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If the rear cargo doors are opened to 90° (detent position), the rear lights will be concealed. The ve- hicle is then not sufficiently safeguarded at the rear and may only be seen by other road users when they are close to the vehicle. This could lead to an accident. The vehicle must then be clearly marked in accordance with state and local laws, e.g., with a warning triangle.
WARNING!
The spare wheel holder should be reattached once the wheel has been changed. Regularly check the spare wheel fastening. A loose spare wheel or spare wheel holder could be loosen or could move around the vehicle interior uncontrollably in the event of sudden braking, a rapid change in direction or an accident. This increases the risk of injury to vehicle occupants and other road users in these situations. Do not use retreaded/remolded tires. This process does not always permit previous damage to be detected. Therefore vehicle safety cannot be guaranteed if retreaded/remolded tires are fitted.
NOTE: Lug wrench and jack, refer to "Vehicle Tool Kit". For reasons of safety, check at regular intervals that the spare wheel is properly secured.
Spare Wheel Beneath the End of the Frame
Spare Wheel in Cargo Area (Optional)
WHAT TO DO IN EMERGENCIES 201
1. Open the rear cargo doors.
Retaining screws for the spare wheel structural member (1) Hook (2) 1. Open the cargo doors and remove the retaining screws (1) with the lug wrench from the vehicle tool kit.
2. Lift the spare wheel structural member, unhinge the hooks (2), and lower the spare wheel structural member. Remove the spare wheel.
202 WHAT TO DO IN EMERGENCIES
Spare Wheel Location for Chassis
2. Turn spare wheel holder to loosen. 3. Remove the spare wheel.
1. Loosen thumb nuts by hand and remove. 2. Use wrench to loosen fixing nut to the thread end. 3. Lift spare wheel holder. 4. Turn hooks to the side and lower spare wheel
holder. Remove the spare wheel.
WHAT TO DO IN EMERGENCIES 203
Using the Jack The jack is located together with the vehicle tool kit under the hatch in the front passenger footwell, refer to "Vehicle Tool Kit". 1. Loosen the wheel bolts before raising the vehicle. 2. Close the release valve on the jack. 3. Assemble the pump lever provided and insert it
into the socket on the jack.
4. Secure the lever by turning it clockwise in the
socket.
Position the jack under the appropriate jack point and raise the vehicle by pumping the lever.
JACK
WARNING!
To avoid the risk of serious or fatal injuries or vehicle damage, please bear the following points in mind: (cid:127) The jack is intended only for raising the vehicle briefly, for instance, when changing a wheel. If it is not designed to enable work to be carried out underneath the vehicle.
Do not crawl under the jacked-up vehicle. For work under the vehicle, stands must be used. (cid:127) The jack must be placed on a firm, flat surface only. (cid:127) Do not change wheels on uphill or downhill
gradients under any circumstances.
(cid:127) Make sure that no persons are present in the vehicle
when jacking up the vehicle.
(cid:127) Do not start the engine while the vehicle is raised. (cid:127) Make sure that the distance between the underside of the tires and the ground does not exceed 1.2 in (30
mm). Otherwise the vehicle may tip over.204 WHAT TO DO IN EMERGENCIES
Front Axle Jack Point (All Vehicles)
Rear Axle Jack Point for 8,550 lbs (3,880 kgs) (Vehicle type 2500 HC/SHC)
The vehicle longitudinal member in front of the front axle.
jacking point is located under the
The vehicle longitudinal member in front of the rear axle.
jacking point is located under the
CAUTION!
Do not position the jack at the leaf spring or the differential housing.
Rear Axle Jack Point for 9,990 lbs (4,530 kgs) (Vehicle type 3500 HC/SHC)
Rear Axle Jack Point for Chassis (Vehicle type 2500 C and 3500 C)
WHAT TO DO IN EMERGENCIES 205
The vehicle longitudinal member in front of the rear axle.
jacking point is located under the
The vehicle jacking point is locked next to the front recess for the leaf spring.
CAUTION!
CAUTION!
Do not position the jack at the leaf spring or the differential housing.
Do not position the jack at the leaf spring or the differential housing.
INSTALLING A WHEEL
206 WHAT TO DO IN EMERGENCIES
REMOVING A WHEEL 1. Loosen the wheel bolts. 2.
Jack up the vehicle until the wheel is clear of the ground.
3. Unscrew the wheel bolts and remove the wheel
(keep the wheel bolts clean).
NOTE: If the vehicle moves forwards or backwards while it is being jacked-up, lower it again and reposition the jack. When the vehicle is jacked-up, the jack must stand vertically (plumb-line).
Wheel bolts for pressed steel wheels (1) Wheel bolts for light-alloy wheels (Optional) (2)
WARNING!
WARNING!
WHAT TO DO IN EMERGENCIES 207
Incorrect mounting bolts or improperly tightened mounting bolts can cause the wheel to come off. To avoid the risk of serious or fatal injuries or ve- hicle damage, please bear the following points in mind: • Always replace wheel bolts that are damaged or rusted. • Never apply oil or grease to wheel bolts • If a wheel hub thread is damaged, you must not drive the vehicle. Consult a qualified specialist workshop.
Different wheel bolts are required for pressed steel and light-alloy wheels. Incorrect wheel lug bolts for the wheels could work loose, thereby causing you to lose control of the vehicle. This could cause an accident resulting in severe personal injuries and and property damage.
NOTE: The optional light alloy wheels are supplied with 5 short wheel lug bolts enclosed for the steel spare wheel in the vehicle tool kit. (cid:127) Before fitting the spare wheel, clean rust and dirt off the contact surfaces of the wheel and the wheel hub, and from the wheel bolts.
(cid:127) Note the specified wheel and tire size, tire load
capacity and speed code.
(cid:127) Do not change the tire’s direction of rotation. (cid:127) Do not damage, grease or oil wheel bolts or their
threads.
208 WHAT TO DO IN EMERGENCIES
Centering wheels with wheel bolts (cid:127) If dual assemblies are used, before placement the inner wheel should be inspected to ensure that all ball bearing rings are in proper position.
(cid:127) Install the wheel and snug the wheel bolts. (cid:127) Slightly tighten wheel bolts. (cid:127) Slowly open jack release valve to lower vehicle until
tire is resting on ground.
WARNING!
Do not tighten the wheel bolts and wheel nuts completely while the vehicle is still jacked up. The vehicle could tip.
(cid:127) Tighten the wheel bolts in a crosswise pattern to the
specified torque with a torque wrench. Tightening torque for 8,550 lbs (3,880 kgs) (vehicle type 2500 C/HC/SHC): Steel wheel – 177 lbf.ft ±7 lbf.ft (240 N.m ±10 N.m) Light alloy wheel – 138 lbf.ft ±14 lbf.ft (190 N.m ±20 N.m)
Tightening torque for 9,990 lbs (4,530 kgs) (vehicle type 3500 C/HC/SHC): Steel wheel – 138 lbf.ft ±14 lbf.ft (190 N.m ±20 N.m)
(cid:127) Remove jack and stow it in the vehicle tool kit. (cid:127) Check the tire pressure. (cid:127) Re-tighten the wheel bolts to the specified torque with a torque wrench after a distance of 30 miles (about 50 km).
WARNING!
After changing a wheel, you must, for safety reasons, (cid:127) have the specified tightening torque checked. The
wheels could otherwise work loose.
(cid:127) check the tire pressure and correct it if necessary. (cid:127) retighten the wheel bolts and wheel nuts to the specified tightening torque once the vehicle has been driven for 30 miles (50 km).
(cid:127) have a reversed direction of tire rotation corrected as soon as possible at a qualified specialist workshop. The vehicle handling characteristics could otherwise be affected.
WHAT TO DO IN EMERGENCIES 209
WARNING!
Battery fluid contains sulfuric acid. Do not allow this fluid to come in contact with eyes, skin or clothing. In case it does, immediately flush affect- ed area with water, and seek medical help. The battery housing could be damaged. Never lean over batteries while connecting or jump- starting. You might get injured. Read all instructions before proceeding.
JUMP STARTING If the battery is dead, the engine can be started with jumper cables from another vehicle’s battery.
WARNING!
A battery will produce hydrogen gas, which is flammable and very explosive. Avoid open flames and the formation of sparks in the vicinity of the batteries. Refrain from smoking or cell phone use. Avoid improper connection of jumper cables. Observe safety precautions when handling batteries. Exercise care near moving engine components and electrical cables. Failure to follow these directions will cause damage to the electronic components and can lead to a battery explosion and severe injury or death.
210 WHAT TO DO IN EMERGENCIES
(cid:127) A dead battery can freeze at a temperature of 14 °F (–10 °C). Never try to start the engine if the battery is frozen. Thaw the battery out first.
(cid:127) Only use a battery of the same rated voltage and of approximately the same capacity for jump-starting.
(cid:127) The two vehicles must not touch. (cid:127) Switch off all electrical accessories. (cid:127) Run the vehicle with the booster battery at idle. (cid:127) Connect the jumper cables in the sequence given in
the illustration.
1. First connect the positive terminals of the two batteries (see illustration, Items 1 + 2). Start with the booster battery.
2. Then connect the negative terminal of the vehicle with the booster battery to a vehicle ground point of the vehicle with the discharged battery, such as to the engine block (see illustration, Items 3 + 4). Start with the booster battery.
3. Start the engine in the customary manner. 4. Allow the engine to run for a short time. 5. Before disconnecting the jumper cables from the vehicle with the booster battery, switch on an electrical consumer (e.g. the blower, but not the lamps).
6. Disconnect the jumper cables in the reverse order to
that in which they were connected.
7. Disconnect
the
jumper cable
from negative terminal and vehicle ground point first (see illustration, items 3 + 4), then from positive terminals of the batteries (see illustration 1 + 2).
NOTE: Never try to start the engine with the aid of a battery quick-charge unit.
TOWING THE VEHICLE
WHAT TO DO IN EMERGENCIES 211
WARNING!
Do not tow the vehicle if the key cannot be turned in the ignition lock. If the key cannot be turned, the ignition lock re- mains locked and the vehicle cannot be steered. With the engine not running there is no power assistance for the braking and steering systems. In this case, it is important to keep in mind that a considerably higher degree of effort is necessary to brake and steer the vehicle. The vehicle must not be towed with the front axle raised and the key in position 2 in the ignition lock as the drive wheels could then lock due to the acceleration skid control (ASR) or the optional Electronic Stability Program (ESP)*.
*Vehicle Type 2500 only
212 WHAT TO DO IN EMERGENCIES
If the Engine is Damaged For towing distances up to 30 miles (about 50 km) (cid:127) Shift gear selector lever to "N" position. (cid:127) Do not exceed a towing speed of 30 mph (50 km/h). For towing distances greater than 30 miles (about 50 km) (cid:127) Remove the propeller shafts leading to the drive
axles. The vehicle can be towed without restriction.
If the Transmission is Damaged (cid:127) Remove the propeller shafts leading to the drive
axles.
If the Front Axle is Damaged (cid:127) Raise the front axle. (cid:127) Observe the same towing restrictions as for engine
damage.
If the Rear Axle is Damaged (cid:127) Raise the rear axle. NOTE: Comply with local legal regulations regarding towing vehicles.
MAINTAINING YOUR VEHICLE
CONTENTS
3 Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . 215
3 Sprinter Original Parts . . . . . . . . . . . . . . . . . . . . . . 217
3 Service Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
U Disposal of Service Products . . . . . . . . . . . . . . 2183 Emission Related Component Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3 Regular Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
U Windshield Washer System Fluid Reservoir . 219
U Air Filter Restriction Indicator (Optional) . . . 219
U Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
U Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 221
U Ribbed V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
U Hydraulic Brake System, ClutchMechanism Fluid Level . . . . . . . . . . . . . . . . . . . 222
U Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
U Engine Cooling System . . . . . . . . . . . . . . . . . . . 223U Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 223
U Checking Coolant Level . . . . . . . . . . . . . . . . . . 224
3 Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
U Disconnecting the Battery . . . . . . . . . . . . . . . . . 227
U Reconnecting the Battery . . . . . . . . . . . . . . . . . . 228
U Charging the Battery . . . . . . . . . . . . . . . . . . . . . 228
3 Replacing Wiper Blades . . . . . . . . . . . . . . . . . . . . . 230
U Appearance Care and Corrosion Protection . 231
U Power Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
U Automatic Car Wash . . . . . . . . . . . . . . . . . . . . . 233
U Tar Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
U Paintwork, Painted Body Components . . . . . . 233
U Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 233
U Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . 234
U Ornamental Moldings . . . . . . . . . . . . . . . . . . . . 234214 MAINTAINING YOUR VEHICLE
U Headlamps, Taillamps, Identification Lamps,
Turn Signal Lenses . . . . . . . . . . . . . . . . . . . . . . . 234
U Reversing Aid Sensors . . . . . . . . . . . . . . . . . . . . 235
U Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . 235
U Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
U Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . 236
U Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 236
U Steering Wheel and Gear Selector Lever . . . . 236
U Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
U Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
U Headliner and Shelf Below Rear Window . . . 237
U Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
U Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . 237
U Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . 238
3 Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
U Standard Fuse and Relay Equipment . . . . . . . 239
U Relay Assignment, Standard Equipment . . . . 242
U Fuse and Relay Optional Equipment . . . . . . . 2423 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 245
U Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . 245
U Taillamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
U License Plate Lamps(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252
U Additional Brake Lamp
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252
U Side-Mounted Turn Signals . . . . . . . . . . . . . . . 253
U Side-Marker Lamps,Standing Lamps (Optional) . . . . . . . . . . . . . . . . 253
U Identification Lamps (Cargo/
passenger vans only) . . . . . . . . . . . . . . . . . . . . . 254
U Interior Lighting in Passenger Compartment
and Load Compartment . . . . . . . . . . . . . . . . . . 254
U Interior Lighting with Reading Lamp . . . . . . . 255
U Interior Lighting with Interior SensorProtection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
U Exit Lamps (Optional) . . . . . . . . . . . . . . . . . . . . 256
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
U Recommended Fluids and Lubricants . . . . . . 258ENGINE COMPARTMENT
MAINTAINING YOUR VEHICLE 215
216 MAINTAINING YOUR VEHICLE
Legend For Engine Compartment 1. Windshield washer system fluid reservoir. 2. Maintenance indicator for air cleaner element
(Optional). 3. Oil dipstick. 4. Oil filler neck. 5. Ribbed V-belt.
Auxiliary drive (Optional) refer to “Auxiliary drive“.
6. Fuel filter with water separator. 7. Hydraulic brake fluid reservoir. 8. Coolant reservoir. 9. Battery
The auxiliary battery is located underneath the front passenger seat (optional equipment).
10. Fuse box
(These special fuses should only be replaced at by an authorized Sprinter Dealer).
SPRINTER ORIGINAL PARTS Every authorized Sprinter Dealer maintains a stock of Sprinter original parts for maintenance and repair work. Over 6,000 retailers around the world guarantee that you can be supplied with Sprinter original parts wherever you are. Over 300,000 different parts and assemblies, including parts for older vehicle models, are distributed from a central parts warehouse using an optimally tuned logistics concept. Sprinter original parts are subjected to the most stringent quality inspections and will ensure that the vehicle is maintained at a high level of operating efficiency and safety, and that it maintains its value. Each part has been specifically designed and manufactured or selected and approved for use in Sprinter vehicles. It is therefore best to use only Sprinter original parts. For cost-effective repairs in accordance with sound recycling principles, the use of non-genuine parts and accessories not authorized by the manufacturer could damage the vehicle or compromise its durability or safety. When ordering original parts, always provide the vehicle identification number and the engine number.
MAINTAINING YOUR VEHICLE 217
SERVICE PRODUCTS Mechanical elements and the lubricants used for them must be carefully matched. For this reason, only brands tested and approved by the manufacturer should be used. Please contact your Sprinter Dealer to obtain the necessary information. No lubricant additives should be used. The use of such additives could affect your warranty rights. Information is available from any authorized Sprinter Dealer. For specifications of engine oils, coolant and brake fluid, contact your authorized Sprinter Dealer.
WARNING!
If handled incorrectly, service products can consti- tute a health risk for people and an environmental hazard. Always observe relevant guidelines for handling, storing and disposing of service products.
218 MAINTAINING YOUR VEHICLE
Disposal of Service Products Dispose of service products and of parts which come into in an environmentally responsible manner. Comply with applicable bars and regulations.
contact with
filters)
them
(e.g.
EMISSION RELATED COMPONENT WARRANTY STATEMENT The Manufacturer warrants to the original and each subsequent owner of a Sprinter heavy-duty on highway diesel engine that: (1) the engine was designed, built and equipped so as to conform at the time of sale with the applicable regulations adopted by the Federal Environmental Protection Agency, and (2) the emission control system of such engine is free from defects in materials and workmanship which would cause it not to conform with those regulations for a period of use of five years or 100 000 miles or 3 000 hours of engine operation, whichever occurs first.
REGULAR CHECKS The following checks should be performed at regular intervals (for example once a week or each time the vehicle is refueled): (cid:127) Windshield cleaner system – fluid reservoir. (cid:127) Air strainer, in vehicles with an air strainer element
maintenance indicator (optional equipment).
(cid:127) Engine oil level. (cid:127) Checking ribbed V-belt. (cid:127) Hydraulic brake system, clutch mechanism fluid
level.
(cid:127) Coolant level. (cid:127) Tire and spare wheel condition and pressures of the same. For more information, refer to "Wheels and Tires".
(cid:127) Vehicle lighting.
Windshield Washer System Fluid Reservoir
Air Filter Restriction Indicator (Optional)
MAINTAINING YOUR VEHICLE 219
1. Washer system fluid reservoir When topping off, add windshield washer fluid ("S" for summer or "W" for winter) to the water. Capacity of fluid reservoir (1): about 7.4 US qt (7 liters).
The indicator on the air filter housing in the engine compartment shows the degree of contamination in the air filter element. If the red field reaches the 100 % range, the air filter element should be replaced as soon as possible.
220 MAINTAINING YOUR VEHICLE
Approved Engine Oils NOTE: Use only engine oils that are labeled on the container as meeting the specifications of API (American Petroleum Institute) and/or DaimlerChrysler specification sheets MB 228.3, 228.5, 229.3 and 229.5, such as MOPAR® SAE 15W-40 HD Diesel Engine Oil (e.g. MOPAR® Part No. 04798231AD), or equivalent. Always refer to the following viscosity chart for the proper viscosity grade based on ambient temperature. Select oil viscosity according to the lowest air temperature expected before the next oil change. For further information, contact your authorized Sprinter Dealer.
NOTE: This chart supercedes ALL previously published viscosity charts.
Engine Oil Level
1. Oil dipstick 2. Oil filler neck
MAINTAINING YOUR VEHICLE 221
Check the engine oil level at regular intervals with the vehicle standing on a level surface. (cid:127) Check engine oil level about 5 minutes after stopping the engine, which should have reached its regular operating temperature. The normal operating temperature should have been reached and maintained for some time.
(cid:127) Wipe the dipstick clean with a lint-free cloth before
checking.
The engine oil level must be between the lower (MIN) and upper (MAX) marks on the dipstick. Add engine oil only up to the MAX mark. Excess oil must be drained or siphoned off.
222 MAINTAINING YOUR VEHICLE
Ribbed V-Belt
Hydraulic Brake System, Clutch Mechanism Fluid Level
The ribbed V-belt drives the accessories, such as generator, coolant pump and hydraulic steering pump. The ribbed V-belt is automatically kept tensioned. Check the state of the ribbed V-belt regularly, such as at every engine oil level check. The belt must not be damaged, worn, oiled or glazed. There must be no cracks in the belt running surface. Replace damaged belts.
1. Brake fluid reservoir Brake fluid level must be between the MIN and MAX marks in the reservoir (1). If the brake fluid is below the MIN mark, there may be a fault in the hydraulic system. Have the system checked as soon as possible by an authorized Sprinter Dealer.
Brake fluid Refer to the "Recommended Fluids" chart later in this section for recommended brake fluids. In the course of its service life, the boiling point of the brake fluid will fall due to the continuous absorption of moisture from the atmosphere. If the brakes are placed under heavy loads (e.g., on steep hills) bubbles of steam can then form in the brake system. This will adversely affect the brakes' effectiveness. Engine Cooling System The use of aluminum components in Sprinter engines requires that anticorrosive/antifreeze specifically formulated to protect aluminum parts be used. The factory approved Service Products are suitable for Sprinter engines and can be mixed with the original anticorrosion/antifreeze filled in at factory. Cooling system design and anticorrosion/antifreeze agent used stipulate the replacement interval for the coolant solution in your vehicle. Please observe the replacement interval specified in the Service Booklet for your vehicle.
MAINTAINING YOUR VEHICLE 223
Failure to use MB 325.0 anticorrosion/antifreeze and/or equivalent to DaimlerChrysler material standard MS- 9769 and/or adhere to the specified replacement interval may result in a significantly shortened service life. For coolant composition and water quality, contact your authorized Sprinter Dealer. Engine Coolant The coolant is a mixture of water and a corrosion inhibitor/antifreeze additive. Within the cooling system, the corrosion inhibitor/antifreeze ensures (cid:127) anti-corrosion protection (cid:127) antifreeze protection (cid:127) a higher boiling point. The coolant added in the factory ensures adequate antifreeze and anti-corrosion protection. Refer to the "Recommended Fluids" chart for coolant recommendations. For reasons of anti-corrosion protection and to increase the boiling point, the coolant added to the cooling system is designed for all year round operation – even in countries with high prevailing temperatures.
224 MAINTAINING YOUR VEHICLE
Have the coolant renewed at least every 15 years or after 160,000 miles. When the coolant is renewed, the new coolant should contain 50% antifreeze/corrosion inhibitor by volume. This corresponds to antifreeze protection down to - 37 °C/-35°F. Do not exceed a proportion of about 55 % by volume (antifreeze protection down to about -45 °C/-49 °F) as the heat dissipation properties then deteriorate. In the event of coolant loss, do not add water only, but sufficient antifreeze/corrosion inhibitor to maintain the correct concentration. in the coolant must satisfy certain The water requirements. These are often met by tap supply drinking water. The water must be specially prepared if the water quality does not come up to the required standards. Have the corrosion inhibitor/antifreeze concentration in the coolant checked at the outset of winter, respectively once a year in countries with high prevailing temperatures.
A regular check is included in the maintenance service. Checking Coolant Level Coolant reservoir (1)
The cooling system is pressurized. Only check the coolant level with the vehicle parking on a level surface and with the engine switched off. – Wait until the coolant temperature has dropped
below 194 °F (+90 °C).
WARNING!
WARNING!
MAINTAINING YOUR VEHICLE 225
compartment, or
In order to avoid any possibly serious burns: (cid:127) If you see flames or smoke coming from the engine coolant temperature gauge indicates that the engine is overheated, do not open the hood. Move away from the vehicle and do not open the hood until the engine has cooled. If necessary, call the fire department.
the
if
(cid:127) Do not remove pressure cap on coolant reservoir if engine temperature is above 194 °F (+90 ×C). Allow engine to cool down before removing cap. The coolant reservoir contains hot fluid and is under pressure.
(cid:127) Using a rag, slowly open cap approximately 1/2
turn to relieve excess pressure. If opened immediately, scalding hot fluid and steam will be blown out under pressure.(cid:127)Do not spill antifreeze on hot engine parts. Anti- freeze contains ethylene glycol which may burn if it comes into contact with hot engine parts.
(cid:127) Check coolant level only with the engine switched off and the key in position 0 in the ignition lock.
(cid:127) Open the hood. (cid:127) At first, only turn the radiator cap to the first detent to release the pressure from the cooling system. Only then should the radiator cap be removed completely.
(cid:127) To add coolant:
If the engine is cold: Add coolant until the coolant level reaches the base area which is visible through the filler opening (area moistened).
226 MAINTAINING YOUR VEHICLE
If the engine is already at its regular operating temperature: Add coolant until the coolant level is about 0.6 inch (1.5 cm) above the base area which is visible through the filler opening.
(cid:127) Replace and tighten the radiator cap. If a large quantity of coolant has been lost, or if smaller amounts are lost at regular intervals, have the engine cooling system examined by an authorized Sprinter Dealer. For coolant composition and water quality, contact your Sprinter Dealer.
WINTER OPERATION Have your vehicle winterized by an authorized Sprinter Dealer before the onset of winter. (cid:127) Have the engine oil changed, if the engine oil filled
is not approved for winter use.
(cid:127) Coolant: antifreeze/anti-corrosion concentration in
the coolant checked.
(cid:127) Windshield washer system: add winter concentrate
to the washer fluid.
(cid:127) Battery:
the battery will
lose capacity as temperatures drop. Only a well-charged battery will ensure reliable engine starting even at low outside temperatures.
(cid:127) Tires: fit M+S radial tires, taking note of the
maximum permissible speed of the tires fitted.
BATTERIES
WARNING!
Failure to follow these instructions can result in severe personal injuries and death. Never lean over batteries while connecting, you might get injured, if the battery explodes. Battery fluid contains sulfuric acid. Do not allow this fluid to come in contact with eyes, skin or clothing. In case it does, immediately flush affected area with water and seek medical help if necessary. A battery will also produce hydrogen gas, which is flammable and explosive. Keep flames or sparks away from battery, avoid improper connection of jumper cables, smoking etc.
Use only impact-resistant batteries with a central gas release cover to prevent corrosion damage and to prevent occupants from caustic burns in the event of an accident.
The standard battery compartment.
is
located
in the engine
MAINTAINING YOUR VEHICLE 227
The auxiliary battery is located underneath the front passenger seat (optional equipment). The battery will not achieve its maximum service life unless it is kept adequately charged at all times. If the vehicle is used primarily for short distances, or left parked for lengthy periods, have the battery charge checked more frequently. Disconnecting the Battery
CAUTION!
Do not loosen or remove the battery terminal clamps while the engine is running or the key is in the ignition lock as this could damage electrical or electronic equipment beyond repair. All electrical consumers must be switched off. Do not place any metal objects on the battery. Doing so may cause a short-circuit. Loosen and remove the negative terminal clamp first, then the positive terminal. Afterwards disconnect vent tube from the fitting.
228 MAINTAINING YOUR VEHICLE
Reconnecting the Battery
1. Vent tube 2. Fitting All electrical consumers must be switched off. First connect and tighten the positive terminal clamp, then the negative terminal. Make sure that the terminal clamps are not switched. NOTE: If batteries have to be replaced, only use batteries with a central vent cap as this will prevent corrosion damage. Connect the battery vent tube (1) to the fitting (2).
Charging the Battery Disconnect the battery before charging it with a battery charger. Comply with the operating instructions for the battery charger. To ensure that the battery is disposed of in an environmentally responsible manner, it should only be replaced by an authorized Sprinter Dealer. Batteries contain material environment with improper disposal. Large 12 volt storage batteries contain lead. Recycling of batteries is the preferred method of disposal. Many states require sellers of batteries to accept old batteries for recycling.
that can harm
the
WARNING!
(cid:127) Use only refrigerants and compressor lubricants approved by the manufacturer for your air conditioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. Refer to Section 3 of the Warranty Information Book for additional warranty information.
(cid:127) The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.
MAINTAINING YOUR VEHICLE 229
Refrigerant Recovery and Recycling R-134a Air Conditioning Refrigerant hydrofluorocarbon (HFC) that is endorsed by the Environmental Protection Agency and is an ozone- saving product. However, the manufacturer recommends service be performed by dealers or other service facilities using recovery and recycling equipment.
that air conditioning
is
230 MAINTAINING YOUR VEHICLE
REPLACING WIPER BLADES
1. Fold over the wiper arm (2) and place the wiper
blade crosswise.
2. Press the retaining spring (1) and push the wiper
blade out of the end of the wiper arm (2).
3. Remove the wiper blade.
4.
Insert the end of the wiper arm (2) into the larger cutout (3) of the wiper blade.
5. Push the wiper blade into the end of the wiper
arm (2) until the retaining spring (1) engages.
Appearance Care and Corrosion Protection
WARNING!
Many cleaning products can be hazardous. Some are poisonous, others are flammable. Always keep cleaning products sealed and out of the reach of children. Always follow the instructions on the particular container. Always open your ve- hicle’s doors or windows when cleaning the in- side. Never use fluids or solvents that are not designed for cleaning your vehicle. Do not use fuel as a cleaning agent. Fuel is flammable and constitutes a health hazard.
In operation, your vehicle is subjected to varying external influences which, if gone unchecked, can attack the paintwork as well as the underbody and cause lasting damage. Such damage is caused not only by extreme and varying climatic conditions, but also by air pollution, road salt, tar, gravel and stone chipping. Grease and oil, fuel, coolant, brake fluid, bird droppings, insects,
MAINTAINING YOUR VEHICLE 231
tree resins etc. should be removed immediately to avoid paint damage. Frequent washing reduces and/ or eliminates the aggressiveness and potency of the above adverse influences. More frequent washings are necessary to deal with unfavorable conditions; for example operation near the ocean, in industrial areas (smoke, exhaust emissions), or during the winter months. You should check your vehicle from time to time for stone chipping or other damage. Any damage should be repaired as soon as possible to prevent the start of corrosion. In doing so, do not neglect the underside of the vehicle. A prerequisite for a thorough check is a washing of the underbody followed by a inspection. Damaged areas need to be undercoated again. Your vehicle has been treated at the factory with a wax- base rustproofing in the body cavities which will last for the lifetime of the vehicle. Post-production treatment is neither necessary nor recommended by DaimlerChrysler Corporation.
thorough
232 MAINTAINING YOUR VEHICLE
Because of the possibility of incompatibility between materials used in the production process and others applied later.
Power Washer When using a power washer for cleaning the vehicle always observe manufacturers’ operating instructions.
CAUTION!
The intense jet of water of a round nozzle can result in damage to the tire. Therefore never use a round nozzle to power wash tires. Always replace a damaged tire. Always keep the jet of water moving across the surface. To avoid damaging the vehicle, do not aim the water jet directly at electrical components, end of electrical lines, electrical connectors, intake or ventilation openings, brake hoses, door joints, seals, other rubber parts.
WARNING!
Never use openings in the bodywork as steps. You could otherwise damage the vehicle and it could lead to an accident.
CAUTION!
Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.
Scratches, corrosive deposits, corrosion or damage due to negligent or incorrect care cannot always be removed or repaired with car-care products. In such cases it is best to seek aid by your authorized Sprinter Dealer. The following topics deal with the cleaning and care of your vehicle and give important "how-to" information as well as references to car-care products.
Automatic Car Wash If the vehicle is very dirty, prewash it before you drive into the car wash.
WARNING!
Smears impair visibility, which is impaired fur- ther by unfavourable conditions (e.g. fog, dark- ness, driving snow). If a wax preservative is sprayed on after washing the vehicle, wipe off the wax from the windshield and the wiper blade rubbers. This will prevent smears forming on the windshield.
Fold in the exterior mirrors before washing the vehicle in an automatic car wash and make sure that the windshield wiper switch is in position 0. The exterior mirrors and windshield wipers could otherwise be damaged. Make sure that mirrors are fully folded out after leaving the automatic car wash.
MAINTAINING YOUR VEHICLE 233
tar remover
to remove. A
Tar Stains Quickly remove tar stains before they dry and become more difficult is recommended. Paintwork, Painted Body Components Paint care should be applied when water drops on the paint surface do not "bead up", normally every 3 to 5 months, depending on climate and washing detergent used. Paint cleaner should be applied if paint surface shows signs of dirt embedding (i.e. loss of gloss). Do not apply any of these products or wax if your vehicle is parked in the sun or if the hood is still hot. Use the appropriate paint stick for quick and provisional repairs of minor paint damage (i.e., chips from stones, vehicle doors etc.). Engine Cleaning Prior to cleaning the engine compartment, make sure to protect electrical components and connectors from the intrusion of water and cleaning agents.
234 MAINTAINING YOUR VEHICLE
Corrosion protection, such as anticorrosion wax should be applied to the engine compartment after every engine cleaning. Before applying, all control linkage bushings and joints should be lubricated. The poly-V-belt and all pulleys should be protected from any wax. Vehicle Washing Do not use hot water or wash your vehicle in direct sunlight. Use only a mild car wash detergent. Thoroughly spray the vehicle with a diffused jet of water. Direct only a very weak spray towards the ventilation intake. Use plenty of water and rinse the sponge and chamois frequently. Rinse with clear water and thoroughly wipe dry with a chamois. Do not allow cleaning agents to dry on the finish. Due to the width of the vehicle, prior to running the vehicle through an automatic car wash, fold back the outside mirrors from getting damaged. In the winter, thoroughly remove all traces of road salt as soon as possible.
to prevent
them
When washing the underbody, do not forget to clean the inner sides of the wheels.
WARNING!
Dirty or iced-up steps and entrances create a risk of slipping or falling. Keep steps, entrances and footwear free from dirt (e.g. mud, clay, snow and ice).
Ornamental Moldings For regular cleaning and care of very dirty chrome- plated parts, use a chrome cleaner. Headlamps, Taillamps, Identification Lamps, Turn Signal Lenses Use a mild car wash detergent with plenty of water. To prevent scratches, never apply strong force and use only a soft, non-scratchy cloth when cleaning the lenses. Do not attempt to wipe dirty lenses with a dry cloth or sponge.
MAINTAINING YOUR VEHICLE 235
Window Cleaning Use a window cleaning solution on all glass surfaces. An automotive glass cleaner is recommended.
N54.65-2046-20
Reversing Aid Sensors Use a mild car wash detergent with plenty of water. To prevent scratches, never apply strong force and use only a soft, non-scratchy cloth when cleaning the sensors. Do not attempt to wipe dirty sensors with dry, coarse or hard cloths and do not scrub. You will otherwise scratch or damage the sensors. If you clean the sensors using a high-pressure cleaner, only direct it at the sensors for a short period and maintain a minimum distance of 4 in (10 cm) from the sensors.
There are 2 steps in the front bumper. This makes it easier to clean the windshield.
236 MAINTAINING YOUR VEHICLE
WARNING!
For safety reasons, remove key from ignition lock before cleaning the windshield, otherwise the wiper motor can suddenly turn on and cause in- jury. Dirty or iced-up steps create a risk of slipping or falling. Do not use the step in the front bumper when it is icy or dirty.
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 OilSAE
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-40MB 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
229.3Long 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 MX15W-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-4015W-40
15W-40228.3
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
229.3228.3
228.3260 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-405W-40
10W-30
15W-40
0W-30228.3
228.5
228.3
229.3
229.3
228.3
228.3
228.3
228.3
228.3229.3
228.3
228.3
229.3Other 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 3353Transmission 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 equivalentMB SHEET
325.0
236.3
235.0
235.6MAINTENANCE SCHEDULES
CONTENTS
3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3 Maintenance - Without ASSYST MaintenanceComputer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
U Maintenance Intervals . . . . . . . . . . . . . . . . . . . . 2653 Maintenance - With ASSYST Maintenance
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3 Regular Check-Ups. . . . . . . . . . . . . . . . . . . . . . . . . 2663 Special Maintenance Requirements . . . . . . . . . . . 267
U Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
U Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
U Dust Filter for Heating/VentilationReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . 270M
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,
