parts warehouse using an optimally tuned logistics concept. Sprinter original parts are subjected to the most stringent quality inspections and will ensure that the vehicle is maintained at a high level of operating efficiency and safety, and that it maintains its value. Each part has been specifically designed and manufactured or selected and approved for use in Sprinter vehicles. It is therefore best to use only Sprinter original parts. For cost-effective repairs in accordance with sound recycling principles, the use of non-genuine parts and accessories not authorized by the manufacturer could damage the vehicle or compromise its durability or safety. When ordering original parts, always provide the vehicle identification number and the engine number.
MAINTAINING YOUR VEHICLE 217
SERVICE PRODUCTS Mechanical elements and the lubricants used for them must be carefully matched. For this reason, only brands tested and approved by the manufacturer should be used. Please contact your Sprinter Dealer to obtain the necessary information. No lubricant additives should be used. The use of such additives could affect your warranty rights. Information is available from any authorized Sprinter Dealer. For specifications of engine oils, coolant and brake fluid, contact your authorized Sprinter Dealer.
WARNING!
If handled incorrectly, service products can consti- tute a health risk for people and an environmental hazard. Always observe relevant guidelines for handling, storing and disposing of service products.
218 MAINTAINING YOUR VEHICLE
Disposal of Service Products Dispose of service products and of parts which come into in an environmentally responsible manner. Comply with applicable bars and regulations.
contact with
filters)
them
(e.g.
EMISSION RELATED COMPONENT WARRANTY STATEMENT The Manufacturer warrants to the original and each subsequent owner of a Sprinter heavy-duty on highway diesel engine that: (1) the engine was designed, built and equipped so as to conform at the time of sale with the applicable regulations adopted by the Federal Environmental Protection Agency, and (2) the emission control system of such engine is free from defects in materials and workmanship which would cause it not to conform with those regulations for a period of use of five years or 100 000 miles or 3 000 hours of engine operation, whichever occurs first.
REGULAR CHECKS The following checks should be performed at regular intervals (for example once a week or each time the vehicle is refueled): (cid:127) Windshield cleaner system – fluid reservoir. (cid:127) Air strainer, in vehicles with an air strainer element
maintenance indicator (optional equipment).
(cid:127) Engine oil level. (cid:127) Checking ribbed V-belt. (cid:127) Hydraulic brake system, clutch mechanism fluid
level.
(cid:127) Coolant level. (cid:127) Tire and spare wheel condition and pressures of the same. For more information, refer to "Wheels and Tires".
(cid:127) Vehicle lighting.
Windshield Washer System Fluid Reservoir
Air Filter Restriction Indicator (Optional)
MAINTAINING YOUR VEHICLE 219
1. Washer system fluid reservoir When topping off, add windshield washer fluid ("S" for summer or "W" for winter) to the water. Capacity of fluid reservoir (1): about 7.4 US qt (7 liters).
The indicator on the air filter housing in the engine compartment shows the degree of contamination in the air filter element. If the red field reaches the 100 % range, the air filter element should be replaced as soon as possible.
220 MAINTAINING YOUR VEHICLE
Approved Engine Oils NOTE: Use only engine oils that are labeled on the container as meeting the specifications of API (American Petroleum Institute) and/or DaimlerChrysler specification sheets MB 228.3, 228.5, 229.3 and 229.5, such as MOPAR® SAE 15W-40 HD Diesel Engine Oil (e.g. MOPAR® Part No. 04798231AD), or equivalent. Always refer to the following viscosity chart for the proper viscosity grade based on ambient temperature. Select oil viscosity according to the lowest air temperature expected before the next oil change. For further information, contact your authorized Sprinter Dealer.
NOTE: This chart supercedes ALL previously published viscosity charts.
Engine Oil Level
1. Oil dipstick 2. Oil filler neck
MAINTAINING YOUR VEHICLE 221
Check the engine oil level at regular intervals with the vehicle standing on a level surface. (cid:127) Check engine oil level about 5 minutes after stopping the engine, which should have reached its regular operating temperature. The normal operating temperature should have been reached and maintained for some time.
(cid:127) Wipe the dipstick clean with a lint-free cloth before
checking.
The engine oil level must be between the lower (MIN) and upper (MAX) marks on the dipstick. Add engine oil only up to the MAX mark. Excess oil must be drained or siphoned off.
222 MAINTAINING YOUR VEHICLE
Ribbed V-Belt
Hydraulic Brake System, Clutch Mechanism Fluid Level
The ribbed V-belt drives the accessories, such as generator, coolant pump and hydraulic steering pump. The ribbed V-belt is automatically kept tensioned. Check the state of the ribbed V-belt regularly, such as at every engine oil level check. The belt must not be damaged, worn, oiled or glazed. There must be no cracks in the belt running surface. Replace damaged belts.
1. Brake fluid reservoir Brake fluid level must be between the MIN and MAX marks in the reservoir (1). If the brake fluid is below the MIN mark, there may be a fault in the hydraulic system. Have the system checked as soon as possible by an authorized Sprinter Dealer.
Brake fluid Refer to the "Recommended Fluids" chart later in this section for recommended brake fluids. In the course of its service life, the boiling point of the brake fluid will fall due to the continuous absorption of moisture from the atmosphere. If the brakes are placed under heavy loads (e.g., on steep hills) bubbles of steam can then form in the brake system. This will adversely affect the brakes' effectiveness. Engine Cooling System The use of aluminum components in Sprinter engines requires that anticorrosive/antifreeze specifically formulated to protect aluminum parts be used. The factory approved Service Products are suitable for Sprinter engines and can be mixed with the original anticorrosion/antifreeze filled in at factory. Cooling system design and anticorrosion/antifreeze agent used stipulate the replacement interval for the coolant solution in your vehicle. Please observe the replacement interval specified in the Service Booklet for your vehicle.
MAINTAINING YOUR VEHICLE 223
Failure to use MB 325.0 anticorrosion/antifreeze and/or equivalent to DaimlerChrysler material standard MS- 9769 and/or adhere to the specified replacement interval may result in a significantly shortened service life. For coolant composition and water quality, contact your authorized Sprinter Dealer. Engine Coolant The coolant is a mixture of water and a corrosion inhibitor/antifreeze additive. Within the cooling system, the corrosion inhibitor/antifreeze ensures (cid:127) anti-corrosion protection (cid:127) antifreeze protection (cid:127) a higher boiling point. The coolant added in the factory ensures adequate antifreeze and anti-corrosion protection. Refer to the "Recommended Fluids" chart for coolant recommendations. For reasons of anti-corrosion protection and to increase the boiling point, the coolant added to the cooling system is designed for all year round operation – even in countries with high prevailing temperatures.
224 MAINTAINING YOUR VEHICLE
Have the coolant renewed at least every 15 years or after 160,000 miles. When the coolant is renewed, the new coolant should contain 50% antifreeze/corrosion inhibitor by volume. This corresponds to antifreeze protection down to - 37 °C/-35°F. Do not exceed a proportion of about 55 % by volume (antifreeze protection down to about -45 °C/-49 °F) as the heat dissipation properties then deteriorate. In the event of coolant loss, do not add water only, but sufficient antifreeze/corrosion inhibitor to maintain the correct concentration. in the coolant must satisfy certain The water requirements. These are often met by tap supply drinking water. The water must be specially prepared if the water quality does not come up to the required standards. Have the corrosion inhibitor/antifreeze concentration in the coolant checked at the outset of winter, respectively once a year in countries with high prevailing temperatures.
A regular check is included in the maintenance service. Checking Coolant Level Coolant reservoir (1)
The cooling system is pressurized. Only check the coolant level with the vehicle parking on a level surface and with the engine switched off. – Wait until the coolant temperature has dropped
below 194 °F (+90 °C).
WARNING!
WARNING!
MAINTAINING YOUR VEHICLE 225
compartment, or
In order to avoid any possibly serious burns: (cid:127) If you see flames or smoke coming from the engine coolant temperature gauge indicates that the engine is overheated, do not open the hood. Move away from the vehicle and do not open the hood until the engine has cooled. If necessary, call the fire department.
the
if
(cid:127) Do not remove pressure cap on coolant reservoir if engine temperature is above 194 °F (+90 ×C). Allow engine to cool down before removing cap. The coolant reservoir contains hot fluid and is under pressure.
(cid:127) Using a rag, slowly open cap approximately 1/2
turn to relieve excess pressure. If opened immediately, scalding hot fluid and steam will be blown out under pressure.(cid:127)Do not spill antifreeze on hot engine parts. Anti- freeze contains ethylene glycol which may burn if it comes into contact with hot engine parts.
(cid:127) Check coolant level only with the engine switched off and the key in position 0 in the ignition lock.
(cid:127) Open the hood. (cid:127) At first, only turn the radiator cap to the first detent to release the pressure from the cooling system. Only then should the radiator cap be removed completely.
(cid:127) To add coolant:
If the engine is cold: Add coolant until the coolant level reaches the base area which is visible through the filler opening (area moistened).
226 MAINTAINING YOUR VEHICLE
If the engine is already at its regular operating temperature: Add coolant until the coolant level is about 0.6 inch (1.5 cm) above the base area which is visible through the filler opening.
(cid:127) Replace and tighten the radiator cap. If a large quantity of coolant has been lost, or if smaller amounts are lost at regular intervals, have the engine cooling system examined by an authorized Sprinter Dealer. For coolant composition and water quality, contact your Sprinter Dealer.
WINTER OPERATION Have your vehicle winterized by an authorized Sprinter Dealer before the onset of winter. (cid:127) Have the engine oil changed, if the engine oil filled
is not approved for winter use.
(cid:127) Coolant: antifreeze/anti-corrosion concentration in
the coolant checked.
(cid:127) Windshield washer system: add winter concentrate
to the washer fluid.
(cid:127) Battery:
the battery will
lose capacity as temperatures drop. Only a well-charged battery will ensure reliable engine starting even at low outside temperatures.
(cid:127) Tires: fit M+S radial tires, taking note of the
maximum permissible speed of the tires fitted.
BATTERIES
WARNING!
Failure to follow these instructions can result in severe personal injuries and death. Never lean over batteries while connecting, you might get injured, if the battery explodes. Battery fluid contains sulfuric acid. Do not allow this fluid to come in contact with eyes, skin or clothing. In case it does, immediately flush affected area with water and seek medical help if necessary. A battery will also produce hydrogen gas, which is flammable and explosive. Keep flames or sparks away from battery, avoid improper connection of jumper cables, smoking etc.
Use only impact-resistant batteries with a central gas release cover to prevent corrosion damage and to prevent occupants from caustic burns in the event of an accident.
The standard battery compartment.
is
located
in the engine
MAINTAINING YOUR VEHICLE 227
The auxiliary battery is located underneath the front passenger seat (optional equipment). The battery will not achieve its maximum service life unless it is kept adequately charged at all times. If the vehicle is used primarily for short distances, or left parked for lengthy periods, have the battery charge checked more frequently. Disconnecting the Battery
CAUTION!
Do not loosen or remove the battery terminal clamps while the engine is running or the key is in the ignition lock as this could damage electrical or electronic equipment beyond repair. All electrical consumers must be switched off. Do not place any metal objects on the battery. Doing so may cause a short-circuit. Loosen and remove the negative terminal clamp first, then the positive terminal. Afterwards disconnect vent tube from the fitting.
228 MAINTAINING YOUR VEHICLE
Reconnecting the Battery
1. Vent tube 2. Fitting All electrical consumers must be switched off. First connect and tighten the positive terminal clamp, then the negative terminal. Make sure that the terminal clamps are not switched. NOTE: If batteries have to be replaced, only use batteries with a central vent cap as this will prevent corrosion damage. Connect the battery vent tube (1) to the fitting (2).
Charging the Battery Disconnect the battery before charging it with a battery charger. Comply with the operating instructions for the battery charger. To ensure that the battery is disposed of in an environmentally responsible manner, it should only be replaced by an authorized Sprinter Dealer. Batteries contain material environment with improper disposal. Large 12 volt storage batteries contain lead. Recycling of batteries is the preferred method of disposal. Many states require sellers of batteries to accept old batteries for recycling.
that can harm
the
WARNING!
(cid:127) Use only refrigerants and compressor lubricants approved by the manufacturer for your air conditioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. Refer to Section 3 of the Warranty Information Book for additional warranty information.
(cid:127) The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.
MAINTAINING YOUR VEHICLE 229
Refrigerant Recovery and Recycling R-134a Air Conditioning Refrigerant hydrofluorocarbon (HFC) that is endorsed by the Environmental Protection Agency and is an ozone- saving product. However, the manufacturer recommends service be performed by dealers or other service facilities using recovery and recycling equipment.
that air conditioning
is
230 MAINTAINING YOUR VEHICLE
REPLACING WIPER BLADES
1. Fold over the wiper arm (2) and place the wiper
blade crosswise.
2. Press the retaining spring (1) and push the wiper
blade out of the end of the wiper arm (2).
3. Remove the wiper blade.
4.
Insert the end of the wiper arm (2) into the larger cutout (3) of the wiper blade.
5. Push the wiper blade into the end of the wiper
arm (2) until the retaining spring (1) engages.
Appearance Care and Corrosion Protection
WARNING!
Many cleaning products can be hazardous. Some are poisonous, others are flammable. Always keep cleaning products sealed and out of the reach of children. Always follow the instructions on the particular container. Always open your ve- hicle’s doors or windows when cleaning the in- side. Never use fluids or solvents that are not designed for cleaning your vehicle. Do not use fuel as a cleaning agent. Fuel is flammable and constitutes a health hazard.
In operation, your vehicle is subjected to varying external influences which, if gone unchecked, can attack the paintwork as well as the underbody and cause lasting damage. Such damage is caused not only by extreme and varying climatic conditions, but also by air pollution, road salt, tar, gravel and stone chipping. Grease and oil, fuel, coolant, brake fluid, bird droppings, insects,
MAINTAINING YOUR VEHICLE 231
tree resins etc. should be removed immediately to avoid paint damage. Frequent washing reduces and/ or eliminates the aggressiveness and potency of the above adverse influences. More frequent washings are necessary to deal with unfavorable conditions; for example operation near the ocean, in industrial areas (smoke, exhaust emissions), or during the winter months. You should check your vehicle from time to time for stone chipping or other damage. Any damage should be repaired as soon as possible to prevent the start of corrosion. In doing so, do not neglect the underside of the vehicle. A prerequisite for a thorough check is a washing of the underbody followed by a inspection. Damaged areas need to be undercoated again. Your vehicle has been treated at the factory with a wax- base rustproofing in the body cavities which will last for the lifetime of the vehicle. Post-production treatment is neither necessary nor recommended by DaimlerChrysler Corporation.
thorough
232 MAINTAINING YOUR VEHICLE
Because of the possibility of incompatibility between materials used in the production process and others applied later.
Power Washer When using a power washer for cleaning the vehicle always observe manufacturers’ operating instructions.
CAUTION!
The intense jet of water of a round nozzle can result in damage to the tire. Therefore never use a round nozzle to power wash tires. Always replace a damaged tire. Always keep the jet of water moving across the surface. To avoid damaging the vehicle, do not aim the water jet directly at electrical components, end of electrical lines, electrical connectors, intake or ventilation openings, brake hoses, door joints, seals, other rubber parts.
WARNING!
Never use openings in the bodywork as steps. You could otherwise damage the vehicle and it could lead to an accident.
CAUTION!
Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.
Scratches, corrosive deposits, corrosion or damage due to negligent or incorrect care cannot always be removed or repaired with car-care products. In such cases it is best to seek aid by your authorized Sprinter Dealer. The following topics deal with the cleaning and care of your vehicle and give important "how-to" information as well as references to car-care products.
Automatic Car Wash If the vehicle is very dirty, prewash it before you drive into the car wash.
WARNING!
Smears impair visibility, which is impaired fur- ther by unfavourable conditions (e.g. fog, dark- ness, driving snow). If a wax preservative is sprayed on after washing the vehicle, wipe off the wax from the windshield and the wiper blade rubbers. This will prevent smears forming on the windshield.
Fold in the exterior mirrors before washing the vehicle in an automatic car wash and make sure that the windshield wiper switch is in position 0. The exterior mirrors and windshield wipers could otherwise be damaged. Make sure that mirrors are fully folded out after leaving the automatic car wash.
MAINTAINING YOUR VEHICLE 233
tar remover
to remove. A
Tar Stains Quickly remove tar stains before they dry and become more difficult is recommended. Paintwork, Painted Body Components Paint care should be applied when water drops on the paint surface do not "bead up", normally every 3 to 5 months, depending on climate and washing detergent used. Paint cleaner should be applied if paint surface shows signs of dirt embedding (i.e. loss of gloss). Do not apply any of these products or wax if your vehicle is parked in the sun or if the hood is still hot. Use the appropriate paint stick for quick and provisional repairs of minor paint damage (i.e., chips from stones, vehicle doors etc.). Engine Cleaning Prior to cleaning the engine compartment, make sure to protect electrical components and connectors from the intrusion of water and cleaning agents.
234 MAINTAINING YOUR VEHICLE
Corrosion protection, such as anticorrosion wax should be applied to the engine compartment after every engine cleaning. Before applying, all control linkage bushings and joints should be lubricated. The poly-V-belt and all pulleys should be protected from any wax. Vehicle Washing Do not use hot water or wash your vehicle in direct sunlight. Use only a mild car wash detergent. Thoroughly spray the vehicle with a diffused jet of water. Direct only a very weak spray towards the ventilation intake. Use plenty of water and rinse the sponge and chamois frequently. Rinse with clear water and thoroughly wipe dry with a chamois. Do not allow cleaning agents to dry on the finish. Due to the width of the vehicle, prior to running the vehicle through an automatic car wash, fold back the outside mirrors from getting damaged. In the winter, thoroughly remove all traces of road salt as soon as possible.
to prevent
them
When washing the underbody, do not forget to clean the inner sides of the wheels.
WARNING!
Dirty or iced-up steps and entrances create a risk of slipping or falling. Keep steps, entrances and footwear free from dirt (e.g. mud, clay, snow and ice).
Ornamental Moldings For regular cleaning and care of very dirty chrome- plated parts, use a chrome cleaner. Headlamps, Taillamps, Identification Lamps, Turn Signal Lenses Use a mild car wash detergent with plenty of water. To prevent scratches, never apply strong force and use only a soft, non-scratchy cloth when cleaning the lenses. Do not attempt to wipe dirty lenses with a dry cloth or sponge.
MAINTAINING YOUR VEHICLE 235
Window Cleaning Use a window cleaning solution on all glass surfaces. An automotive glass cleaner is recommended.
N54.65-2046-20
Reversing Aid Sensors Use a mild car wash detergent with plenty of water. To prevent scratches, never apply strong force and use only a soft, non-scratchy cloth when cleaning the sensors. Do not attempt to wipe dirty sensors with dry, coarse or hard cloths and do not scrub. You will otherwise scratch or damage the sensors. If you clean the sensors using a high-pressure cleaner, only direct it at the sensors for a short period and maintain a minimum distance of 4 in (10 cm) from the sensors.
There are 2 steps in the front bumper. This makes it easier to clean the windshield.
236 MAINTAINING YOUR VEHICLE
WARNING!
For safety reasons, remove key from ignition lock before cleaning the windshield, otherwise the wiper motor can suddenly turn on and cause in- jury. Dirty or iced-up steps create a risk of slipping or falling. Do not use the step in the front bumper when it is icy or dirty.
