2005 Dodge Sprinter Owners Manual

STARTING THE ENGINE

STARTING AND OPERATING 141

WARNING!

When the engine is not running, there is no power assistance for the brake and steering system. 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.

Battery charge warning lamp (1) Engine oil level indicator lamp (2) Preheater indicator lamp (3)

142 STARTING AND OPERATING

1. Apply the parking brake. 2. Automatic transmission, shift selector lever to "P" or "N" position, refer to "Automatic Transmission".

3. Do not depress the accelerator pedal. 4. Turn the key to position 2 in the ignition lock. The preheater indicator lamp q lights up.

5. Turn the key clockwise to the stop as soon as the

preheater indicator lamp q goes out. If the engine is at its normal operating temperature, the preheater indicator lamp will only light up briefly.

Release the key as soon as the engine is running. NOTE: The key must be returned to position 0 in the ignition lock before repeating the starting procedure. If the display Á lights up alternately with î in the multi-function display, there is an immobilizer malfunction or the key used has not been programmed. The : engine oil level warning lamp and the # battery charge warning lamp must go out after the engine is started. If either lamp remains on, stop the engine at once and have the cause traced and repaired by an authorized Sprinter Dealer. During the trip, check the displays and the warning/ indicator lamps in the instrument cluster at regular intervals. Maximum Engine Speed The maximum engine speed for all vehicles is 4,200 rpm.

Constant RPMs (Optional) The switch for the Constant RPMs is located on the center section of the dashboard. Constant RPMs the engine-idling RPMs set working-RPM level and maintains this level regardless of work load.

increases to a

It can only be used when the vehicle is stationary, the parking brake is engaged and the gear selector level is in position "P".

STARTING AND OPERATING 143

Constant RPMs indicator lamp To switch it on: (cid:127) Press the top of the switch; the indicator lamp in the

switch and the constant RPMs indicator lamp will light up.

To switch off (cid:127) Press bottom of switch.

144 STARTING AND OPERATING

NOTE: The Constant RPMs will automatically switch off when the parking brake is released, the vehicle is in motion or the control unit detects a malfunction. The Constant RPMs will also automatically switch off when you depress the brake pedal. In this case it will automatically switch on again as soon as you release the brake pedal.

STOPPING THE ENGINE After having brought the vehicle to a stop: 1. Do not depress the accelerator pedal. 2. Apply the parking brake. 3. Turn the key back to position 0 in the ignition lock. NOTE: When the engine is very hot, such as after climbing a long steep slope, allow the engine to idle for 1 to 2 minutes so that it can return to its normal operating temperature.

AUTOMATIC TRANSMISSION

The automatic transmission selects individual gears automatically, dependent upon: (cid:127) Gear Selector lever position (cid:127) Accelerator position (cid:127) Vehicle speed The gear shifting process is continuously adapted, dependent on the driving style, the driving situation and the road characteristics. NOTE: When parking the vehicle or before working on the vehicle with the engine running, apply the parking brake and shift the gear selector lever into "P".

STARTING AND OPERATING 145

Driving The gear selector lever is automatically locked while in position "P". To move the gear selector lever out of position "P", the service brake is applied and the key in position 2 in the ignition lock or the engine running before the shift lock will release. Shift gear selector lever to the desired position only when the engine is idling normally and the service brake is applied. Do not release the brake until ready to drive. The vehicle may otherwise start creeping when the gear selector lever is in drive or reverse position.

WARNING!

It is dangerous to shift the gear selector lever out of "P" or "N" if the engine speed is higher than idle speed. If your foot is not firmly on the brake ped- al, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or something. Only shift into gear when the engine is idling normally and when your right foot is firmly on the brake pedal.

146 STARTING AND OPERATING

NOTE: After selecting any driving position from "N" or "P", wait a moment to allow the gear to fully engage before accelerating, especially when the engine is cold. Accelerator Position Partial throttle, for early upshifting and normal acceleration Full throttle, for later upshifting and rapid acceleration Kickdown, (depressing the accelerator beyond full throttle) for downshifting to a lower gear and maximum acceleration. Once the desired speed is attained, ease up on the accelerator, the transmission shifts up again. Stopping For brief stops, such as at traffic lights, leave the transmission in gear and hold vehicle with the service brake. For longer stops with the engine idling, shift into "N" or "P" and hold the vehicle with the service brake. When stopping the vehicle on an uphill grade, do not hold it with the accelerator, use the brake. This avoids unnecessary transmission heat build up.

Maneuvering To maneuver in tight areas, such as when pulling into a parking space, control the vehicle speed by gradually releasing the brakes. Accelerate gently and never abruptly step on the accelerator. To rock a vehicle out of soft ground (mud or snow), alternately shift from forward to reverse, while applying slight partial throttle.

WARNING!

Getting out of your vehicle with the gear selector le- ver not fully engaged in position "P" is dangerous. Also, when parked on an incline, position "P" alone may not prevent your vehicle from moving, possibly hitting people or objects. Always set the parking brake in addition to shifting to position "P". When parked on an incline, also turn front wheel against curb.

Gear Selector Lever Position

vPark Position

STARTING AND OPERATING 147

The park position is to be used when parking the vehicle. Engage only with the vehicle stopped. The park position is not intended to serve as a brake when the vehicle is parked. Rather, the driver should always use the parking brake in addition to placing the gear selector lever in park position to secure the vehicle.

NOTE: With a malfunction in the vehicle’s electrical system the gear selector lever could remain locked in position "P". To unlock the gear selector lever manually, refer to "Transmission Gear Selector Lever, Manually Unlocking". t Reverse Gear

Shift to reverse gear only with the vehicle stopped. s Neutral

No power is transmitted from the engine to the drive axle. When the brakes are released, the vehicle can be moved freely (pushed or towed). Do not engage "N" while driving as you may otherwise lose control of the vehicle.

The current gear selector lever position (1) is indicated in the gear range indicator display. The automatic gear shifting process can be adapted to specific operating conditions using the gear selector lever.

148 STARTING AND OPERATING

NOTE: Coasting the vehicle, or driving with gear selector lever in "N" can result in transmission damage that is not covered by the Sprinter Warranty. w The transmission automatically upshifts through 5th gear. Position "D" provides optimum driving characteristics under all normal operating conditions.

Gear Selection for Special Circumstances The transmission gear ranges for special circumstances can be selected by pushing the gear selector lever to the right or the left with the gear selector lever in position "D". The gear range currently selected is indicated in the instrument cluster display. Briefly press gear selector lever in the ç direction: The transmission downshifts, one gear range at a time, in the order "4", "3", "2", "1". Press and hold gear selector lever in the ç direction: The transmission will shift to a gear range which favorably accelerates or decelerates the vehicle. This way downshiftings can be caused.

Briefly press gear selector lever in the æ direction: The transmission will shift from the current gear range to the next higher gear range. If the transmission is already in gear range "D", an additional upshift of one gear is not possible. Press and hold gear selector lever in the æ direction: The transmission will shift from the current gear range directly to gear range "D".

WARNING!

On slippery road surfaces, never downshift in order to slow the vehicle down. This could result in drive wheel slip and reduced vehicle control. Your vehi- cle’s ABS will not prevent this type of loss of control.

NOTE: With transmission in gear range "D", "4" or "3", upshifting from 1st to 2nd to 3rd gear is delayed depending on vehicle speed and engine temperature. This allows the catalytic converter to heat up more quickly to operating temperatures. During the brief warm-up period this delayed upshift and increased engine noise might be perceived as a the engine nor malfunction. However, neither

lever

is moved to a

transmission are negatively affected by this mode of operation. The delayed upshift is effective with vehicle speeds below 31 mph (50 km/h) at partial throttle and engine temperatures below 95 °F (+35 °C). To avoid overrevving the engine when the gear selector lower gear, the transmission will not shift to a lower gear if the engine’s revolutions per minute limit would be exceeded. In this case there will be no downshift, even when the vehicle speed reaches the engine’s rpm limit of that gear, for example by applying the service brakes. To prevent the engine from laboring at low rpm when driving uphill grades or with your vehicle heavily loaded, the automatic transmission will downshift when necessary to maintain engine rpm within the best torque range.

STARTING AND OPERATING 149

Gear q Upshift through 4th gear only. Suitable for

performance driving.

p Upshift through 3rd gear only. Suitable for moderately steep hills. Since the transmission does not shift higher than 3rd gear, this gear selection will allow use of the engine’s braking power downhill.

o Upshift through 2nd gear only. For driving in extreme mountainous operating conditions. This gear selection will allow use of the engine’s braking power when descending steep grades.

regions or under

n Use this position, which makes maximum use of the engine’s braking effect, while descending very steep or lengthy downgrades and only at speeds below 25 mph (38 km/h).

150 STARTING AND OPERATING

TRANSMISSION SELECTOR LEVER, MANUALLY UNLOCKING

In the case of power failure the transmission selector lever can be manually unlocked (for vehicle towing). To do so, insert a pin (1) (ball point pen), into the covered opening below the position "D" of the shift pattern. While pushing the pin down, move selector lever from position "P". After removal of the pin from the opening, the cover will not close fully. Only after moving the selector lever to positions "D+" and "D–" does the cover return to its closed position.

N54.65-2043-20

Reversing Aid (Optional) 1. Reversing aid sensors The reversing aid monitors the rear area of the vehicle by means of four sensors in the rear bumper. The reversing aid automatically provides you with a visual and audible indication of the distance between your vehicle and an obstacle, when the key is in position 2 in the ignition lock and the reverse gear is engaged.

The system is operational if after reverse gear is engaged: (cid:127) an acknowledgement tone sounds (cid:127) the multi-function indicator shows the distance to

an obstacle that has been detected.

STARTING AND OPERATING 151

WARNING!

The reversing aid is feature designed to provide as- sistance and may not detect all obstacles. The sys- tem is not a replacement for your own diligence. The reversing aid does not detect people and/or objects within a range of approximately 12 in (30
cm). There is a possibility that certain objects which could come into contact with the vehicle at the rear will not be detected by the system’s sensors. This could cause an accident resulting in severe personal injuries, death and property damage. For this reason, you should make sure before manuevring that no people or animals are in the maneuvring range of the vehicle. Pay particular attention to people and/or objects above or below sensors when parking, such as small children, toddlers, flower pots or trailer towbars. You are always responsible for safety at all times and must continue to pay attention to your immediate surroundings when manoeuvring. A second person should assist you in manouevring if necessary.

152 STARTING AND OPERATING

WARNING!

Ultrasonic sources, such as the compressed-air brakes of heavy trucks, a car wash or a pneumatic drill, and other parts attached to the vehicle, such as load carriers, could cause the reversing aid to malfunction. The reversing aid sensors must not be scratched or damaged. They must be free from dirt, ice and slush, otherwise they might not function correctly. The rear area sensors will be restricted in all of these cases. This will increase the risk of damage to the vehicle or the object and the risk of injury to other persons. Clean the sensors regularly, taking care not to scratch or damage them.

N54.65-2044-20

N54.65-2045-20

Range of Sensors The sensors are able to detect a distance within a range of up to 70 in (180 cm) centrally or up to 40 in (100 cm) laterally behind the bumper.

For all sensors, the minimum distance between sensor and obstacle is 12 in (30 cm). In the event of a malfunction, a continuous warning signal sounds for approximately three seconds when the vehicle is reversing NOTE: Distance display – "in" in USA only – "cm" in Canada only

STARTING AND OPERATING 153

LOADING THE VEHICLE

WARNING!

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 and personal injury. In addition, braking and stopping distances can be significantly longer if the vehicle is overloaded.

WARNING!

Always close the sliding and rear doors when driving. Otherwise exhaust fumes could enter the vehicle interior and poison you.

154 STARTING AND OPERATING

WARNING!

Unsecured or poorly secured loads, and seats that have been removed, could move around the vehi- cle interior uncontrollably in the event of sudden braking, a rapid change in direction or an acci- dent. This increases the risk of injury to occu- pants in these situations. Secure and position a load as described in the following loading guidelines. Piling up heavy objects or placing them on upper shelves or loading them otherwise high up in the vehicle will significantly raise the center of gravity of the vehicle. Placing excessive loads on individual points of the load surface or behind the rear axle will also adversely affect the handling characteristics of your vehicle and may lead to loss of control over the vehicle. Road safety and tire durability are adversely affected if the permissible axle loads or gross vehicle weight are exceeded due to the vehicle’s load. Braking and stopping distances can be significantly longer.

The handling characteristics of a vehicle when laden are dependent on the type of load and the distribution of the load within the vehicle. Carrying heavy or bulky loads may alter the vehicle’s handling characteristic. Loading Guidelines Please note and comply with the following information when loading and transporting goods. (cid:127) Do not allow the load, including passengers, to exceed the permitted gross vehicle weight or the permitted axle loads for the vehicle. Bear in mind that the unladen weight could be increased by installing items of optional equipment and accessories.

(cid:127) Distribute the load uniformly. Excessive loads on individual points of the load surface could cause damage to the floor covering.

(cid:127) Transport heavy loads between the axles near the

rear axle as low as possible in the vehicle.

(cid:127) Secure any kind of load with sufficient wear and

tear-resistant load restraints. See tie-down rings.

(cid:127) Protect sharp edges with padding. (cid:127) Check the tire pressures after loading the vehicle. For passenger vans: (cid:127) Do not stack loads higher than the upper edge of the

backrests.

(cid:127) Always place the load against the backrests of the

seat benches.

(cid:127) Whenever possible, transport loads behind seats

that are not occupied.

(cid:127) Distribute the load in such a way that the permissible axle loads are not exceeded when the vehicle is equipped with the maximum number of seats. Loading the luggage compartment up to the maximum payload would cause the permissible rear axle load to be exceeded.

STARTING AND OPERATING 155

BRAKES Service Brake

WARNING!

When the engine is not running, the brake and steering systems are without power assistance. Under these circumstances, a much greater effort is necessary to stop or steer the vehicle. After driving in heavy rain for some time without applying the brakes or through water deep enough to wet brake components, the first braking action may be somewhat reduced and increased pedal pressure may be necessary. Be sure to maintain a safe distance from vehicles in front. Resting your foot on the brake pedal will cause excessive and premature wear of the brake pads. It can also result in the brakes overheating, thereby significantly reducing their effectiveness. It may not be possible to stop the vehicle in sufficient time to avoid an accident.

156 STARTING AND OPERATING

NOTE: On long and steep downhill slopes, reduce the load on the brakes by shifting down a gear to utilize the braking effect of the engine. To prevent corrosion on the brake pads, after driving on very wet roads, especially if road salts have been used, apply brakes before parking the vehicle. The heat generated will help to dry the brake disks.

Brake Pad Wear Indicator

When the key is turned to position 2 in the ignition lock, the indicator lamp 2 in the instrument cluster lights up for about 2 seconds. It must go out when the engine is running. If the 2 indicator lamp lights up while the engine is running, the brake pads are worn almost to their limit. Have the brake system examined as soon as possible by an authorized Sprinter Dealer.

STARTING AND OPERATING 157

If the indicator lamp does not go out after about 2 seconds, the brake fluid level has sunk below the minimum filling capacity. If the brake indicator lamp comes on while driving, the brake fluid level is below the minimum filling capacity or the electronic brake force distribution (EBD) is malfunctioning. For distribution, refer Distribution (EBD)".

force "Electronic Brake Force

the electronic brake

information on

to

Brake Indicator and Electronic Brake Force Distribution (EBD) Indicator Lamp

; USA only

3 Canada only

With the key in position 2 in the ignition lock and the parking brake released, the indicator lamp ; (3) lights up for about 2 seconds.

158 STARTING AND OPERATING

WARNING!

Driving with the brake indicator lamp ; (3) illuminated can result in an accident. There may be a malfunction in the brake system or in the electronic brake force distribution. The braking characteristics are affected and the vehicle could skid if it is braked hard. Have your brake system checked immediately if the brake indicator lamp ; (3) stays on. Do not add brake fluid before checking the brake system. Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts and the brake fluid catching fire. There is a risk of injury due to hot engine parts or hot steam.

NOTE: If you find that the minimum mark on the brake fluid reservoir is reached, have the brake system checked for pad thickness and leaks.

Parking Brake Indicator Lamp

With the key in position 2 in the ignition lock and the parking brake released, the indicator lamp lights up for about 2 seconds. If the parking brake is on, the indicator lamp not go out before the parking brake is released.

does

Parking Brake

Only apply the parking brake when the vehicle is stationary. To apply: Pull the lever up as many notches as possible. When the key is in position 2 in the ignition lock, the parking brake indicator lamp will light up in the instrument cluster.

STARTING AND OPERATING 159

To release: Lift the lever up slightly, press the button on the lever in and move the lever down to the stop. The parking brake indicator lamp

should go out.

WARNING!

Always fully apply the parking brake when leav- ing your vehicle, or vehicle may roll and cause damage or injury.

WARNING!

On uphill or downhill grades steeper than 15% the vehicle must be safeguarded. Vehicles which are not secured could roll away and result in se- vere personal injuries, death and property dam- age. Safeguard an unloaded vehicle by chocking the front axle. Safeguard a loaded vehicle by chocking the rear axle.

160 STARTING AND OPERATING

WARNING!

When leaving the vehicle always remove the key from the ignition lock, and lock your vehicle. Do not leave children unsupervised in the vehicle, even if they are secured by a child restraint system. The children could (cid:127) injure themselves on parts of the vehicle (cid:127) release the child-proof locks by pressing the central locking button and could thereby open the doors and

(cid:127) cause injury to others as a result (cid:127) get out of the vehicle and could either injure themselves when doing so or they could be injured by the traffic approaching from the rear (cid:127) suffer serious or fatal effects in the event of long

periods of hot weather

(cid:127) release the parking brake. The vehicle could

then start moving of its own accord.

Unsupervised use of vehicle equipment may cause severe personal injuries, death and property damage.

Driving Safety Systems The vehicle can be equipped with the following Driving Safety Systems: (cid:127) Anti-lock brake system (ABS) (cid:127) Electronic brake force distribution (EBV) (cid:127) Acceleration skid control (ASR) (cid:127) Brake assist system (BAS)1
(cid:127) Electronic stability program (ESP)* NOTE: The maximum effectiveness of ABS, EBV, ASR and ESP is only achieved if you drive with correct tire pressures and adjust tire pressures to correspond with the vehicle’s load. In winter operation, the maximum effectiveness of the ABS and the ESP is only achieved with winter tires (M+S tires), or snow chains as required.

WARNING!

The following factors increase the risk of acci- dents: (cid:127) Excessive speed, especially in turns (cid:127) Wet and slippery road surfaces (cid:127) Following another vehicle too closely The ABS, EBV, ASR, BAS and ESP cannot reduce this risk nor can they prevent the natural laws of physics from acting on the vehicle. Always adapt your speed and driving style to the prevailing road, traffic and weather conditions and maintain a safe distance between your vehicle and other road users as well as objects on the road.

STARTING AND OPERATING 161

Anti-Lock Brake System (ABS) Indicator Lamp

indicator

light up

lamp - will

When the key is in position 2 in the ignition lock, the ABS in the instrument cluster. It goes out after about 2 seconds. If the ABS indicator lamp - remains on or lights up when the engine is running, the ABS is malfunctioning. NOTE: If the voltage in the vehicle’s electrical system drops below 10 volts, the ABS indicator lamp - will also light up in the instrument cluster and the ABS will be deactivated. The indicator lamp will go out as soon

162 STARTING AND OPERATING

as the voltage reaches this level again – the ABS is then reactivated. If ABS malfunctions, the other driving safety systems are deactivated. The handling and braking characteristics of your vehicle change. The other braking and driving systems still function normally.

WARNING!

If the ABS indicator lamp - does not go out or lights up again while driving, the ABS is malfunc- tioning. If ABS malfunctions, the other driving safety systems are deactivated. The vehicle’s brak- ing characteristics may be affected. There is an in- creased risk that your vehicle could skid in the event of sharp braking. Have the malfunction traced and repaired without delay by an autho- rized Sprinter Dealer. Adapt your speed and driving style to the prevailing road, traffic and weather conditions. Driving too fast increases the risk of an accident.

Anti-Lock Brake System (ABS) ABS prevents the wheels from locking at any speed above about 5 mph (8 km/h), regardless of road surface conditions. The vehicle remains steerable even if the brakes are applied fully. A light vibrating of the steering wheel and pulsating of the brake pedal indicate that the ABS is working. On slippery road surfaces, the ABS will respond even with light brake pedal pressure because of the increased likelihood of locking wheels. The pulsating brake pedal can be an indication of hazardous road conditions and works as a reminder to take extra care while driving.

WARNING!

WARNING!

STARTING AND OPERATING 163

Do not reduce the force applied to the brake pedal if it is necessary to brake the vehicle further. This will negate the main benefit of ABS – the ability to brake without affecting the steerability of the vehicle. In the event of an emergency stop, fully depress the brake pedal. Do not pump the brake pedal, rather use firm, steady brake pedal pressure. Pumping the pedal defeats the purpose of ABS and significantly reduces braking effectiveness.

Anti-lock brake system (ABS) cannot prevent the natural laws of physics from acting on the vehicle, nor can it increase braking or steering efficiency beyond that afforded by the condition of the vehi- cle brakes and tires or the traction afforded. The ABS cannot prevent accidents, including those resulting from excessive speed in turns, following another vehicle too closely, or hydroplaning. Only a safe, attentive, and skillful driver can prevent accidents. The capabilities of an ABS equipped vehicle must never be exploited in a reckless or dangerous manner which could jeopardize the user’s safety or the safety of others. Adapt your speed and driving style to the prevailing road, traffic and weather conditions. Driving too fast increases the risk of an accident.

164 STARTING AND OPERATING

Electronic Brake Force Distribution (EBD) The electronic brake force distribution (EBD) prevents the rear wheels from being overbraked when there is little load on the rear axle or if there is not much friction between the tires and road (e.g., if the road is wet).

WARNING!

If the brake indicator lamp ; (-) does not go out or lights up again while driving, the brake fluid level may not necessarily have dropped be- low the minimum filling capacity but a malfunc- tion may have occurred in the EBD. In this case continue driving, but with even greater care. The wheels of the rear axle could lock if the vehicle is braked hard. This could lead to a skidding of the vehicle. Have the malfunction traced and repaired without delay by an authorized Sprinter Dealer. Adapt your speed and driving style to the prevailing road, traffic and weather conditions. Driving too fast increases the risk of an accident.

Acceleration Skid Control Indicator Lamp (ASR) and Brake Assist System (BAS)1 if equipped

When the key is in position 2 in the ignition lock, the indicator lamp k will light up in the instrument cluster as a function check. It goes out when the engine is running. 12500 Type vehicles only

STARTING AND OPERATING 165

WARNING!

If the indicator lamp k remains on, the acceler- ation skid control (ASR) or the brake assist system (BAS) is malfunctioning. Your vehicle’s handling characteristics can change. Drive with extra caution. Have the malfunction traced and repaired as soon as possible by an authorized Sprinter Dealer.

If the indicator lamp k remains on or lights up when the engine is running, the acceleration skid control (ASR) or the brake assist system (BAS) is malfunctioning. Then the ASR will be switched off automatically. NOTE: If the ABS is malfunctioning or the voltage in the vehicle’s electrical system drops below 10 volts, the indicator lamp k will also light up in the instrument cluster and the ASR and the BAS will be deactivated. The indicator lamp will go out as soon as the voltage reaches this level again or the ABS is operational again – the ASR and the BAS are then reactivated. If a malfunction is present in the acceleration skid control (ASR), the engine’s power output may be reduced.

166 STARTING AND OPERATING

Acceleration Skid Control (ASR) Warning Lamp and Electronic Stability Program (ESP)* – if equipped

When the key is in position 2 in the ignition lock, the warning lamp v in the speedometer will light up for about 2 seconds. It must go out when the engine is running. The warning lamp v flashes when: (cid:127) The ASR or ESP is activated. (cid:127) The drive wheels spin with the ASR shut off. *2500 type vehicles only

The warning lamp v lights up when the ASR is shut off. Deactivate the acceleration skid control, refer to "Deactivating Acceleration Skid Control (ASR)".

WARNING!

If the warning lamp v in the speedometer lights up or flashes: (cid:127) Do not deactivate the acceleration skid control

(ASR).

(cid:127) Only depress the accelerator pedal as far as

necessary when pulling away.

(cid:127) Ease off on the accelerator pedal when driving at

a steady speed.

(cid:127) Adapt your speed and driving style to the prevailing road, traffic and weather conditions. Failure to heed these warnings could cause the vehicle to enter a skid and may result in an accident.

Acceleration Skid Control (ASR) ASR makes it possible to pull away and accelerate on a slippery surface. A spinning wheel is braked and its tractive power is transferred to the wheel with full grip. The acceleration skid control (ASR) improves driving stability at all speeds only on vehicles of the chassis and cargo/passenger vans type 3500 C/HC/SHC (without ESP). The engine’s torque is limited to improve driving stability. When this is happening, the warning lamp v in the speedometer flashes. If the road surface is not capable of providing traction, bearing in mind the tires, load and grade, it may not be possible to pull away even with ASR. If wheels with tires of a different size than those offered by an authorized Sprinter Dealer are used, the correct operation of the ASR cannot be guaranteed.

STARTING AND OPERATING 167

WARNING!

ASR cannot prevent the natural laws of physics from acting on the vehicle, nor can it increase the traction afforded. The ASR cannot prevent accidents, including those resulting from excessive speed in turns, following another vehicle too closely, or hydroplaning. Only a safe, attentive, and skillful driver can prevent accidents. The capabilities of an ASR equipped vehicle must never be exploited in a reckless or dangerous manner which could jeopardize the user’s safety or the safety of others. If the ASR function is used for a prolonged period of time, the rear axle brakes may fail due to overheating. If the vehicle is to be towed away with the front wheels clear of the ground, or if the brakes are to be tested on a brake dynamometer, do not pull the key in position 2 in the ignition lock, because the drive wheels could lock.

168 STARTING AND OPERATING

Deactivating the Acceleration Skid Control (ASR) See Section 4, Understanding Your Instrument Panel, for switch locations.

When driving with snow chains, in deep snow, or on sand or gravel, it can be beneficial to deactivate the acceleration skid control (ASR). The engine’s torque is then no longer limited and the drive wheels are free to spin, which can help them cut into loose surfaces.

P54.25-0294-20

The ASR can only be shut off with the engine running. If the engine is shut off with the ASR deactivated, the ASR is automatically re-activated after the engine is started again.

WARNING!

On a slippery road surface if both drive wheels start to spin there is a risk of skidding. Adapt your speed and driving style to the prevailing road, traffic and weather conditions.

Vehicle Type 2500 only: If there is a danger of skidding, and/or starting at a speed of 38 mph (60 km/h) ESP activates ASR automatically.

WARNING!

Vehicle type 2500 only: Even when ASR is deactivated, ESP remains active and regulates braking to improve stability as necessary. The warning lamp v flashes in the speedometer. The danger of your vehicle’s brake system overheating and being damaged is increased during long, demanding application of the brakes. Furthermore, an overheated brake system could result in a longer stopping distance. Thus, only deactivate ASR if it is absolutely necessary.

To deactivate the ASR: – Press the upper section of the switch – the warning lamp v in the speedometer lights up. Traction control continues to cut in if, for example, a wheel on one side of the vehicle reaches its limit of adhesion. The wheel is then braked to increase the vehicle’s overall traction. The warning lamp v will flash in the speedometer at any speed when a tire reaches its limit of adhesion and spins. To activate the ASR: – Press the upper section of the switch again – the warning lamp v in the speedometer goes out.

STARTING AND OPERATING 169

Brake Assist System (BAS) (vehicle type 2500 only) The Brake Assist System (BAS) operates in emergency situations. If you apply the brakes very quickly, the BAS automatically provides full brake boost, thereby potentially reducing braking distance. Apply continuous full braking pressure until the emergency braking situation is over. The ABS will prevent the wheels from locking. When you release the brake pedal, the brakes function again as normal. The BAS is then deactivated.

WARNING!

If the indicator lamp k remains on, a malfunc- tion may not only have occurred in the ASR sys- tem but also in the BAS. The handling and braking characteristics of your vehicle change. Drive with extra caution. Have the malfunction traced and repaired as soon as possible by an authorized Sprinter Dealer.

170 STARTING AND OPERATING

For the indicator lamp k refer to "Indicator Lamp Acceleration Skid Control (ASR) and Brake Assist System (BAS)".

WARNING!

The Brake Assist system (BAS) cannot prevent the natural laws of physics from acting on the vehicle, nor can it increase braking efficiency beyond that afforded by the condition of the vehicle brakes and tires or the traction afforded. The BAS cannot prevent accidents, including those resulting from excessive speed in turns, following another vehicle too closely, or hydroplaning. Only a safe, attentive, and skillful driver can prevent accidents. The capabilities of an BAS equipped vehicle must never be exploited in a reckless or dangerous manner which could jeopardize the user’s safety or the safety of others. Adapt your speed and driving style to the prevailing road, traffic and weather conditions. Driving too fast increases the risk of an accident.

Indicator Lamp Electronic Stability Program (ESP) (vehicle type 2500 only)

When the key is in position 2 in the ignition lock, the ESP indicator lamp will light up in the instrument cluster as a function check. It goes out when the engine is running. If the indicator lamp remains on or lights up when the engine is running, the electronic stability program (ESP) off automatically. The engine’s power output may be then reduced.

is malfunctioning

switched

and

NOTE: If the ABS is malfunctioning or the voltage in the vehicle’s electrical system drops below 10 volts, the indicator lamp will also light up in the instrument cluster and the ESP will be deactivated. The indicator lamp will go out as soon as the voltage reaches this level again or the ABS is operational again – the ESP is then reactivated.

WARNING!

remains on, the If the ESP indicator lamp electronic stability program (ESP) is malfunction- ing. The vehicle stability will no longer be auto- matically regulated in good time. The danger that your vehicle breaks into a skid, is increased in certain driving situations. Drive with extra caution. Have the ESP repaired as soon as possible by an authorized Spinter Dealer.

STARTING AND OPERATING 171

Electronic Stability Program (ESP) (vehicle type 2500 only) The Electronic Stability Program (ESP) monitors the vehicle’s traction (force of adhesive friction between the tires and the road surface) and handling. The ESP recognizes when a wheel is spinning or if the vehicle starts to skid. By applying brakes to the appropriate wheel and by limiting engine output, the ESP works to stabilize the vehicle. The ESP is especially useful while driving off and on wet or slippery road surfaces. The warning lamp v in the speedometer flashes when the ESP is engaged, refer also to "Warning Lamp Acceleration Skid Control (ASR) and Electronic Stability Program (ESP)". If wheels with tires of a different size than those offered by an authorized Sprinter Dealer are used, the correct operation of the ESP cannot be guaranteed.

172 STARTING AND OPERATING

WARNING!

ESP cannot prevent the natural laws of physics from acting on the vehicle, nor can it increase the traction afforded. The ESP cannot prevent accidents, including those resulting from excessive speed in turns, following another vehicle too closely, or hydroplaning. Only a safe, attentive, and skillful driver can prevent accidents. The capabilities of an ESP equipped vehicle must never be exploited in a reckless or dangerous manner which could jeopardize the user’s safety or the safety of others. If the vehicle is to be towed away with the front wheels clear of the ground, or if the brakes are to be tested on a brake dynamometer, do not put the key in position 2 in the ignition lock because the ESP would engage the brakes to stabilize the vehicle. If the ESP function is used for a prolonged period of time, the rear axle brakes may fail due to overheating.

AUXILIARY DRIVE (OPTIONAL)

1. Auxiliary drive 2. Ribbed V-belt (not part of factory package) 3. Tensioner pulley 4. Support 5. Unit (not part of factory package) NOTE: When retrofitting a unit pay attention to the running direction of the engine.

CAUTION!

Break in new tires at moderate speeds for a distance of about 65 miles (about 100 km).

STARTING AND OPERATING 173

Power take off must not exceed 10 kW. Exceeding the power take off may cause damage to the auxiliary drive and/or ribbed V-belt.

STEERING When the engine is not running, there is no power assistance for the steering. Greater force will be required to steer the vehicle.

WHEELS AND TIRES Check tires regularly for even tread wear, tread depth (note legal requirements) and signs of external damage. Only use wheels and tires of the same size, make and pattern. Do not install tires that are not approved for the size and type of wheel installed or the vehicle itself. Only use those wheel sizes which were delivered to you by your authorized Sprinter Dealer. Use only wheels and tires which have been tested and approved by the vehicle manufacturer.

WARNING!

in

Fitting other wheel sizes to the vehicle will change the vehicle’s handling characteristics and may lead to an accident resulting in severe personal in- juries, death and property damage. Only certain tires meeting the tire size/load/speed rating specifications contained the Tire Pressure Tables at the end of this chapter 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. 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.

WARNING!

Sprinter tire valves are tested and approved under rough operating conditions. The installation of additional hub caps or other wheel simulators could cause damage to the tire valve and lead to a loss of tire pressure at the valve stem. Do not install any of these parts on your Sprinter vehicle. To help ensure safe and reliable operation of your Sprinter vehicle, only use parts and accessories tested and approved by the vehicle manufacturer for your Sprinter vehicle.

174 STARTING AND OPERATING

WARNING!

In order to avoid losing a wheel and in order to re- duce the risk of fatal or serious injuries or vehicle damage, please follow these safety instructions: (cid:127) Always replace wheel bolts that are damaged or

rusted.

(cid:127) 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. (cid:127) Be sure to use correct mounting bolts. Check tightness of wheel bolts or nuts regularly and retighten with a torque wrench, if necessary. Tighten wheel bolts or nuts in a cross-pattern sequence.

(cid:127) After changing a wheel, the wheel bolts or nuts must be tightened once the vehicle has been driven for about 30 miles (50 km).

If new or repainted wheels are fitted, the wheel bolts or nuts must be retightened again after about 600 to 3,000 miles (about 1,000 to 5,000 km).

Tire Grip Tire grip is greatly reduced on a wet or icy road. Speed 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 load

3,858 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 America

STARTING 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

3 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 . . . . . . . . . . . . . . . 212

196 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!