2005 Dodge Sprinter Owners Manual

Wiper Blade Clean the wiper blade rubber with a clean cloth and detergent solution.

WARNING!

For safety reasons, remove key from ignition lock before cleaning the wiper blade, otherwise the wiper motor can suddenly turn on and cause se- vere personal injuries and death.

Light Alloy Wheels A wheel care product should be used for regular cleaning of the light alloy wheels. If possible, clean wheels once a week, using a soft bristle brush and a strong spray of water. Follow instructions on container. NOTE: Use only acid-free cleaning materials. The acid could lead to corrosion. Instrument Cluster Use a gentle dishwashing detergent or mild detergent for delicate fabrics as a washing solution. Wipe with a cloth moistened in lukewarm solution. Do not use scouring agents. Steering Wheel and Gear Selector Lever Wipe with a damp cloth and dry thoroughly or clean with a leather care product.

Cup Holder Use a gentle dishwashing detergent or mild detergent for delicate fabrics as a washing solution. Wipe with a cloth moistened in lukewarm solution. Do not use scouring agents. Seat Belts The webbing must not be treated with chemical cleaning agents. Use only clear, lukewarm water and soap. Do not dry the webbing at temperatures above 176 °F (+80 °C) or in direct sunlight.

WARNING!

Do not bleach or dye seat belts as this may severe- ly weaken them. Due to this treatment they may not be able to provide adequate protection. For ex- ample, in a crash the belts can be torn.

Headliner and Shelf Below Rear Window Clean with soft bristle brush, or use a dry-shampoo cleaner in case of excessive dirt.

MAINTAINING YOUR VEHICLE 237

lining

Upholstery Using aftermarket seat covers or wearing clothing that have the tendency to give off coloring (e.g. when wet etc.) may cause the upholstery to become permanently discolored. By the seats with a proper intermediate cover, contact discoloration will be prevented. Leather Upholstery Wipe leather upholstery with a damp cloth and dry thoroughly or clean with a leather care product. Exercise particular care when cleaning perforated leather as its underside should not become wet. Cloth Upholstery Clean with soft bristle brush, or use a dry-shampoo cleaner in case of excessive dirt. Tex Upholstery Pour an interior care product onto soft lint-free cloth and apply with light pressure. Hard Plastic Trim Items Pour an interior care product onto soft lint-free cloth and apply with light pressure.

Fuses, relays and diodes (optional equipment) are below the driver’s seat, refer to "Optional Fuse and Relay Equipment".

CAUTION!

When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected.

238 MAINTAINING YOUR VEHICLE

Plastic and Rubber Parts Do not use oil or wax on these parts. Do not use any caustic or alcohol-based or solvent- based substances to clean plastic surfaces. Avoid the use of stain removers, iodine tincture, nail varnish and nail varnish remover, acetone, methylated spirits, chlorine or ammonium-based cleaning agents, cleaning agents containing abrasive substances.

ELECTRICAL FUSES Damaged fuses are recognizable from their burnt-out filament. Prior to exchanging a fuse, turn the key in the ignition- column lock to the 0 position and switch off the consumer involved. NOTE: Fuses must not be bridged. Replace fuses with specified rated current. Only replace fuses when the cause of the malfunction has been rectified. NOTE: Fuses and relays (standard equipment) are on the underside of the ignition column, refer to "Fuses and Relays Standard Equipment".

Standard Fuse and Relay Equipment

Position of fuses and relays

MAINTAINING YOUR VEHICLE 239

1. Locked 2. Unlocked 3. Detent spring – engage when the cover is fitted

4. Fuses 5. Relays

240 MAINTAINING YOUR VEHICLE

Fuse Assignment, Standard Equipment

No. Rated 1. 2. 3.

10A 10A 10A

4. 5. 6. 7.

8.

9.

10A 10A 20A 15A

20A

15A

Circuit Parking lamp right, taillamp right High beam head lamp,right High beam head lamp, left, high beam indicator lamp Backup lamp Brake lamp Windshield wiper motor Horn, heated rear window, air recirculation switch, optional equipment relay (terminal 15) Interior lighting, cigarette lighter, radio (terminal 30) Clock, hazard warning lamps, parking lamps

10.

10A

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

10A 10A 10A 15A 10A 25A 15A 15A 15A 15A 30A

MAINTAINING YOUR VEHICLE 241

Instrument lighting, license plate lamp daytime driving lamps Side lamp, left; taillamp, left Low beam headlamp, right Low beam headlamp, left Fog lamp Radio (terminal 15) Engine control unit Engine control unit Ignition (terminal 15) Not in use Heater controls (terminal 30) Heater blower (terminal 30)

242 MAINTAINING YOUR VEHICLE

Relay Assignment, Standard Equipment 1. Windshield wiper motor (W) 2. Diesel engine control unit (M) 3. Turn signals (B)

Fuse and Relay Optional Equipment The cover is located below the driver’s seat. Remove cover: 1. Press both detent springs down and remove cover.

Install cover:

2. Position cover at bottom and engage both detent

springs.

Fuse, Relay, and Diode Assignments – Optional Equipment

MAINTAINING YOUR VEHICLE 243

244 MAINTAINING YOUR VEHICLE

NOTE: The arrangement of the fuses (1) depends on the optional equipment installed on the vehicle. The assignments are shown on the inside of the cover of the fuse box. Diodes: No.

Circuit

1. 2. 3. 4.

Not in use Not in use Not in use Not in use

Fuses: No. Rated

Circuit

5. 6.

7.

8.

10A 7.5A

25A

40A

40A

9. 10. Relays: No.

Immobilizer Anti-lock brake system (ABS) Electronic Stability program (ESP)* Anti-lock brake system (ABS) Electronic Stability program (ESP)* Not in use Electronic Stability program (ESP)* Anti-lock brake system (ABS) Not in use

Circuit

Not in use 11. Starter relay 12. 13. Not in use * 2500 Type Vehicles only

BULB REPLACEMENT

Front Lamp Unit

MAINTAINING YOUR VEHICLE 245

WARNING!

Bulbs and bulb holders can become very hot. Al- low the lamp to cool down before changing the bulb. Keep bulbs out of reach of children. Do not use bulbs which have been dropped or which show signs of scratches on the glass. They could explode. Changing an H7 bulb: The bulb is pressurized. Always wear eye and hand protection.

Switch the lights off to prevent short circuits. Only touch new bulbs with a clean, lint-free cloth. Do not touch bulbs with wet or greasy fingers. Only fit 12 volt bulbs of the same type as before and with the correct wattage rating.

from

changed

Bulbs are compartment. Move the retainer bar to the side and remove the housing cover.

the engine

inside

246 MAINTAINING YOUR VEHICLE

Turn Signal Lamps and Side-Marker Lamps

1. Turn signal lamp and sidemarker lamp,

3457 NA – 12V 28/7.5W, yellow glass

2. Low beam headlamp, H7 – 12V 55W 3. Fog lamp, H1 – 12V 55W 4. Side and parking lamps, W5W – 12V 5W 5. High beam headlamps, H1 – 12V 55

1. Turn

bulb

holder,

together with

counterclockwise and remove.

bulb,

2. Remove the bulb from the bulb holder. 3. 4.

Insert a new bulb in the bulb holder. Insert the bulb holder together with the bulb and turn clockwise to the stop.

Low Beam Headlamps

1. Unplug the cable connector from the bulb. 2. Unclip in the retaining springs. Press the retaining the headlamps and down

towards

springs (direction of arrow).

MAINTAINING YOUR VEHICLE 247

3. Remove the bulb. 4.

Insert the new bulb so that the retaining lugs are fed into the recesses in the reflector section of the bulb holder.

5. Clip in the retaining springs. 6. Press on the cable connector. 7. Secure the housing cap.

248 MAINTAINING YOUR VEHICLE

Fog Lamp (Optional)

3. Remove the bulb. 4. Put in the new bulb so that the retaining lugs on the bulb holder are inserted into the recesses in the bulb holder reflector section. 5. Secure both retaining springs. 6. Press on the cable connector. 7. Secure the housing cap.

1. Remove the cable connector from the bulb holder. 2. Press both retaining springs in the direction of the headlamps and then outward (in the direction of the arrow).

Side and Parking Lamps

High Beam Headlamp

MAINTAINING YOUR VEHICLE 249

1. Pull out the bulb holder with the bulb. 2. Replace the bulb. 3. 4. Secure the housing cap.

Insert the bulb holder.

1. Unplug the cable connector from the bulb. 2. Press the retaining spring towards the headlamps

and outwards (direction of arrow).

3. Remove the bulb. 4.

Insert the new bulb so that the retaining lugs are fed into the recesses in the reflector section of the bulb holder.

5. Clip in the retaining springs. 6. Press on the cable connector. 7. Secure the housing cap.

250 MAINTAINING YOUR VEHICLE

Taillamps Cargo/Passenger Van

1. Locked 2. Unlocked Bulbs are changed from inside the cargo area. The rear lamp cluster bulb holder is located behind the interior paneling. Remove the paneling.

(1) Brake lamp, taillamp, standing lamp,

P21/5W – 12V 21/5W

(2) Backup lamp, P21W – 12V 21W (3) Turn signal lamp, P21W – 12V 21W (4) Side-marker lamp, R5W – 12V 5W

1. Unclip and remove the bulb socket. 2. To change a bulb, press the bulb into the bulb

socket, turn it counterclockwise and remove.

3. Insert the new bulb. 4. Clip the bulb socket into place.

Chassis

MAINTAINING YOUR VEHICLE 251

1. Loosen retaining screw a and remove lamp

housing.

2. To change a bulb, press the bulb into the bulb

socket, turn it counterclockwise and remove. Insert the new bulb. Install lamp housing.

3. 4.

(1) Retaining screws (2) Clearance lamp, R5W - 12V 5W (3) Turn signal lamp, P21W - 12V 21W (4) Stop lamp, P21W - 12V 21W (5) Taillamp, R5W - 12V 5W (6) Backup lamp, P21W - 12V 21W (7) License plate lamp (driver‘s side only),

R5W - 12V 5W

252 MAINTAINING YOUR VEHICLE

License Plate Lamps (Cargo/Passenger Vans Only)

Additional Brake Lamp (Cargo/Passenger Vans Only)

1. Press the bulb socket to the left, against the force of

the spring, and remove.

2. Replace the bulb, C5W – 12V 5W. 3. 4. Re-install the bulb socket.

Install the cover.

(1) Retaining screws 1. Take out the retaining screws (1) and remove the

lamp housing.

2. To change a bulb, P21W – 12V 21W

Press the bulb into the bulb socket, turn it counterclockwise and remove. Insert the new bulb. Install the lamp housing.

3. 4.

Side-Mounted Turn Signals

Side-Marker Lamps, Standing Lamps (Optional)

MAINTAINING YOUR VEHICLE 253

1. Press the lamp housing to the front, against the

force of the spring, and remove. 2. Replace the bulb, W5W - 12V 5W 3.

Install the bulb socket.

Retaining screws (1) Bulb socket (2) 1. Take out the retaining screws (1) and remove the

lamp housing.

2. Turn the bulb socket (2) counterclockwise and

remove.

3. Replace the bulb, W3W – 12V 3W. 4.

Install the bulb socket (2).

254 MAINTAINING YOUR VEHICLE

Identification Lamps (Cargo/passenger vans only)

Interior Lighting in Passenger Compartment and Load Compartment

(1) Retaining screw 1. Take out the retaining screw (1) and remove the

lamp housing.

2. To change a bulb, 12V 4CP

Press the bulb into the bulb socket, turn it counterclockwise and remove. Insert the new bulb. Install the lamp housing.

3. 4.

1. Align a screwdriver on the retaining spring, press it

in and pry the lamp housing out.

2. Replace the bulb, K – 12V 18W 3.

Install the lamp housing.

Interior Lighting with Reading Lamp

Interior Lighting with Interior Sensor Protection

MAINTAINING YOUR VEHICLE 255

1. Use a screwdriver on the catch spring to press in

and remove the bulb housing. 2. Replace the bulb, K – 12V 10W. 3.

Install the lamp housing.

1. Use a screwdriver on the catch spring, remove the

bulb housing.

2. Turn the bulb holder with the bulb in the direction

of the arrow and remove it.

3. Replace the bulb holder and bulb, K – 12V 6W 4.

Install the lamp housing.

256 MAINTAINING YOUR VEHICLE

Exit Lamps (Optional)

(1) Lamp housing (2) Cable connector (3) Bulb holder

1. Use a screwdriver on the catch spring to remove the

lamp housing (1).

2. Press the locating spring on the cable connector (2), hold it down, and remove the cable connector (2). 3. Turn the bulb holder (3) to the left and remove it. 4. Replace the bulb, W5W - 12V 5W. 5.

Install the bulb holder (3) and attach the cable connector (2).

MAINTAINING YOUR VEHICLE 257

CAPACITIES

Engine with oil filter

Engine oil

Fuel tank

Including reserve fuel

Cooling system Windshield washer

system

All vehicles

about 9.5 US qt (9.0 l)

about 26.4 US gal (100 l)

about 2.8 US gal (10.5 l)

about 2.7 US gal (10.0 l)

about 7.4 US qt (7.0 l)

258 MAINTAINING YOUR VEHICLE

Recommended Fluids and Lubricants The manufacturer recommends for your vehicle model the use of DaimlerChrysler approved fluids and lubricants, e.g. engine oil, gear oil, automatic transmission fluid, brake fluid, power steering fluid, coolant and anti-corrosion/anti-freeze fluid only.

WARNING!

Failure to use fluids and lubricants which meet the standards and specifications described in this booklet or failure to adhere to the specified re- placement intervals may result in damage to safe- ty-related systems of your vehicle, such as the brake system, which could cause an accident and/ or serious injury to you and others. Use only fluids and lubricants meeting the standards and specifications and adhere to specified replacement intervals.

CAUTION!

Failure to use fluids and lubricants which meet the standards and specifications described in this booklet or failure to adhere to the specified replacement intervals may result in a significantly shortened service life and/or damage to components of your vehicle, the repair of which will not be covered by Warranty. Use only fluids and lubricants meeting the standards and specifications and adhere to specified replacement intervals.

MAINTAINING YOUR VEHICLE 259

The following oils have been determined to meet DaimlerChrysler requirements.

MB approved Engine Oil

76 Pure Synthetic Motor Oil 76 Royal Triton QLT Agip All Guard Motor Oil Agip Eurosport Agip Synthetic PC Akron Ultra Clear C1-41
BP Vanellus C6 Global Plus Brad Penn Euro-Diesel LD Castrol Elixion1
Castrol Tection S1
Chevron Delo 400 Multigrade Diesel Special Benz M&A Dislub Premium Exxon XD-3 Extra1
FormulaShell Ultra FormulaShell Ultra AB Gonher Super Fleet MB-III Hydroclear Power-D Engine Oil IDO Premium 15W-40
Kendall GT-1 Full Synthetic Motor Oil

SAE

5W-40
15W-40
15W-40
5W-40
5W-40
15W-40
10W-40
15W-40
5W-30
15W-40
15W-40
15W-40
15W-40
15W-40
5W-40
5W-30
15W-40
15W-40
15W-40
5W-40

MB Sheet 229.3
228.3
228.3
229.3
229.3
228.3
228.3
228.3
228.5
228.3
228.3
228.3
228.3
228.3
229.3
229.5
228.3
228.3
228.3
229.3

Long Life EF Diesel Engine Oil Multi- grade Lubral Super Diesel MB-III Max Raloy Diesel MB Motorenöl 000 989 60 01 13
Mexlub CF-4 MB-3P Mobil 1 0W-40
Mobil Delvac 1
Mobil Delvac 1300 Super1
Mobil SHC Formula MB MOPAR® Part No. 04798231AD Motul 8100 E-Tech 0W-40
Motul 8100 X-cess 5W-40
Panolin Indy SV Pennzoil European Formula Ultra Pennzoil Synthetic European Formula Premium Synthetik Motorenöl QS Superfleet Quaker State European Formula Ultra Quaker State Full Synthetic European For- mula Quaker State Super Series III1
Raloy Diesel Turbo MX

15W-40

228.3

15W-40
5W-30
10W-40
15W-40
0W-40
5W-40
15W-40
5W-30
15W-40
0W-40
5W-40
5W-40
5W-30
5W-40
5W-30
15W-40
5W-30
5W-40

15W-40
15W-40

228.3
228.5
228.5
228.3
229.5
228.5
228.3
229.5
228.3
229.3
229.3
229.3
229.5
229.3
229.5
228.3
229.5
229.3

228.3
228.3

260 MAINTAINING YOUR VEHICLE

Raloy Motor Diesel Repsol Turbo UHPD Roshfrans Voltro Diesel1
Shell Helix Ultra Shell Helix Ultra Shell Rimula X CH-4
Shell Rimula X CH-4
Shell Rotella T Multigrade1
Super Diesel Oil MB-3
Supreme Duty Diesel Engine Oil Multi- grade Unoil GX-7
Ursa Premium TDX Ursa Premium TDX Valvoline SynPower MXL 1. Engine oil also meets API classification CI-4.

15W-40
10W-40
15W-40
5W-30
5W-40
15W-40
20W-50
15W-40
15W-40
15W-40

5W-40
10W-30
15W-40
0W-30

228.3
228.5
228.3
229.3
229.3
228.3
228.3
228.3
228.3
228.3

229.3
228.3
228.3
229.3

Other oils may meet requirements - see oil label to determine.

COMPONENT

SERVICE INTERVAL

PRODUCT NAME/PRODUCT NUMBER

MB SHEET

MAINTAINING YOUR VEHICLE 261

Air Conditioning The air conditioning system of your vehicle contains R-134a, a refrigerant that does not deplete the ozone layer in the upper atmosphere. Refrigerant R-134a Automatic

361.0
236.10

— once only at 80,000 mi (128,000 km)

Refrigerant R-134a Shell ATF 3403/M-115
MOPAR® Part No. 05127382AA, or equivalent Fuchs/Shell ATF 3353

Transmission Fluid

236.12

Brakes Use brake fluid approved to DaimlerChrysler standard MB 331.0 and/or DaimlerChrysler material standard MS-9971, brake fluid certified to DOT 4 Plus standards, that also maintains a minimum dry boiling point (ERBP) of 500°F (260°C), a minimum wet boiling point (WERBP) of 356°F (180°C) and maximum viscosity of 1500 mm2/s, conforming to FMVSS 116 and ISO 4925.

Brake Fluid

2 years

Intac B026D

Dry boiling point: 500°F (260°C) Wet boiling point: 356°F (180°C),

331.0

Engine Oil

12 months or 10,000 mi (16,000 km)

MOPAR® MS-9971 Part No. 04549625AC, or equivalent

See "Approved Engine Oils"

262 MAINTAINING YOUR VEHICLE

COMPONENT

Engine Coolant, Anticorrosion/ Antifreeze Fluid

SERVICE INTERVAL

15 years or 160,000 mi (256,000 km)

PRODUCT NAME/PRODUCT NUMBER

EURO Peak Coolant/Anti-freeze, OLD WORLD INDUSTRIES Zerex G05, The Valvoline Company Zerex G48, The Valvoline Company Glysantin G05, BASF AG MOPAR® Part No. 05066386AA, or equivalent

Power Steering Power Steering, no fluid service required

Power Steering fluid — Rear Axle Gear Oil

120,000 mi (192,000 km)

Mobil ATF-D, Exxon Mobil Corporation, or equivalent

Shell Spirax MB 90
Caltex Hypoid LD MOPAR® Part No. 4874469, or equivalent

MB SHEET

325.0

236.3

235.0
235.6

MAINTENANCE SCHEDULES

CONTENTS

3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3 Maintenance - Without ASSYST Maintenance

Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
U Maintenance Intervals . . . . . . . . . . . . . . . . . . . . 265

3 Maintenance - With ASSYST Maintenance

Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3 Regular Check-Ups. . . . . . . . . . . . . . . . . . . . . . . . . 266

3 Special Maintenance Requirements . . . . . . . . . . . 267
U Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
U Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
U Dust Filter for Heating/Ventilation

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3 Engine Oil Change and Filter Replacement . . . . 267
U Once a Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3 Scope of Work for Maintenance service . . . . . . . 268
U Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
U Additional Maintenance Work . . . . . . . . . . . . . 270
U Additional Maintenance Work After ... Years . . . 270

M

264 MAINTENANCE SCHEDULES

INTRODUCTION This is intended as a guide to the service requirements of your vehicle. It contains all necessary instructions concerning service intervals and operations which have to be carried out. Scope and frequency of maintenance work primarily depend on the vehicle's operating conditions. In the interest of maintaining the vehicle's operating safety, the specified work should be performed regularly and in good time. Our vehicles are subject to ongoing development. Technical progress may also affect the scope of service work performed. "Daily vehicle checks" before starting a journey are the responsibility of the driver.

in accordance with

WARRANTY The Sprinter Dealer network is at your disposal for maintenance work. Each of these workshops has the equipment and tools, the specially trained, skilled and experienced personnel and receives regular technical instruction from DaimlerChrysler Corporation to ensure that your vehicle is inspected and maintained thoroughly and latest procedures. Please follow the instructions given in this Owner’s Manual and ensure that they are observed, even if you hand the vehicle over to a third party for use or care. By not observing these instructions you may void your warranty rights. If the specified oil and maintenance services are not carried out regularly or at the time intervals specified, a decision as to the validity of a warranty claim can only be made after DaimlerChrysler Corporation has investigated your claim.

the

lubricant additives

The use of Special is not recommended. The use of such additives may affect your warranty rights. With regard to legal stipulations concerning emissions control, please note that engines have to be serviced and adjusted in accordance with special instructions and using special measuring equipment. Modifications to or interference with the emissions control systems are not permissible. All Sprinter Dealer are familiar with the relevant and appliable regulations.

MAINTENANCE SCHEDULES 265

MAINTENANCE - WITHOUT ASSYST MAINTENANCE COMPUTER Maintenance Intervals

Oil service and fuel filter replacement – Refer to

Normal Operation

every 10,000 miles or 16,000 km or 12 months

Maintenance service

every 30,000 miles or 48,000 km

Additional work must be carried out at yearly intervals. As a general rule, to avoid unnecessary visits to the workshop you should try to have necessary repair work performed together with other maintenance work.

M

266 MAINTENANCE SCHEDULES

MAINTENANCE - WITH ASSYST MAINTENANCE COMPUTER ASSYST provides you with information on the best possible timing for maintenance work. When the next maintenance service is due, this will be indicated in the multi-function display with the symbol 9 Oil service and fuel filter replacement 9 Maintenance service - displayed in km/miles

or days.

If the display shows the number of days, the symbol È will also appear in the multi-function display. You should have the maintenance performed within the stated period/distance. The service indicator will be reset by your Sprinter Dealer after an oil service and/or maintenance service has been performed.

REGULAR CHECK-UPS To maintain the safe operation of your vehicle, it is recommended that you perform the following tasks on a regular basis (i.e., weekly or whenever the vehicle is refueled). Check: (cid:127) Engine oil level (cid:127) Brake system, clutch mechanism – fluid level (cid:127) Battery – acid level (cid:127) Windshield washer system and headlamp cleaning

system – fluid level

(cid:127) Mechanical assemblies (e. g. ,engine, transmission,

etc.) – check for leaks

(cid:127) Condition of tires and tire pressures (cid:127) All exterior lights

SPECIAL MAINTENANCE REQUIREMENTS If bodies built by manufacturers other than DaimlerChrysler Corporation are fitted to the vehicle, the maintenance requirements and lubrication intervals specified by the body manufacturer must be adhered to, in addition to all standard maintenance requirements. Brake Fluid Only use brake fluids approved by the manufacturer (DOT 4 plus). Information about brake fluids is available from your Sprinter Dealer. Coolant Have the corrosion inhibitor/antifreeze concentration in the coolant checked before the onset of winter (once a year in countries with high prevailing temperatures). Have the coolant renewed every five years or 100,000
miles. Dust Filter for Heating/Ventilation Replacement The dust filter and the tailgate interior filter are renewed during service. However, if operating conditions are dusty, these filters should be renewed more frequently.

routine maintenance

MAINTENANCE SCHEDULES 267

ENGINE OIL CHANGE AND FILTER REPLACEMENT In a minimum, change the engine oil and oil filter once a year - even if the vehicle mileage per year is extremly low. For standard oil service schedules, please see the chapter oil service and maintenance service. Once a Year Select the viscosity of the engine oil (SAE classes) according to the outside air temperature. Only use engine oil approved by DaimlerChrysler Corporation system guidelines. Information is available from your Sprinter Dealer. If the fuel used has a sulphur content exceeding 0.05 % by weight, the service intervals should be split in half. If the sulphur content of the fuel used is between 0.3% and 0.8% by weight, the service intervals should be split in half (i.e. every 5,000 miles instead of every 10,000 miles).

the ASSYST

following

if

M

268 MAINTENANCE SCHEDULES

SCOPE OF WORK FOR MAINTENANCE SERVICE Oil Service Oil change Engine: Oil change and filter replacement Check fluid levels of the following system, refill as necessary. If fluid is lost, trace and eliminate cause – as a separate order. Power-assisted steering Lubrication work: Trailer tow hitch (original equipment) Maintenance ASSYST maintenance computer reset

Function check Signalling system, warning and indicator lamps Headlamps, exterior lighting Windscreen wipers, windscreen washer system Check for leaks and damage. Check for abrasion points and ensure that lines are correctly routed! All assemblies: Engine, transmission, transfer case, front axle, rear axle, steering, power steering pump All lines and hoses, sensor cables Rubber boots on front axle drive shafts, rubber boots on front axle suspension ball joints, shock absorbers

Check fluid levels for the following systems, correct as necessary. Should there be a loss of fluid which cannot be explained by regular use, trace and eliminate the cause. Engine cooling system Check corrosion inhibitor/antifreeze, refill as necessary.

Hydraulic brake system Battery Windscreen washer system Engine Fuel filter renewal Air cleaner with maintenance indicator: Check degree of contamination. Air cleaner filter element renewed as necessary.

MAINTENANCE SCHEDULES 269

Chassis and body Trailer coupling: Check operation, play and retaining fixtures Secondary rubber springs: Visual check Tire pressures: Correct as necessary, including spare tyre Check thickness of brake pads Brake test Check condition of brake disks. Brake disks renewal as necessary – as a separate order Check condition of steering mechanism Heating/ventilation dust filter renewal

270 MAINTENANCE SCHEDULES

Additional Maintenance Work Automatic transmission once only at 80,000 miles/ 128000km Oil and filter change During every second maintenance service Air cleaner without maintenance indicator: Air cleaner filter element renewal Check poly-V-belt for wear and signs of damage During every sixth maintenance service Rear axle

Additional Maintenance Work After ... Years Every 2 years Change brake fluid Every 3 years Air cleaner filter element renewal (note installation date) Every 15 years or 100,000 miles Coolant renewal Note coolant composition

IF YOU NEED CONSUMER ASSISTANCE

CONTENTS

3 Suggestions For Obtaining Service For

Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
U Prepare for the Appointment . . . . . . . . . . . . . . 272
U Prepare a List . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
U Be Reasonable with Request . . . . . . . . . . . . . . . 272

3 If You Need Assistance . . . . . . . . . . . . . . . . . . . . . 272
3 Warranty Information . . . . . . . . . . . . . . . . . . . . . . 275
3 Mopar® Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3 Reporting safety Defects . . . . . . . . . . . . . . . . . . . . 275

272 IF YOU NEED CONSUMER ASSISTANCE

SUGGESTIONS FOR OBTAINING SERVICE FOR YOUR VEHICLE Prepare for the Appointment If you’re having warranty work done, be sure to have the right papers with you. Take your warranty folder. All work to be performed may not be covered by the warranty, discuss additional charges with the service manager. Keep a maintenance log of your vehicle’s service history. This can often provide a clue to the current problem

Prepare a List Make a written list of your vehicle’s problems or the specific work you want done. If you’ve had an accident, or work done that is not on your maintenance log, let the service advisor know.

Be Reasonable with Request If you list a number of items, and you must have your vehicle by the end of the day, discuss the situation with the service advisor and list the items in order of priority. At many dealers you may obtain a rental vehicle at a minimal daily charge. If you need a rental, it is advisable to make these arrangements when you call for an appointment.

IF YOU NEED ASSISTANCE

The manufacturer and its dealers are vitally interested in your satisfaction. We want you to be happy with our products and services.

Your selling dealer is best equipped and most anxious to provide prompt resolution for any warranty issue or related matter that you may experience. The manufacturer’s dealer have the facilities, factory- trained technicians, special tools, and the latest information to assure your vehicle is fixed correctly and in a timely manner. The manufacturer has empowered its dealers to make warranty and repair decisions that ensure you are not inconvenienced. There are no need for you to wait for a decision from the manufacturer. If a special circumstance occurs that requires information from the manufacturer, we have asked the dealer’s service management to make the contact on your behalf.

This is why you should always talk to your dealer’s service manager first. Most matters can be resolved with this process.

(cid:127) If for some reason you are still not satisfied, talk to the general manager or owner of the dealership. They want to know if you need assistance.

(cid:127) If your dealership is unable to resolve the concern, you may contact the Manufacturer’s Customer Center.

Any communication to the Manufacturer’s Customer Center should include the following information:

(cid:127) Owner’s name and address

(cid:127) Owner’s telephone number (home and office)

(cid:127) Dealership name

(cid:127) Vehicle identification number

(cid:127) Vehicle delivery date and mileage

DaimlerChrysler Motors Corporation Customer Center P.O. Box 21-8004

Auburn Hills, MI 48321-8004

Phone: (800) 992-1997

IF YOU NEED CONSUMER ASSISTANCE 273

DaimlerChrysler Canada, Inc. Customer Center P.O. Box 1621
Windsor, Ontario N9A 4H6
Phone: (800) 465-2001
In Mexico contact: Av. Prolongacion Paseo de la Reforma, 1240
Sante Fe C.P. 05109
Mexico, D.F. In Mexico (915) 729-1248 or 729-1240
Outside Mexico (525) 729-1248 or 729-1240
Customer Assistance For The Hearing Impaired Or Speech Impaired (TDD/TTY) To assist customers who have hearing difficulties, the manufacturer TDD (Telecommunication Devices for the Deaf) equipment at its Customer Center. Any hearing or speech impaired customer who has access to a TDD or a conventional teletypewriter (TTY) in the United States can communicate with the manufacturer by dialing 1- 800-380-CHRY.

installed

special

has

274 IF YOU NEED CONSUMER ASSISTANCE

Service Contract

You may have purchased a service contract for your vehicle to help protect you from the high cost of unexpected repairs after your manufacturer’s new vehicle limited warranty expires. The manufacturer stands behind only the manufacturer’s Service Contracts. If you purchased a manufacturer’s Service Contract, you will receive Plan Provisions and an Owner Identification Card in the mail within three weeks of your vehicle delivery date. If you have any questions about your service contract, call the manufacturer’s Service Contract National Customer Hotline at 1-800-521-9922.

We appreciate that you have made a major investment when you purchased your new vehicle. Your dealer has also made a major investment in facilities, tools, and training to assure that you are absolutely delighted with your ownership experience. You’ll be pleased with their sincere efforts to resolve any warranty issues or related concerns.

The manufacturer will not stand behind any service contract that is not the manufacturer’s Service Contract. It is not responsible for any service contract other than the manufacturer’s Service Contract. If you purchased a is not a manufacturer’s Service Contract, and you require service after your manufacturer’s new vehicle limited warranty expires, please refer to your contract documents and contact the person listed in those documents.

service contract

that

IF YOU NEED CONSUMER ASSISTANCE 275

To contact NHTSA, you may either call the Auto Safety Hotline toll free at 1–888-327-4236 (TTY: 1-800-424- 9153) or go to http://www.NHTSA.gov or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline. In Canada: If you believe that your vehicle has a safety defect, you should contact the Customer Service Department immediately. Canadian customers who wish to report a safety defect to the Canadian government should write to: Transport Canada, Motor Vehicle Defect Investigations and Recalls, 2780 Sheffield Road, Ottawa, Ontario, K1B 3V9.

WARRANTY INFORMATION See your manufacturer’s Warranty Information Booklet for information on your warranty coverage and transfer of warranty.

MOPAR® PARTS Mopar® fluids, lubricants, parts, and accessories are available from your dealer. They will help you keep your vehicle operating at its best.

REPORTING SAFETY DEFECTS In the 50 United States and Washington D.C.: If you believe that your vehicle has a defect which could cause a crash or cause injury or death, you should immediately inform the National Highway Traffic Safety Administration to notifying the manufacturer.

in addition

(NHTSA)

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, and the manufacturer.

INDEX

A Special Note Concerning Vehicle Alteration. . . . 194
Acceleration Skid Control . . . . . . . . . . . . . . . . . . . . . 164
Deactivating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . 143, 166
Acceleration Skid Control (ASR). . . . . . . . . . . . 166, 167
Air Conditioner for the Rear Passenger Compartment 125

Air Recirculation. . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Air Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Air Conditioning

Climate Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Rear Passenger Compartment . . . . . . . . . . . . . . . 124
Air Conditioning, Regulated . . . . . . . . . . . . . . . . . . . 122
Air Filter Restriction Indicator. . . . . . . . . . . . . . . . . . 219

Air Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Air Vents

Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Airbag and Belt Tensioners . . . . . . . . . . . . . . . . . . . . . 49
Airbag Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Alarm Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Anti-Lock Brake System (ABS) Indicator Lamp . . . 161
Appearance and Care . . . . . . . . . . . . . . . . . . . . . . . . . 231
Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ASSYST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

10

278 INDEX

ASSYST Maintenance Computer . . . . . . . . . . . . . . . 110
Automatic Lock Feature . . . . . . . . . . . . . . . . . . . . . . . . 19
Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . 145
Accelerator Position . . . . . . . . . . . . . . . . . . . . . . . . 146
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Gear Selector Lever Position . . . . . . . . . . . . . . . . . 147
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Selector Lever Manually Unlocking. . . . . . . . . . . 150
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Auxiliary Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Auxiliary Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 137
Auxiliary Heater

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Timer Auxiliary Heater (Water and Air Heater) 132
Tips for Coping with Problems . . . . . . . . . . . . . . 138

Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . 228
Disconnecting the Battery . . . . . . . . . . . . . . . . . . . 227
Reconnecting the Battery. . . . . . . . . . . . . . . . . . . . 228
Replacing Batteries in Remote Keyless Entry. . . . 22
Battery Charge Indicator Lamp. . . . . . . . . . . . . . . . . 104

Belt Tensioners

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Belt Tensioners and Airbag . . . . . . . . . . . . . . . . . . . . . 49
Bleeding the Diesel Fuel System . . . . . . . . . . . . . . . . 185
Body Builder Guideline . . . . . . . . . . . . . . . . . . . . . . . 193
Brake Assist System (BAS) . . . . . . . . . . . . . . . . . . . . . 169
Brake fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Brake Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 222
Brake Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 157
Brake Pad Wear Indicator. . . . . . . . . . . . . . . . . . . . . . 156
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Brake System, Anti-Lock . . . . . . . . . . . . . . . . . . . . . . 162
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Brake Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Bulbs

Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Care of Vehicle

Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Headlamps, Taillamps, Turn Signal Lenses . . . . 234
Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Care of vehicle

Paintwork, painted body components . . . . . . . . 233
Power washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Tar stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Central Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Locking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Central Locking Switch. . . . . . . . . . . . . . . . . . . . . . . . . 17
Locking and Unlocking . . . . . . . . . . . . . . . . . . . . . . 19
Locking Status Display . . . . . . . . . . . . . . . . . . . . . . 18
To Program the Automatic Lock Feature . . . . . . . 19
Chains, Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Changing a Bulb

Additional Brake Lamp . . . . . . . . . . . . . . . . . . . . . 252
Exit Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Interior Lighting with Interior Sensor Protection255

INDEX 279

License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 252
Reading Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Side-Marker Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 253
Side-Mounted Turn Signal . . . . . . . . . . . . . . . . . . 253
Taillamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 224
Checking Weights of Vehicle and Trailer. . . . . . . . . 188
Cigar Lighter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Cleaning

Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . . . . 237
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . 236
Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 236
Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . . . 238
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Steering Wheel and Gear Selector Lever . . . . . . . 236
Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

10

280 INDEX

Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Comfort Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . 178
Compartments in Front Doors. . . . . . . . . . . . . . . . . . . 86
Constant RPMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Consumer Assistance

Be Reasonable with Request . . . . . . . . . . . . . . . . . 272
If You Need Assistance . . . . . . . . . . . . . . . . . . . . . 272
Prepare a List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Prepare for the Appointment . . . . . . . . . . . . . . . . 272
Coolant Level Indicator Lamp. . . . . . . . . . . . . . . . . . 106
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . 101
Coolant, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Cooling System, Engine . . . . . . . . . . . . . . . . . . . . . . . 223
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Cup Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
De-Fogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Dehumidification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
De-Icing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Diesel Fuels for Use at Very Low Temperatures . . 180
Displaying Engine Oil Level . . . . . . . . . . . . . . . . . . . 113
Doors

Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Cargo Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Sliding Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Draining Fuel Filter with Water Separator . . . . . . . 184
Driver’s Airbag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Driving Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . 160
Electric Sun Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Fuse and Relay Optional Equipment . . . . . . . . . . 242
Fuse, Relay, and Diode Assignments - Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Relay Assignment, Standard Equipment . . . . . . 242
Standard Fuse and Relay Equipment. . . . . . . . . . 239
Electrical Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Electronic Brake Force Distribution . . . . . . . . . . . . . 164
Electronic Brake Force Distribution Lamp. . . . . . . . 157
Electronic Stability Program . . . . . . . . . . . . . . . . . . . 166
Emission Label, Vehicle/Engine . . . . . . . . . . . . . . . . . . 7
Emission Related Component . . . . . . . . . . . . . . . . . . 218
Emissions Control System . . . . . . . . . . . . . . . . . . . . . 192
Engine Break-in Recommendations . . . . . . . . . . . . . . 52

Engine Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Engine Control Unit Indicator Lamp . . . . . . . . . . . . 107
Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . 223
Engine Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . 53
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Indicator in Instrument Cluster . . . . . . . . . . . . . . 115
Engine Oil Level - Display in Instrument Cluster . 112
Engine Oil Level Indicator Lamp . . . . . . . . . . . . . . . 105
Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Engine oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Engine Speed, Maximum . . . . . . . . . . . . . . . . . . . . . . 142
Engine, Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Exhaust Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Exhaust Gas, Inhalation of . . . . . . . . . . . . . . . . . . 54, 192
Fax Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Fog Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Folding Seat at Partition . . . . . . . . . . . . . . . . . . . . . . . . 63
Fording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Front Seat Passenger Airbag . . . . . . . . . . . . . . . . . . . . 48

INDEX 281

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Fuel Filter with Water Separator . . . . . . . . . . . . . . . . 180
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Bleeding the Diesel Fuel System. . . . . . . . . . . . . . 185
Diesel Fuels for Use at Very Low Temperatures 180
Draining Fuel Filter with Water Separator . . . . . 184
Fuel Filter with Water Separator . . . . . . . . . . . . . 180
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 182
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Fuse and Relay Optional Equipment . . . . . . . . . . . . 242
Fuse, Relay, and Diode Assignments - Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Fuses, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Gear Selector Lever Position . . . . . . . . . . . . . . . . . . . 147
Glove Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Lockable Glove Compartment . . . . . . . . . . . . . . . . 86

Hazard Warning Flasher Switch . . . . . . . . . . . . . . . . 196
Head Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

10

282 INDEX

Headlamp Range Control. . . . . . . . . . . . . . . . . . . . . . . 68
Headlamps, taillamps, turn signal lenses . . . . . . . . 234
Heated Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . 121
Heater, Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116, 118
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Hydroplaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Ignition

Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Indicator Lamp Symbols . . . . . . . . . . . . . . . . . . . . . . 108
Inhalation of Exhaust Gas . . . . . . . . . . . . . . . . . . . . . . 54
Installing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Instrument and Display Lighting . . . . . . . . . . . . . . . . 97
Instrument Cluster

Battery Charge Indicator Lamp . . . . . . . . . . . . . . 104
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Coolant Level Indicator Lamp . . . . . . . . . . . . . . . 106
Coolant Temperature Gauge. . . . . . . . . . . . . . . . . 101
Engine Control Unit Indicator Lamp. . . . . . . . . . 107

Engine Oil Level Indicator Lamp . . . . . . . . . . . . . 105
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Trip Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Water in Fuel Indicator Lamp . . . . . . . . . . . . . . . . 104
Instrument Cluster and Indicator Lamps. . . . . . . . . . 91
Instruments and Controls. . . . . . . . . . . . . . . . . . . . . . . 89
Interior Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cargo Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Driver and Rear-Seat Passenger/Cargo Area. . . . 69
Interior Sensor Protection . . . . . . . . . . . . . . . . . . . . 69
Reading Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Intervals, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 265
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intrument Cluster

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Jack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Lamps

Acceleration Skid Control . . . . . . . . . . . . . . . . . . . 164

Acceleration Skid Control Warning Lamp . 143, 166
Additional Brake Lamp . . . . . . . . . . . . . . . . . . . . . 252
Anti-Lock Brake System (ABS) Indicator Lamp. 161
Battery Charge Indicator Lamp . . . . . . . . . . . . . . 104
Brake Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Coolant Level Indicator Lamp . . . . . . . . . . . . . . . 106
Electronic Brake Force Distribution . . . . . . . . . . . 157
Engine Control Unit Indicator Lamp. . . . . . . . . . 107
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Engine Oil Level Indicator Lamp . . . . . . . . . . . . . 105
Exit Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
License Plate Lamp. . . . . . . . . . . . . . . . . . . . . . . . . 252
Reading Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Reserve Fuel Indicator Lamp . . . . . . . . . . . . . . . . 103
Seat Belt Warning Lamp . . . . . . . . . . . . . . . . . . . . . 44
Side-Marker Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 253
SRS Malfunction Indicator Lamp . . . . . . . . . . . . . . 49
Taillamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Water in Fuel Indicator Lamp. . . . . . . . . . . . . . . . 104

INDEX 283

Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Lighter, Cigar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Lighting, Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Lock, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Locking, Central. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lumbar Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Maintenance Computer . . . . . . . . . . . . . . . . . . . . . . . 110
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . 265
Maintenance Schedules

Additional Maintenance Work After ... Years . . 270
Brake Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Dust Filter for Heating/Ventilation Replacement . . 267
Engine Oil Change and Filter Replacement . . . . 267
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Once a Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Regular Check-Ups. . . . . . . . . . . . . . . . . . . . . . . . . 266
Scope of Work for Maintenance service . . . . . . . 268

10

284 INDEX

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
With ASSYST Maintenance Computer . . . . . . . . 266
Without ASSYST Maintenance Computer . . . . . 265
Maximum Engine Speed . . . . . . . . . . . . . . . . . . . . . . 142
Mechanical Sun Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Mechanical Sun Roof Operation . . . . . . . . . . . . . . . . . 81
Mirror Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Mirrors

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Mobile Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Mopar® Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Multi-Function Indicator . . . . . . . . . . . . . . . . . . . . . . . 94
Multifunction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Occupant Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Opening/Closing doors . . . . . . . . . . . . . . . . . . . . . . . . 27
Operation, Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ornamental Moldings. . . . . . . . . . . . . . . . . . . . . . . . . 234
Outlet, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Outside Temperature Display . . . . . . . . . . . . . . . . . . . 98
Overheating (Air Heater) . . . . . . . . . . . . . . . . . . . . . . 138
Passenger Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Passenger Airbag, Front Seat . . . . . . . . . . . . . . . . . . . . 48
Passenger Compartment Protection . . . . . . . . . . . . . . 25
Alarm Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pedals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Permissible Roof Load . . . . . . . . . . . . . . . . . . . . . . . . 186
Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Power Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Programmed Top Speed . . . . . . . . . . . . . . . . . . . . . . . 182
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Radio Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Rear Cargo Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rear Seat Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removal and Installation. . . . . . . . . . . . . . . . . . . . . 64
Recommended Fluids and Lubricants . . . . . . . . . . . 258
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Regular Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Relay Assignment, Standard Equipment. . . . . . . . . 242
Remote Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Locking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Replacing Wiper Blades . . . . . . . . . . . . . . . . . . . . . . . 230
Reporting safety Defects. . . . . . . . . . . . . . . . . . . . . . . 275
Reserve Fuel Indicator Lamp. . . . . . . . . . . . . . . . . . . 103
Residual Engine Heat Utilization . . . . . . . . . . . . . . . 122
Residual Engine Heat Utilization (REST) . . . . . . . . 122
Restraints, Occupant . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Retrofitting Seat Mounting Cups . . . . . . . . . . . . . . . . 65
Reversing Aid

Audible Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Ribbed V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Roof Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
RPMs, Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Seat Belt Warning Lamp and Airbag Malfunction . . 44
Seat Belts

INDEX 285

Belt Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Fastening and Removing . . . . . . . . . . . . . . . . . . . . . 45
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Seats

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Armrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Driver’s and Front Passenger’s Seat. . . . . . . . . . . . 60
Folding Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Head Restraint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Rear Seat Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Security System with Towing and Passenger Compartment Protection . . . . . . . . . . . . . . . . . . . . . . . 23
Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Switching off the Alarm. . . . . . . . . . . . . . . . . . . . . . 24
Visual Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Service Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Disposal of Service Products . . . . . . . . . . . . . . . . . 218
Skid Control, Acceleration . . . . . . . . . . . . . . . . . . . . . 164

10

286 INDEX

Sliding Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Snow Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Spare Wheel Location . . . . . . . . . . . . . . . . . . . . . . . . . 200
Special Maintenance Requirements . . . . . . . . . . . . . 267
Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Sprinter Original Parts . . . . . . . . . . . . . . . . . . . . . . . . 217
SRS Malfunction Indicator Lamp . . . . . . . . . . . . . . . . 49
Standard Fuse and Relay Equipment . . . . . . . . . . . . 239
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Suggestions For Obtaining Service For Your Vehicle . 272
Sun Roof

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . 81
Sun Roof, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Switch,Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99, 101
Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Tie Down Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Tire Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Tire Pressure Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tires

Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Comfort Tire Pressures. . . . . . . . . . . . . . . . . . . . . . 178
Hydroplaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Pressure Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Snow Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Spare Wheel Location. . . . . . . . . . . . . . . . . . . . . . . 200
Tire Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tire Pressures Table . . . . . . . . . . . . . . . . . . . . . . . . 177
Tires, Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Towing a Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Towing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Towing Protection and Passenger Compartment Protection Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
If the Engine is Damaged. . . . . . . . . . . . . . . . . . . . 212
If the Front Axle is Damaged . . . . . . . . . . . . . . . . 212
If the Rear Axle is Damaged . . . . . . . . . . . . . . . . . 212
If the Transmission is Damaged . . . . . . . . . . . . . . 212
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Attaching a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 188
Checking Weights of Vehicle and Trailer . . . . . . 188
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . 186
Loading a Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Parking a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Towing a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Trailer Hitches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Vehicle and Trailer Weights . . . . . . . . . . . . . . . . . 187
Transmission, Automatic . . . . . . . . . . . . . . . . . . . . . . 145
Trip Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Two Way Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

INDEX 287

Using the Jack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Vehicle / Engine Emission Label . . . . . . . . . . . . . . . . . 7
Vehicle Alteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Vehicle and Trailer Weights. . . . . . . . . . . . . . . . . . . . 187
Vehicle Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Vehicle Safety Certification Label . . . . . . . . . . . . . . . . . 6
Vehicle Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Ventilation, Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Wading Capability. . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 153
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . 275
Water in Fuel Indicator Lamp . . . . . . . . . . . . . . . . . . 104
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Window Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

10

288 INDEX

Windows

De-Fogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
De-Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Windshield Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Windshield Washer System Fluid Reservoir. . . . . . 219
Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . 75
Windshield wipers with rain sensor. . . . . . . . . . . . . . 76
Winter Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226