INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

UNDERSTANDING THE FEATURES OF YOUR VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

UNDERSTANDING YOUR INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

STARTING AND OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

WHAT TO DO IN EMERGENCIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

MAINTAINING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

IF YOU NEED CONSUMER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

TABLE OF CONTENTS

PAGE

Table of Contents

Chapters

Table of Contents

Summary of Contents for Dodge 2005 Sprinter

Page 1 SECTION INTRODUCTION ................3 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE .
Page 3: Table Of Contents
CONTENTS Introduction....... . . 4 How to Use this Manual ..... . 5 Warnings and Cautions .
Page 4: Introduction
4 INTRODUCTION INTRODUCTION This manual provides information needed to operate and understand the vehicle and its components. Additional detailed information is contained in the Owner’s Warranty Information Book and the Sprinter Service Booklet. WARNING! Be sure to read the Operating Instructions. Other- wise you may not be aware of certain risks and could injur yourself or others.
Page 5: How To Use This Manual
HOW TO USE THIS MANUAL Consult the table of contents to determine which section contains the information you desire. The detailed index, at the rear of this manual, contains a complete listing of all subjects. WARNINGS AND CAUTIONS This manual contains WARNINGS against operating procedures which could result in an accident or bodily injury.
Page 6: Vehicle Safety Certification Label, Sample
6 INTRODUCTION Vehicle identification number (location: on the chassis, right hand). VEHICLE SAFETY CERTIFICATION LABEL, SAMPLE AND LOCATION Location: below the driver’s seat on an outward facing position of the mounting pillar. 1. Incomplete vehicle certification label for chassis/cab. 2. Type plate (vehicle identification...
Page 7: And Location
Sample Incomplete Vehicle Certification Label (Label 1) Sample Type Plate (Label 2) VEHICLE/ENGINE EMISSION LABEL, SAMPLE AND LOCATION Location: on valve cover of the engine Sample: Important Engine Information This is a LOW EMISSION VEHICLE engine and meets all applicable requirements of US EPA CFFV as “ILEV”...
Page 8: Environmental Concerns And Recommendations
8 INTRODUCTION ENVIRONMENTAL CONCERNS AND RECOMMENDATIONS In this manual, whenever you see instructions to discard materials, you should first attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials. DRINKING ALCOHOL OR TAKING DRUGS WHILE DRIVING WARNING! Drinking or taking drugs and driving can be a...
Page 9: Information Regarding Electronic
INFORMATION REGARDING ELECTRONIC RECORDING DEVICES (Including notice pursuant to California Code § 9951) Please note that your vehicle is equipped with devices that can record vehicle systems data. This information helps, for example, to diagnose vehicle systems after a collision and to continuously improve vehicle safety.
Page 11 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE CONTENTS Ignition Lock/Starter Switch ....13 Immobilizer ......14 Central Locking (Optional) .
Page 12 12 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Seat Belts ........41 Seat Belt Warning Lamp and Airbag Malfunction .
Page 13: Ignition Lock/Starter Switch
IGNITION LOCK/STARTER SWITCH 0 The steering wheel is locked when the key is removed To remove the key, place the gear selector lever in position "P"; rotate the key in the ignition lock to position 0; and remove the key. 1 The steering wheel is unlocked 2 Preheating and driving position 3 Start position...
Page 14: Immobilizer
14 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Immobilizer The immobilizer is automatically activated when the key is removed from the ignition lock. The engine cannot be started. As soon as the correct key is inserted into the ignition lock, the immobilizer is deactivated. For notes on the remote keyless entry, refer to "Remote Keyless Entry".
Page 15: Central Locking (Optional)
CENTRAL LOCKING (OPTIONAL) To unlock (1) To lock (2) CAUTION! An unlocked vehicle is an invitation to thieves. Always remove the key from the ignition and lock all doors when leaving the vehicle unattended. THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 15 WARNING! For personal security and safety in the event of an accident, lock the vehicle doors when you drive...
Page 16: Unlocking
16 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 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 •...
Page 17: U Central Locking Switch
After the engine is started (about 1 second), all doors with the exception of the driver-side door are locked automatically. CAUTION! In case of an accident, rescue from the outside may be more difficult if the vehicle is locked. To unlock the vehicle after the engine is started, "...
Page 18: U Locking Status Display
18 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 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 •...
Page 19: Locking And Unlocking
Locking and Unlocking To lock entire vehicle: Press top of central locking switch. The left and the right indicator lamp in the switch illuminate. If one of the two indicator lamps blinks, at least one door is not closed properly. To unlock entire vehicle: Press top of central locking switch again.
Page 20: Remote Keyless Entry (Optional)
20 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE flashes four times. Automatic locking when the engine is started is switched on (standard setting). NOTE: A door which is closed after the engine has been started will not be locked automatically. CAUTION! In case of an accident, rescue from the outside may be more difficult if the vehicle is locked.
Page 21: Unlocking With Remote Keyless Entry
The remote keyless entry transmitter transmits in all directions. It does not have to be pointed at the vehicle. Do not expose the remote keyless entry transmitter to high levels of electromagnetic radiation in order to avoid the risk of malfunctions. The remote keyless entry transmitter has an average range of about 32 ft (about 10 m).
Page 22: Locking With Remote Keyless Entry
22 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Press the Œ button a second time. The passenger door and cargo doors are unlocked and the turn signal lamps, as well as the remote keyless entry transmitter indicator lamp, blink once again. The button must be pressed a second time within about 2.5 seconds, otherwise the second request to open can not be performed.
Page 23: Security System With Towing And Passenger Compartment Protection (Optional)
Replacing Batteries 3. Remove the battery and install new one (note correct polarity; positive terminal up). 4. Press on the battery cover until it snaps into place. THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 23 SECURITY SYSTEM WITH TOWING AND PASSENGER COMPARTMENT PROTECTION Rated voltage: 6 V (OPTIONAL)
Page 24: Audible Alarm
24 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE The alarm is triggered if the security system has been activated and • A door is opened, • a door is unlocked from inside, • the engine cover is opened, • the key is used to unlock the vehicle at any door, •...
Page 25: Passenger Compartment Protection
1. Place the key in position 0 or 1 in the ignition lock. 2. Press the switch up (1) to switch off the towing protection. The indicator lamp (2) is briefly illuminated. If passenger compartment protection will be switched off as well, wait until the indicator lamp (2) goes out, 3.
Page 26: Alarm Pushbutton
26 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 3. Press switch up (1). The indicator lamp (2) is briefly illuminated. To activate the setting (passenger compartment/ towing protection switched off): 4. Lock the vehicle using the remote keyless entry transmitter. The passenger compartment protection will remain switched off until the vehicle is locked again with the remote keyless entry transmitter.
Page 27: Opening/Closing Doors
The vehicle will be centrally locked if all doors are closed. Switching Off the Alarm and Unlocking the Vehicle Press the alarm pushbutton up one more time. The vehicle will be centrally unlocked if it was not centrally locked before the alarm was manually triggered.
Page 28 28 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE WARNING! Only drive with the doors properly closed. You could lose the load, for example, and endanger ve- hicle occupants or other road users if the doors are open. Only open the doors when road and traffic conditions permit.
Page 29 From the Inside To unlock (1) To lock (2) To unlock and open Pull handle. To lock: Press the handle in. All closed doors will be locked. The door is locked when the white patch in the handle can be seen. If an open door is detected, refer to "Central Locking".
Page 30: Sliding Door
30 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Sliding Door WARNING! Only drive with the doors properly closed. You could lose the load, for example, and endanger ve- hicle occupants or other road users if the doors are open. To prevent possible personal injury, always keep hands and fingers away from the door opening when closing a door.
Page 31 From the Inside without Lock Button To unlock (1) To lock (2) To unlock and open: Pull handle. To lock: Press the handle in. The door is locked when the white patch in the handle can be seen. If an open door is detected, refer to "Central Locking".
Page 32 32 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Press lock button (1) (all doors are locked) If the central locking automatically unlocks again after having been locked, at least one door is closed incorrectly. If it then locks again within about 5 seconds, then all closed doors are locked.
Page 33: Rear Cargo Doors
Rear Cargo Doors WARNING! Only drive with the doors properly closed. You could lose the load, for example, and endanger ve- hicle occupants or other road users if the doors are open. To prevent possible personal injury, always keep hands and fingers away from the door opening when closing a door.
Page 34 34 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE From the Inside without Lock Button To unlock and open: Pull handle. To lock: Press the handle in. The door is locked when the white patch in the handle can be seen. If an open door is detected, refer to "Central Locking".
Page 35 If the central locking automatically unlocks again after having been locked, at least one door is closed incorrectly. If it then locks again within about 5 seconds, then all closed doors are locked. The central locking displays vehicle locking with one or more open doors by means of a special function sequence (locking, unlocking, locking).
Page 36 36 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE To lock manually: Move the handle down until it is in the vertical position. Automatic locking: If the left-hand door is closed, it will be automatically locked as soon as the right-hand door has been closed. NOTE: If an open tailgate is locked before being closed, then only the tailgate will be locked.
Page 37: Passenger/Cargo Area Door
To close: Pull the doors away from the retaining plates on the outer sidewalls. THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 37 Passenger/Cargo Area Door WARNING! Always drive with the doors properly closed, be- cause if the vehicle is operated with the doors open, serious personal injury may result.
Page 38 38 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE To Unlock the Door from the Passenger Area To unlock, turn key to left (1) To open door (2) To close door and lock (3) To Unlock the Door from the Cargo Area (Optional) To unlock, press latch in direction (1) To open door (2) To close door and lock (3)
Page 39: Occupant Restraints
OCCUPANT RESTRAINTS Seat belts, belt tensioners, airbag and child restraint systems are independent restraint systems whose functions complement each other. All states and provinces require use of child restraints that comply with U.S. Federal Motor Vehicle Safety Standard 213 and Canadian Motor Vehicle Safety Standard 213.
Page 40 40 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE WARNING! Airbag and belt tensioners are designed to func- tion on a one-time-only basis. An airbag or belt tensioner that was activated must be replaced. An airbag system component integrated in the steering wheel gets hot after the airbag has inflated.
Page 41: Things To Know Before Starting Your Vehicle
WARNING! Children should never ride sitting on the lap of another occupant. In an accident they will be com- pletely without protection and could even be in- jured by the person they are sitting on. For the safety of all occupants read the child restraint sys- tem manufacturer’s instructions carefully when fitting any child restraint system.
Page 42 42 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE WARNING! Wear your seat belt snugly. A belt that is worn under your arm is very dangerous. Your body could strike the inside surfaces of the vehicle in a collision, increasing head and neck injury. A belt worn under the arm can cause internal injuries.
Page 43 WARNING! Never ride in a moving vehicle with the backrest reclined. Sitting in an excessively reclined posi- tion can be dangerous. You could slide under the seat belt in a collision. If you slide under it, the belt would apply force at the abdomen or neck. This could result in severe personal injuries and death.
Page 44: Malfunction
44 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Seat Belt Warning Lamp and Airbag Malfunction When the key is in position 2 in the ignition lock, the warning lamp < lights up for about 6 seconds; this takes place whether or not the driver’s seat belt is fastened.
Page 45: Fastening And Removing
Fastening and Removing Belt tongue (1) Belt buckle (2) Release button (3) THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 45 Fastening Seat Belts 1. Pull the seat belt over the body. The seat belt must not be twisted or you could be injured. 2.
Page 46: Belt Height Adjustment
46 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Removing Seat Belts 1. Press the release button in the belt buckle. 2. Guide the seat belt back to its rest position. WARNING! A frayed or torn belt could rip apart in a collision and leave you with no protection.
Page 47: Driver's Airbag
DRIVER’S AIRBAG The driver’s airbag is located within the padded center of the steering wheel. THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 47 WARNING! To reduce the risk of injury when the front airbag inflates, it is very important for the driver to al- ways be in a properly seated position and to wear the seat belt.
Page 48: Front Seat Passenger Airbag (Not In Conjunction With Folding Seat In Partition Wall)
48 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE FRONT SEAT PASSENGER AIRBAG (NOT IN CONJUNCTION WITH FOLDING SEAT IN PARTITION WALL) WARNING! To reduce the risk of injury when the front airbag inflates, it is very important for the driver to al- ways be in a properly seated position and to wear the seat belt.
Page 49: Airbag And Belt Tensioners
AIRBAG AND BELT TENSIONERS The vehicle is equipped with an airbag for the driver and the front seat passenger as well as belt tensioners for the driver and the front passenger. The system is known as a Supplemental Restraint System (SRS). It has been designed to work together with the seat belt and to supplement.
Page 50: Safety Precautions For The Airbag
50 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE Safety Precautions for the Airbag WARNING! Airbags can seriously injure or kill you, especially if you are close to the airbag when it deploys. Always wear your seat belt. Airbags do not replace seat belts but instead supplement the protection offered by seat belts.
Page 51 WARNING! Do not attempt to manually open the front airbag covers. You may damage the airbags and you could be injured because the airbags may not function as designed. These protective covers for the airbag cushions are designed to open only when the airbags are inflating.
Page 52: Pedals
52 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE PEDALS The freedom of movement of the pedals must not be impaired in any way, such as by floormats. WARNING! Do not lay any objects in the driver’s footwell. Be careful that floor mats or carpets in the driver’s footwell have sufficient clearance for the pedals.
Page 53: Engine Oil Consumption
Engine Oil Consumption When the engine has passed the break-in period, oil consumption may reach 0.5 % of the fuel consumption recorded in actual operating circumstances. In isolated cases and in arduous operating conditions, oil consumption may increase to 1 % of the fuel consumption recorded circumstances.
Page 54: Inhalation Of Exhaust Gas
54 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE INHALATION OF EXHAUST GAS WARNING! When driving or parking the vehicle, make sure that its exhause system does not come into contact with flamable material (such as dry leaves) as these materials my otherwise catch fire. Inhalation of exhaust gas is hazardous to your health.
Page 55 WARNING! If you tension the tensioning belts between the sidewalls, the maximum permissible load for the lashing rings could be exceeded if the brakes are applied suddenly or in the event of an accident. The load would no longer be secured, which could result in serious injuries caused by the load slip- ping.
Page 57 UNDERSTANDING THE FEATURES OF YOUR VEHICLE CONTENTS Mirror Adjustment ......59 Interior Mirror (Optional) ....59 Electrically Adjustable Exterior Mirror (Optional) .
Page 58 58 UNDERSTANDING THE FEATURES OF YOUR VEHICLE Speed Control (Optional) ....77 Sunroof (Optional) ......79 Manual Sun Roof (Optional) .
Page 59: Mirror Adjustment
MIRROR ADJUSTMENT Interior Mirror (Optional) 1. Normal position (DAY) 2. Anti-glare position (NIGHT) UNDERSTANDING THE FEATURES OF YOUR VEHICLE 59 Electrically Adjustable Exterior Mirror (Optional) The switch is located in the door lining next to the door handle. Mirror adjustment, left (1) Mirror adjustment, right (2) When the key is in position 2 in the ignition lock, each mirror may be adjusted by pressing the adjustment...
Page 60: Seat Adjustment
60 UNDERSTANDING THE FEATURES OF YOUR VEHICLE SEAT ADJUSTMENT Driver’s and Front Passenger’s Seat WARNING! Do not adjust the driver’s seat while driving. Ad- just the seat only while the vehicle is parked. Adjusting the seat while driving could cause the driver to lose control of the vehicle.
Page 61: Lumbar Support
Comfortseat (Optional) Seat adjustment, fore/aft (1) Seat cushion depth (Optional) (2) Seat height adjustment, front (3) Seat height adjustment, rear (4) Backrest tilt (5) UNDERSTANDING THE FEATURES OF YOUR VEHICLE 61 Lumbar Support Hand pump (1) Bleeder valve (2) Reinforce support: Use hand pump (1).
Page 62: Armrest (Optional)
62 UNDERSTANDING THE FEATURES OF YOUR VEHICLE Armrest (Optional) Tilt adjustment (1) By adjusting the tilt adjustment (thumbwheel) (1) the tilt of the armrest can be changed. Head Restraint If you need to remove the head restraint, press the catch at the head restraint socket and pull the head restraint up and out.
Page 63: Folding Seat At Partition (Optional)
Folding Seat at Partition (Optional) Key (1) Seat cushion (2) Fold down the seat cushion of the folding seat. UNDERSTANDING THE FEATURES OF YOUR VEHICLE 63 WARNING! When folding down the seat cushion, make sure that nobody can become trapped. The risk of injury to the front-passenger is increased in the event of sharp movements or an accident if a key is inserted in...
Page 64: Rear Seat Bench Removal And Installation
64 UNDERSTANDING THE FEATURES OF YOUR VEHICLE REAR SEAT BENCH REMOVAL AND INSTALLATION WARNING! The integrated seat belt can only offer the degree of protection for which it is designed if you install the specified rear bench seats correctly. Never op- erate vehicle unless all rear bench seats are prop- erly installed and all release levers are locked.
Page 65: Retrofitting Seat Mounting Cups
To install: 1. With the rear bench seat facing in the direction of travel, insert the legs of the rear bench seat in the respective seat mounting cups on the floor. 2. Slide the rear bench seat forwards with some force as far as it will go, until the release levers are heard to engage and all release levers are parallel to the vehicle floor.
Page 66: Hood
66 UNDERSTANDING THE FEATURES OF YOUR VEHICLE HOOD WARNING! When the hood is open, there is a risk of injury due to very hot engine components. When the engine is running or the key is in position 2 in the ignition lock, there is a risk of injury due to moving engine components and the electrical system.
Page 67 2. Open the safety catch (2). 3. Swing the hood up until the support strut (3) engages. UNDERSTANDING THE FEATURES OF YOUR VEHICLE 67 To close: 1. Lift the hood up slightly. 2. Press the support strut (3) down. 3. Swing the hood down and make sure that it engages in its retaining catch.
Page 68: Headlamp Range Control
68 UNDERSTANDING THE FEATURES OF YOUR VEHICLE WARNING! Be sure the hood is properly closed before driving. If the hood is not fully latched, it could fly up when the vehicle is moving and block your for- ward vision. Be sure all hood latches are latched fully before driving.
Page 69: Interior Lighting
INTERIOR LIGHTING Interior Lamps in the Driver and Rear-Seat Passenger Area/Cargo Area 1. Permanently on 2. Off 3. Interior lamps are switched on/off by the door contact switches UNDERSTANDING THE FEATURES OF YOUR VEHICLE 69 Interior Lamps with Interior Sensor Protection (Optional) Interior lamp switch (1) Reading lamp switch (2)
Page 70: Interior Lighting With Reading Lamp, Front
70 UNDERSTANDING THE FEATURES OF YOUR VEHICLE Operation of Interior Lamps Position 1: Continuous operation Position 2: The door contact switches are used to switch the interior lamps on and off Position 3: Switched off Operation of Reading Lamps Position 1: Left-hand reading lamp switched on Position 2: Switched off Position 3: Right-hand reading lamp switched on Interior Lighting with Reading Lamp, Front...
Page 71: Interior Cargo Area Lighting (Optional)
Interior Cargo Area Lighting (Optional) The switch is located on the center section of the dashboard. To switch on: Press top of switch: The indicator lamp in the switch will illuminate. To switch off: Press bottom of switch. UNDERSTANDING THE FEATURES OF YOUR VEHICLE 71 The switch (1) is located on the right side of the cargo area at the entrance for the sliding door.
Page 72: Multifunction Switch
72 UNDERSTANDING THE FEATURES OF YOUR VEHICLE The switch (2) is located in the right rear of the cargo area. To switch on: Press top of switch, the indicator lamp in the switch will illuminate. To switch off: Press bottom of switch. NOTE: The interior cargo area lighting will shut off automatically after 15 min.
Page 73 Lamp switch (3) C Side lamps, license plate and instrument lighting õ Low beam headlamps, headlamps ƒ Marker lamps, right, combination switch up (1) Marker lamps, left, combination switch down (2) UNDERSTANDING THE FEATURES OF YOUR VEHICLE 73 High beam headlamps (lamp switch positionõ) (4) Headlamp flasher (also when turn signals are on) (5) NOTE: When the key is in the ignition lock in the 0 position and the driver’s or passenger’s door is open, a...
Page 74: Window Operation
74 UNDERSTANDING THE FEATURES OF YOUR VEHICLE WINDOW OPERATION Mechanical Window Operation To open the window: Turn manual window counterclockwise direction. To close the window: Turn the manual window control in a clockwise direction. Electric Window Operation (Optional) Make certain that no one gets caught when the side windows are closed.
Page 75: Windshield Wiper Switch
Place the key in position 2 in the ignition lock. To open the window: Keep switch pressed downward until the window has reached the desired position. To close the window: Keep switch pressed upward until the window has reached the desired position. UNDERSTANDING THE FEATURES OF YOUR VEHICLE 75 WINDSHIELD WIPER SWITCH Intermittent wipe and rain sensor (optional) (1)
Page 76: (Optional)
76 UNDERSTANDING THE FEATURES OF YOUR VEHICLE WARNING! Sudden loss of visibility through the windshield caused by e. g. ice, steam, fog or water could lead to an accident. You might not see other vehicles or other obstacles. To avoid sudden icing of the windshield during freezing weather, warm the windshield with the defroster or with the wind- shield heater (optional) before and during wind-...
Page 77: Speed Control (Optional)
SPEED CONTROL (OPTIONAL) Set/accelerate speed (1) Set/decelerate speed (2) Off (3) Resume set speed (4) UNDERSTANDING THE FEATURES OF YOUR VEHICLE 77 The speed control allows you to drive in a more relaxed manner, for example over long distances, as it automatically maintains the set speed by actively regulating the throttle setting.
Page 78 78 UNDERSTANDING THE FEATURES OF YOUR VEHICLE WARNING! Leaving the Speed Control on when not in use is dangerous. You could accidently set the system or cause it to go faster than you want. You could lose control and have an accident. Always turn the system off when you are not using it.
Page 79: Sunroof (Optional)
WARNING! The speed control does not adapt itself automati- cally to road conditions; therefore do not use cruise control on icy roads. There is a risk of skid- ding and loss of vehicle control. This could cause an accident resulting in severe personal injuries, death and property damage.
Page 80: Manual Sun Roof (Optional)
80 UNDERSTANDING THE FEATURES OF YOUR VEHICLE Manual Sun Roof (Optional) – To open, turn the handwheel counterclockwise. Maximum opening = turn until the stop is reached. – To close, turn the handwheel clockwise until the stop is reached. WARNING! Never allow fingers or other body parts, or any ob- ject to project through the sun roof opening.
Page 81: Mechanical Sun Roof Operation
Mechanical Sun Roof Operation The sun roof does not open or close: Check electrical fuse. Electrical fuses refer to “Electrical Fuses“. If the fuse works correctly, the sun roof can also be closed or opened manually. UNDERSTANDING THE FEATURES OF YOUR VEHICLE 81 Remove cover (1) at the front frame of the sun roof.
Page 82: Ashtray/Cigar Lighter
82 UNDERSTANDING THE FEATURES OF YOUR VEHICLE ASHTRAY/CIGAR LIGHTER Ashtray in the driver’s compartment. Ashtray (1) Cigar lighter (2) To open the ashtray (1): Pull the ashtray (1) out until it locks into place. To close the ashtray (1): Push the ashtray (1) forward over the working point until it reaches the stop.
Page 83: Electrical Outlet
Ashtray in the rear passenger compartment. The ashtrays are located in the side linings in the passenger compartment. UNDERSTANDING THE FEATURES OF YOUR VEHICLE 83 ELECTRICAL OUTLET The electrical outlet is located on the lower right in the center of the dashboard.
Page 84: Control And Operation Of Radio Transmitters
84 UNDERSTANDING THE FEATURES OF YOUR VEHICLE CONTROL AND OPERATION OF RADIO TRANSMITTERS Radio, Telephone and Two Way Radio WARNING! Please do not forget that your primary responsi- bility is to drive the vehicle. Only operate the ra- dio, telephone, navigation system, two-way radio or fax when road and traffic conditions permit.
Page 85: Cup Holder
CUP HOLDER The cup holder in the driver’s compartment is located below the instrument panel between the driver’s and front passenger’s seats. UNDERSTANDING THE FEATURES OF YOUR VEHICLE 85 The cup holders in the passenger compartment are located in the center below the seat benches. Pull out cup holder in the direction of arrow.
Page 86: Glove Compartment
86 UNDERSTANDING THE FEATURES OF YOUR VEHICLE WARNING! Your primary responsibility is to drive the vehicle. Do not use cup holder while the vehicle is in motion. Otherwise you could be distracted from traffic and cause an accident or liquid could spill from the containers due to for example breaking or other vehicle movement.
Page 87: Understanding Your Instrument Panel
UNDERSTANDING YOUR INSTRUMENT PANEL CONTENTS Instruments and Controls ....89 Instrument Cluster and Indicator Lamps ..91 Indicator Lamp Symbols .
Page 88 88 UNDERSTANDING YOUR INSTRUMENT PANEL Upper Air Vents ......120 Heated Rear Window (Optional) ... 121 Windshield Heater (Optional) .
Page 89: Instruments And Controls
UNDERSTANDING YOUR INSTRUMENT PANEL 89 INSTRUMENTS AND CONTROLS...
Page 90 90 UNDERSTANDING YOUR INSTRUMENT PANEL Legend For Instruments And Controls 1. Left-hand air vent. 2. Multifunction switch. 3. Speed control. 4. Hood release lever. 5. Instrument cluster, refer to "Instrument Cluster and Indicator Lamps". 6. Hazard warning flasher switch. 7. Steering wheel with horn, front driver airbag. 8.
Page 91: Instrument Cluster And Indicator Lamps
UNDERSTANDING YOUR INSTRUMENT PANEL 91 INSTRUMENT CLUSTER AND INDICATOR LAMPS...
Page 92 92 UNDERSTANDING YOUR INSTRUMENT PANEL Legend For Instrument Cluster And Indicator Lamps 1. Tachometer (Engine rpm), refer to "Tachometer (Engine rpm)". 2. Turn signal indicator lamp (left), refer to "Multifunction Switch". 3. Turn signal indicator lamp (right), refer to "Multifunction switch". 4.
Page 93: Indicator Lamp Symbols
Indicator Lamp Symbols Acceleration skid control (ASR) or electronic stability program (ESP)* or slippery surface warning. Airbag Malfunction (USA only). Parking brake applied. High beam on, refer to "Multifunction Switch". Battery not being charged, refer to "Battery Charge Indicator Lamp". Water in fuel filter, refer to "Water in Fuel Indicator Lamp".
Page 94: Multi-Function Indicator
94 UNDERSTANDING YOUR INSTRUMENT PANEL Multi-Function Indicator WARNING! Never operate buttons (1, 2, 3 and 4) in the multi- function indicator while driving. To operate these buttons the driver must reach through steering wheel, significantly impede its movement. Your attention will also be diverted from the road and traffic conditions.
Page 95 The multi-function indicator can be used to call up the odometer, trip meter, clock and outside temperature, or information such as remaining time/distance until the next service is due, or the engine oil level. If your vehicle is equipped with reversing aid, the multi-function indicator also displays the distance between your vehicle and a detected obstacle.
Page 96: Clock
96 UNDERSTANDING YOUR INSTRUMENT PANEL Clock Activate the multi-function indicator, refer to "Multi- Function Indicator". Button I – to reverse the time adjustment/ switch between hours and minutes (1) Button ç – to turn the time back (2) Button æ – to advance the time (3) To switch between Time and Outside Temperature Display (Optional) Press the I button briefly.
Page 97: Odometer And Trip Meter
Odometer and Trip Meter Activate the multi-function indicator. The total distance covered by the vehicle will be shown. 1. To switch between the odometer and the trip meter, press button (1) briefly. 2. To reset the trip meter, call up trip meter. Press button (1) and hold until the trip meter shows 0000.
Page 98: Outside Temperature Display
98 UNDERSTANDING YOUR INSTRUMENT PANEL Instrument and display lighting: 1. Switch on the marker lamps, refer to "Combination Switch" 2. Press button ç, to instrument and display lighting dimmer 3. Press button æ, to instrument display lighting brighter Outside Temperature Display 1.
Page 99: Reversing Aid Distance Display (Optional)
The outside temperature is displayed when the multi- function indicator is activated. Sudden changes in temperature, for instance when leaving a garage, are only shown after a certain delay. NOTE: Outside temperature display °F in USA only. °C in Canada only. WARNING! Even if the display still reads a few degrees above °...
Page 100 100 UNDERSTANDING YOUR INSTRUMENT PANEL The following display appears if the reversing aid does not detect an obstacle. NOTE: Distance display – "in" in USA only. – "cm" in Canada only. The distance between the sensors and an obstacle detected within the monitoring range is displayed in increments of 2 in (5 cm).
Page 101: Tachometer (Engine Rpm)
Tachometer (Engine rpm) Do not exceed the maximum permissible engine speed. NOTE: To protect the engine, its fuel supply is interrupted when the maximum rpm is reached. Despite this, the maximum rpm can still be exceeded in overrun mode (e.g. when driving downhill). UNDERSTANDING YOUR INSTRUMENT PANEL 101 Coolant Temperature Gauge The coolant temperature is displayed when the key is...
Page 102 102 UNDERSTANDING YOUR INSTRUMENT PANEL CAUTION! Do not leave your vehicle unattended with the engine running as you would not be able to react to the temperature indicator if the engine overheats. This would lead in turn to engine damage. For coolant level indicator lamp /, refer to "Coolant Level Indicator Lamp".
Page 103: Fuel Gauge With Reserve Fuel Indicator
Fuel Gauge with Reserve Fuel Indicator Lamp The fuel level is displayed when the key is in position 2 in the ignition lock. UNDERSTANDING YOUR INSTRUMENT PANEL 103 The reserve fuel indicator lamp (1) lights up for about 2 seconds. If the reserve fuel indicator lamp remains on or lights up again when the engine is running, the fuel in the tank hasreached reserve level.
Page 104: Battery Charge Indicator Lamp
104 UNDERSTANDING YOUR INSTRUMENT PANEL Battery Charge Indicator Lamp When the key is in position 2 in the ignition lock, the battery charge indicator lamp # will light up in the instrument cluster. It must go out when the engine is running.
Page 105: Engine Oil Level Indicator Lamp
NOTE: Should the water in fuel indicator lamp still not go out after the fuel filter has been drained, the cause should be examined by an authorized Sprinter Dealer. If the indicator lamp does not light up for about 2 seconds with the key in the ignition lock in position 2, there is a malfunction in the water separator system.
Page 106: Coolant Level Indicator Lamp
106 UNDERSTANDING YOUR INSTRUMENT PANEL If the engine oil level indicator lamp : does not go out, or if it lights up again while the vehicle is moving, the engine oil level has dropped to a point close to the minimum level mark on the dipstick.
Page 107: Engine Control Unit Indicator Lamp
If a large quantity of coolant is being lost, or if smaller amounts are lost at regular intervals, have the engine cooling system examined by an authorized Sprinter Dealer. CAUTION! Never run the engine if the coolant level is too low.
Page 108: Switch Locations
108 UNDERSTANDING YOUR INSTRUMENT PANEL SWITCH LOCATIONS...
Page 109 Legend for Switch Locations 1. Fog lamp switch (Optional), refer to "Fog Lamp Switch". 2. Headlamp range control, refer to "Headlamp Range Control". 3. Auxiliary heat exchanger switch (Optional). 4. Heated rear window (Optional). 5. Left-hand seat heater switch (Optional). 6.
Page 110: Assyst Maintenance Computer (Optional)
110 UNDERSTANDING YOUR INSTRUMENT PANEL ASSYST MAINTENANCE COMPUTER (OPTIONAL) Function button (‘) (1) Approximately one month or 2,000 miles (3,000 km) before a service is due, the maintenance symbol Symb N00.00-2387-00 lights up when the key is turned to position 2 in the ignition lock.
Page 111 Depending on the driving style, the mileage covered and the operating conditions, the next service due is displayed either as a remaining distance in "mi" (in km) or as a remaining time in "days". The length of time between services should not exceed 2 years. display will cancelled...
Page 112: Engine Oil Level - Display In Instrument Cluster (Vehicles With Assyst Maintenance Computer Only)
112 UNDERSTANDING YOUR INSTRUMENT PANEL Engine Oil Level – Display in Instrument Cluster (Vehicles with ASSYST Maintenance Computer only) If the : indicator lamp lights up briefly when the engine is running, the engine oil level has dropped to the minimum mark. Check the engine oil level without delay and add oil to the upper mark on the dipstick.
Page 113: Displaying Engine Oil Level With
If the warning Symb N00.00-2150-00 is displayed in the multi-function indicator while the engine is running, the engine oil level is above maximum. CAUTION! Do not operate the engine if the oil level is above maximum. There is a danger of damage to the engine or catalytic converter.
Page 114 114 UNDERSTANDING YOUR INSTRUMENT PANEL Briefly press button (1) twice within 1 second. The following displays can then appear in the multi- function indicator: Symb It is not necessary to add N00.00-2151-00 engine oil. Symb 1 quart (about 1 liter) of N00.00-2385-00 engine oil must be added.
Page 115: Engine Oil Level Indicator In Instrument Cluster
ENGINE OIL LEVEL INDICATOR IN INSTRUMENT CLUSTER (VEHICLES WITHOUT ASSYST MAINTENANCE COMPUTER) If the : indicator lamp lights up when the engine is running, the engine oil level has dropped to the minimum mark. Check the engine oil level without delay and add engine oil up to the upper mark on the dipstick.
Page 116: Heating, Ventilation
116 UNDERSTANDING YOUR INSTRUMENT PANEL HEATING, VENTILATION Temperature control (1) Airflow control (2) Air distribution control (3) Z Air to the windshield and from the air vents X Air to the windshield and footwell and from the air vents Y Air to the footwell and from the air vents h Air from the air vents NOTE: If the vehicle interior has been heated up by intense sunlight, ventilate the interior briefly before...
Page 117: Ventilation
Ventilation 1. Set the airflow control (2) to position 3 or 4. 2. Set the temperature control (1) as illustrated (heater switched off). 3. Set the air distribution control (3) to h. NOTE: Adjust the air vents as required, Air Vents and Center Air Vents". UNDERSTANDING YOUR INSTRUMENT PANEL 117 Air Recirculation 1.
Page 118: Heating
118 UNDERSTANDING YOUR INSTRUMENT PANEL Select air recirculation if dust or unpleasant odors enter the vehicle. NOTE: Prolonged air recirculation can worsen the air quality and lead to fogging up of the windows. Shut off air recirculation as soon as possible. Only with automatic heat regulation and regulated air conditioning (Optional): Air recirculation is automatically switched off after...
Page 119: De-Fogging And De-Icing The Front
De-Fogging and De-Icing The Front Windows 1. Set the airflow control (2) to position 3 or 4. 2. Set the temperature control (1) to P. 3. Set the air distribution control (3) to Z. 4. Switch recirculation, Recirculation". UNDERSTANDING YOUR INSTRUMENT PANEL 119 NOTE: On vehicles with auxiliary heater (water heater): additional...
Page 120: Side Air Vents And Center Air Vents
120 UNDERSTANDING YOUR INSTRUMENT PANEL Side Air Vents and Center Air Vents To open, turn the thumbwheel outwards. To close, turn the thumbwheel inwards. Intermediate settings are possible. Upper Air Vents The upper air vents supply fresh air (not heated) to the passenger/load compartment.
Page 121: Heated Rear Window (Optional)
Heated Rear Window (Optional) The switch for the heated rear window is located on the right-hand side next to the steering column. It can be used only when the engine is running. To switch it on: • Press upward; the indicator lamp in the switch will light up.
Page 122: Residual Engine Heat Utilization (Rest)
122 UNDERSTANDING YOUR INSTRUMENT PANEL Residual Engine Heat Utilization (REST) The REST switch (1) is located on the center section of the dashboard. The residual engine heat utilization system can be used to keep the vehicle interior warm for some time after the engine is switched off.
Page 123: Climate Control
To switch on: Press switch (1), the indicator lamp (2) in the switch lights up. To switch off: Press switch (1) again, the indicator lamp (2) goes out. NOTE: Run the air conditioning at least once a month for about 10 minutes. possible that the air...
Page 124: Dehumidification (On Vehicles With Air Conditioning)
124 UNDERSTANDING YOUR INSTRUMENT PANEL NOTE: Open and adjust the air vents as required, refer to "Side Air Vents and Center Air At high outside temperatures, a better cooling performance is achieved by switching on air recirculation. For note on air recirculation, Recirculation".
Page 125: Air Conditioner For The Rear Passenger Compartment (Optional)
NOTE: It is possible that the air conditioning will automatically switch off at outside temperatures below 41 °F (+5 °C). Dehumidification is then also not possible. To switch on air conditioner, press switch (4). Open the side air vents as required, refer to "Side Air Vents and Center Air Vents".
Page 126: Air Recirculation
126 UNDERSTANDING YOUR INSTRUMENT PANEL To switch it on: 1. Press switch (1) on air conditioning, regulated. The indicator lamp (2) will light up. 2. Operate the airflow switch (3). Blower level 1, press the airflow switch (3) upwards; the left-hand indicator lamp will light up. Blower level 2, press the airflow switch (3) downwards;...
Page 127: Air Strainer
Air Strainer To lock fasteners (1) To unlock fasteners (2) The air strainer is located at the rear of the air conditioner for rear passenger compartment. Increased quantities of sand or dust may settle on the air conditioner for rear passenger compartment air strainer when driving on dusty or sandy streets.
Page 128: Electric Blower (Optional)
128 UNDERSTANDING YOUR INSTRUMENT PANEL Installing the Air Strainer 1. Affix the air strainer (3) to the grating (5) (make certain that the ends project evenly). 2. Replace the air strainer (3) and grating (5) on the cover and press the Velcro closure (4) on the cover (6).
Page 129: Heater Booster
HEATER BOOSTER The switch (1) for activating the heater booster system is located in the center section of the dashboard. The heater booster system can be switched on while the vehicle is being driven to help the engine to reach normal temperature more quickly, which will help to heat up the passenger compartment as...
Page 130: Auxiliary Heater - Water Or Air Heater
130 UNDERSTANDING YOUR INSTRUMENT PANEL AUXILIARY HEATER – WATER OR AIR HEATER (OPTIONAL) WARNING! The auxiliary heating must not be operated at gas stations due to the risk of fire and explosion. For this reason, switch off the auxiliary heating before refuelling.
Page 131 NOTE: After three successive attempts to start the heater, a malfunction will be recorded in the integrated diagnostic system and no further operation on auxiliary heater will be available (lock-out). The work to annul the lock-out must be carried out at an authorized Sprinter Dealer.
Page 132: Auxiliary Heater Switch
132 UNDERSTANDING YOUR INSTRUMENT PANEL Auxiliary Heater Switch To switch it on: Press the switch upward. The indicator lamp in the switch will light up. auxiliary automatically switch off after about 120 minutes. The auxiliary heater will switch over to after-running mode (about 2 minutes).
Page 133 6. Button H – Select memory (1 – 3), activate preselected time 7. Button ö – Switch on heater 8. Button ý – Set time, day, and preselected time; shorten heating period (min. 1 minute) 9. Button þ – Set time, day, and preselected time; lengthen heating period (max.
Page 134 134 UNDERSTANDING YOUR INSTRUMENT PANEL The auxiliary heater is running. Display: Symbol ö, current time and current day of the week. If the ignition is switched off, the auxiliary heater will remain on for another 15 minutes before automatically switching off. The remaining heating period can be lengthened by using the button þ...
Page 135 Press the button H until the desired memory (1 – 3) and the preselected time both flash. The preselected time has been activated when the display stops flashing. Within the next 24 hours, the heater will switch on at the preselected time displayed. Activate the preselected time (from 24 hours to a max.
Page 136: U Settings With The Auxiliary Heater
136 UNDERSTANDING YOUR INSTRUMENT PANEL Heat operation: Different operating conditions will be in effect depending on the heat level required. The integrated control unit adjusts the heat flow using the following operating levels: High – Low – Off Safety Equipment For safety reasons, the heater will automatically switch off if faults occur which cause the device to overheat.
Page 137: Auxiliary Heat Exchanger In Load Compartment, Only With Auxiliary Heater
NOTE: Only on vehicles with automatic heater control/regulated air conditioner: Before switching on the heater or entering the switch- on time, the temperature control (1) must be set to maximum heater output (as illustrated). Set the air distribution control (3) as required between Y and Z.
Page 138: Auxiliary Heater - Tips For Coping With
138 UNDERSTANDING YOUR INSTRUMENT PANEL AUXILIARY HEATER – TIPS FOR COPING WITH PROBLEMS NOTE: After three successive attempts to start the heater, a malfunction will be recorded in the integrated diagnostic system and no further operation on auxiliary heater will be available (lock-out). The work to annul the lock-out must be carried out at an authorized Sprinter Dealer.
Page 139: Starting And Operating
STARTING AND OPERATING CONTENTS Power Assistance ......141 Starting the Engine ......141 Maximum Engine Speed .
Page 140 140 STARTING AND OPERATING Deactivating the Acceleration Skid Control (ASR) ......168 Brake Assist System (BAS) (vehicle type 2500 only) .
Page 141: Power Assistance
POWER ASSISTANCE 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. STARTING AND OPERATING 141 STARTING THE ENGINE Battery charge warning lamp (1)
Page 142: Maximum Engine Speed
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.
Page 143: Constant Rpms (Optional)
Constant RPMs (Optional) The switch for the Constant RPMs is located on the center section of the dashboard. Constant RPMs engine-idling working-RPM level and maintains this level regardless of work load. It can only be used when the vehicle is stationary, the parking brake is engaged and the gear selector level is in position "P".
Page 144: Stopping The Engine
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.
Page 145: Automatic Transmission
AUTOMATIC TRANSMISSION The automatic transmission selects individual gears automatically, dependent upon: • Gear Selector lever position • Accelerator position • 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".
Page 146: Accelerator Position
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...
Page 147: Gear Selector Lever Position
Gear Selector Lever Position 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. STARTING AND OPERATING 147 Park Position The park position is to be used when parking the vehicle.
Page 148: Gear Selection For Special Circumstances
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.
Page 149 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 lever is moved to a lower gear, the transmission will not shift to a lower gear if the engine’s revolutions per minute limit would be...
Page 150: Transmission Selector Lever, Manually
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.
Page 151 The system is operational if after reverse gear is engaged: • an acknowledgement tone sounds • 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.
Page 152 152 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.
Page 153: Loading The Vehicle
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 –...
Page 154: Loading Guidelines
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.
Page 155: Brakes
• Protect sharp edges with padding. • Check the tire pressures after loading the vehicle. For passenger vans: • Do not stack loads higher than the upper edge of the backrests. • Always place the load against the backrests of the seat benches.
Page 156: Brake Pad Wear Indicator
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.
Page 157: Brake Indicator And Electronic Brake Force Distribution (Ebd) Indicator Lamp
Brake Indicator and Electronic Brake Force Distribution (EBD) Indicator Lamp USA only 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. STARTING AND OPERATING 157 If the indicator lamp does not go out after about 2 seconds, the brake fluid level has sunk below the...
Page 158: Parking Brake Indicator Lamp
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.
Page 159: Parking Brake
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.
Page 160: Driving Safety Systems
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 •...
Page 161: Lamp
WARNING! The following factors increase the risk of acci- dents: • Excessive speed, especially in turns • Wet and slippery road surfaces • 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.
Page 162: Anti-Lock Brake System (Abs)
162 STARTING AND OPERATING as the voltage reaches this level again – the ABS is then reactivated. If ABS malfunctions, the other driving safety systems deactivated. handling 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-...
Page 163 WARNING! 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.
Page 164: Electronic Brake Force Distribution (Ebd)
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 ;...
Page 165 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.
Page 166: Acceleration Skid Control (Asr) Warning Lamp And Electronic Stability Program (Esp) - If Equipped
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.
Page 167: Acceleration Skid Control (Asr)
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).
Page 168: U Deactivating The Acceleration Skid
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).
Page 169: (Vehicle Type 2500 Only)
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.
Page 170: U Indicator Lamp Electronic Stability Program (Esp) (Type 2500 Vehicles Only)
170 STARTING AND OPERATING For the indicator lamp k refer to 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.
Page 171: Electronic Stability Program (Esp) (Vehicle Type
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 –...
Page 172: Auxiliary Drive (Optional)
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 hydroplaning.
Page 173: Steering
CAUTION! 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.
Page 174 174 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: • Always replace wheel bolts that are damaged or rusted.
Page 175: Tire Grip
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.
Page 176 176 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).
Page 177: Tire Pressures Of Loaded Vehicle In Psi (Kpa)
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 3,858 lbs (1,750 kg) – Rear axle with max. axle load 5,357 lbs (2,430 kg) Tire pressures for size LT225/75 R 16 115 N –...
Page 178: Comfort Tire Pressures In Psi (Kpa)
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 Axle loads in lbs (kg), see Size...
Page 179: Snow Chains
SNOW CHAINS Install snow chains on rear wheels only. Install snow chains on exterior wheel in vehicles with double tires. Comply with manufacturer’s 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.
Page 180: Fuel Filter With Water Separator
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.
Page 181: Refueling
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)
Page 182: Capacity
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.
Page 183: Bleeding Diesel Fuel System
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.
Page 184: Draining Fuel Filter With Water Separator
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 Delaying draining of the fuel filter for a considerable time after the indicator lamp lights...
Page 185: Bleeding The Diesel Fuel System
• Open immediately the water drain screw (3) about 1 turn (counterclockwise) until fluid emerges. Ensure that the fluid is collected in the receptacle. • Close the water drain screw (3) as soon as about 0.25 US qt (0.2 liters) are emerged. •...
Page 186: Permissible Roof Load
186 STARTING AND OPERATING PERMISSIBLE ROOF LOAD The maximum permissible roof load is: • Vehicles with low roof 660 lbs (300 kg) • Vehicles with high roof 330 lbs (150 kg) • The weight of any load carried on the roof, including the roof rack, must not exceed the maximum permissible roof load.
Page 187: Vehicle And Trailer Weights And Ratings
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.
Page 188: Checking Weights Of Vehicle And Trailer
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.
Page 189: Towing A Trailer
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.
Page 190 190 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.
Page 191: Parking A Trailer
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.
Page 192: Emissions Control System (Catalytic Converter)
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...
Page 193: Body Builder Guideline
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.
Page 194: Alteration
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...
Page 195: What To Do In Emergencies
WHAT TO DO IN EMERGENCIES CONTENTS Hazard Warning Flasher Switch ... . . 196 Fire Extinguisher (Optional) ....197 Vehicle Tool Kit .
Page 196: Hazard Warning Flasher Switch
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.
Page 197: Fire Extinguisher (Optional)
FIRE EXTINGUISHER (OPTIONAL) 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. WHAT TO DO IN EMERGENCIES 197 NOTE: Read the manufacturer’s instructions on the fire extinguisher carefully and make yourself familiar...
Page 198: Changing The Tire
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).
Page 199 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";...
Page 200: Spare Wheel Location
200 WHAT TO DO IN EMERGENCIES Spare Wheel Location WARNING! If the rear cargo doors are opened to 90° (detent position), the rear lights will be concealed. The ve- hicle is then not sufficiently safeguarded at the rear and may only be seen by other road users when they are close to the vehicle.
Page 201 Spare Wheel Beneath the End of the Frame Retaining screws for the spare wheel structural member 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.
Page 202 202 WHAT TO DO IN EMERGENCIES 2. Turn spare wheel holder to loosen. 3. Remove the spare wheel. Spare Wheel Location for Chassis 1. Loosen thumb nuts by hand and remove. 2. Use wrench to loosen fixing nut to the thread end. 3.
Page 203: Jack
JACK WARNING! To avoid the risk of serious or fatal injuries or vehicle damage, please bear the following points in mind: • 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.
Page 204 204 WHAT TO DO IN EMERGENCIES Front Axle Jack Point (All Vehicles) The vehicle jacking point is located under the longitudinal member in front of the front axle. Rear Axle Jack Point for 8,550 lbs (3,880 kgs) (Vehicle type 2500 HC/SHC) The vehicle jacking point is located under the longitudinal member in front of the rear axle.
Page 205 Rear Axle Jack Point for 9,990 lbs (4,530 kgs) (Vehicle type 3500 HC/SHC) The vehicle jacking point is located under the longitudinal member in front of the rear axle. CAUTION! Do not position the jack at the leaf spring or the differential housing.
Page 206: Removing 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.
Page 207 WARNING! 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.
Page 208 208 WHAT TO DO IN EMERGENCIES Centering wheels with wheel bolts • If dual assemblies are used, before placement the inner wheel should be inspected to ensure that all ball bearing rings are in proper position. • Install the wheel and snug the wheel bolts. •...
Page 209: Jump Starting
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.
Page 210 210 WHAT TO DO IN EMERGENCIES • 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. • Only use a battery of the same rated voltage and of approximately the same capacity for jump-starting.
Page 211: Towing The Vehicle
WHAT TO DO IN EMERGENCIES 211 TOWING THE VEHICLE 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.
Page 212: If The Engine Is Damaged
212 WHAT TO DO IN EMERGENCIES If the Engine is Damaged For towing distances up to 30 miles (about 50 km) • Shift gear selector lever to "N" position. • Do not exceed a towing speed of 30 mph (50 km/h). For towing distances greater than 30 miles (about 50 km) •...
Page 213 MAINTAINING YOUR VEHICLE CONTENTS Engine Compartment..... . . 215 Sprinter Original Parts ..... . 217 Service Products .
Page 214 214 MAINTAINING YOUR VEHICLE Headlamps, Taillamps, Identification Lamps, Turn Signal Lenses ..... . . 234 Reversing Aid Sensors ....235 Window Cleaning .
Page 215: Engine Compartment
MAINTAINING YOUR VEHICLE 215 ENGINE COMPARTMENT...
Page 216 216 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.
Page 217: Sprinter Original Parts
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.
Page 218: Disposal Of Service Products
218 MAINTAINING YOUR VEHICLE Disposal of Service Products Dispose of service products and of parts which come into contact with them (e.g. environmentally responsible manner. Comply with applicable bars and regulations. 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...
Page 219: U Windshield Washer System Fluid Reservoir . 219 U Air Filter Restriction Indicator (Optional)
Windshield Washer System Fluid Reservoir 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). MAINTAINING YOUR VEHICLE 219 Air Filter Restriction Indicator (Optional) The indicator on the air filter housing in the engine compartment shows the degree of contamination in the...
Page 220: U Engine Oils
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.
Page 221: Engine Oil Level
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. • Check engine oil level about 5 minutes after stopping the engine, which should have reached its regular operating temperature.
Page 222: Ribbed V-Belt
222 MAINTAINING YOUR VEHICLE Ribbed V-Belt 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.
Page 223: Brake Fluid
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.
Page 224: Checking Coolant Level
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.
Page 225 WARNING! In order to avoid any possibly serious burns: • If you see flames or smoke coming from the engine compartment, 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.
Page 226: Winter Operation
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. • 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...
Page 227: Batteries
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.
Page 228: Reconnecting The Battery
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.
Page 229 WARNING! • Use only refrigerants and compressor lubricants approved by the manufacturer for your air conditioning system. Some 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.
Page 230: Replacing Wiper Blades
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.
Page 231: Appearance Care And Corrosion Protection
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.
Page 232: Power Washer
232 MAINTAINING YOUR VEHICLE Because of the possibility of incompatibility between materials used in the production process and others applied later. 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...
Page 233: Automatic Car Wash
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.
Page 234: Vehicle Washing
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.
Page 235: Maintaining Your Vehicle
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.
Page 236: Wiper Blade
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.
Page 237: Cup Holder
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.
Page 238: Plastic And Rubber Parts
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.
Page 239: U Standard Fuse And Relay Equipment
Standard Fuse and Relay Equipment 1. Locked 2. Unlocked 3. Detent spring – engage when the cover is fitted MAINTAINING YOUR VEHICLE 239 Position of fuses and relays 4. Fuses 5. Relays...
Page 240 240 MAINTAINING YOUR VEHICLE Fuse Assignment, Standard Equipment...
Page 241 No. Rated 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,...
Page 242: Relay Assignment, Standard Equipment
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.
Page 243 MAINTAINING YOUR VEHICLE 243 Fuse, Relay, and Diode Assignments – Optional Equipment...
Page 244 244 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: Circuit Not in use Not in use Not in use Not in use Fuses:...
Page 245: Bulb Replacement
BULB REPLACEMENT 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.
Page 246 246 MAINTAINING YOUR VEHICLE 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.
Page 247 Low Beam Headlamps 1. Unplug the cable connector from the bulb. 2. Unclip in the retaining springs. Press the retaining springs towards the headlamps and down (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.
Page 248 248 MAINTAINING YOUR VEHICLE Fog Lamp (Optional) 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). 3. Remove the bulb. 4.
Page 249 Side and Parking Lamps 1. Pull out the bulb holder with the bulb. 2. Replace the bulb. 3. Insert the bulb holder. 4. Secure the housing cap. MAINTAINING YOUR VEHICLE 249 High Beam Headlamp 1. Unplug the cable connector from the bulb. 2.
Page 250: Taillamps
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 –...
Page 251 Chassis (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 MAINTAINING YOUR VEHICLE 251 1.
Page 252: License Plate Lamps (Cargo/Passenger Vans Only)
252 MAINTAINING YOUR VEHICLE License Plate Lamps (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. Install the cover. 4. Re-install the bulb socket. Additional Brake Lamp (Cargo/Passenger Vans Only) (1) Retaining screws...
Page 253: U Side-Mounted Turn Signals
Side-Mounted Turn Signals 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. MAINTAINING YOUR VEHICLE 253 Side-Marker Lamps, Standing Lamps (Optional) Retaining screws (1) Bulb socket (2) 1.
Page 254: Identification Lamps
254 MAINTAINING YOUR VEHICLE Identification Lamps (Cargo/passenger vans only) (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.
Page 255: Interior Lighting With Reading Lamp
Interior Lighting with Reading Lamp 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. MAINTAINING YOUR VEHICLE 255 Interior Lighting with Interior Sensor Protection 1.
Page 256: U Exit Lamps (Optional)
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).
Page 257: Capacities
CAPACITIES Engine with oil filter Engine oil All vehicles about 9.5 US qt (9.0 l) Fuel tank Cooling system Including reserve fuel about about about 26.4 US gal 2.8 US gal 2.7 US gal (100 l) (10.5 l) (10.0 l) MAINTAINING YOUR VEHICLE 257 Windshield washer system...
Page 258: Recommended Fluids And Lubricants
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...
Page 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 C1-4 BP Vanellus C6 Global Plus Brad Penn Euro-Diesel LD Castrol Elixion Castrol Tection S...
Page 260 260 MAINTAINING YOUR VEHICLE Raloy Motor Diesel Repsol Turbo UHPD Roshfrans Voltro Diesel Shell Helix Ultra Shell Helix Ultra Shell Rimula X CH-4 Shell Rimula X CH-4 Shell Rotella T Multigrade Super Diesel Oil MB-3 Supreme Duty Diesel Engine Oil Multi- grade Unoil GX-7 Ursa Premium TDX...
Page 261 COMPONENT SERVICE INTERVAL 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 once only at Transmission Fluid 80,000 mi (128,000 km) 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),...
Page 262 262 MAINTAINING YOUR VEHICLE COMPONENT SERVICE INTERVAL Engine Coolant, 15 years or Anticorrosion/ 160,000 mi Antifreeze Fluid (256,000 km) Power Steering Power Steering, no fluid service required Power Steering fluid — Rear Axle Gear Oil 120,000 mi (192,000 km) PRODUCT NAME/PRODUCT NUMBER EURO Peak Coolant/Anti-freeze, OLD WORLD INDUSTRIES Zerex G05, The Valvoline Company Zerex G48, The Valvoline Company...
Page 263: Maintenance Schedules
MAINTENANCE SCHEDULES CONTENTS Introduction ......264 Warranty ....... . . 264 Maintenance - Without ASSYST Maintenance Computer .
Page 264: Introduction
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.
Page 265: Computer
The use of Special lubricant additives is not recommended. The use of such additives may affect your warranty rights. With regard to legal stipulations concerning emissions control, please note that engines have to be serviced and adjusted in accordance with special instructions and using special measuring equipment.
Page 266: Computer
266 MAINTENANCE SCHEDULES MAINTENANCE - WITH ASSYST MAINTENANCE COMPUTER ASSYST provides you with information on the best possible timing for maintenance work. When the next maintenance service is due, this will be indicated in the multi-function display with the symbol 9 Oil service and fuel filter replacement 9 Maintenance service - displayed in km/miles or days.
Page 267: Special Maintenance Requirements
SPECIAL MAINTENANCE REQUIREMENTS bodies built manufacturers DaimlerChrysler Corporation are fitted to the vehicle, the maintenance requirements and lubrication intervals specified by the body manufacturer must be adhered to, in addition to all standard maintenance requirements. Brake Fluid Only use brake fluids approved by the manufacturer (DOT 4 plus).
Page 268: Scope Of Work For Maintenance Service
268 MAINTENANCE SCHEDULES SCOPE OF WORK FOR MAINTENANCE SERVICE Oil Service Oil change Engine: Oil change and filter replacement Check fluid levels of the following system, refill as necessary. If fluid is lost, trace and eliminate cause – as a separate order.
Page 269 Check fluid levels for the following systems, correct as necessary. Should there be a loss of fluid which cannot be explained by regular use, trace and eliminate the cause. Engine cooling system Check corrosion inhibitor/antifreeze, refill as necessary. Hydraulic brake system Battery Windscreen washer system Engine...
Page 270: Additional Maintenance Work
270 MAINTENANCE SCHEDULES Additional Maintenance Work Automatic transmission once only at 80,000 miles/ 128000km Oil and filter change During every second maintenance service Air cleaner without maintenance indicator: Air cleaner filter element renewal Check poly-V-belt for wear and signs of damage During every sixth maintenance service Rear axle Additional Maintenance Work After ...
Page 271: If You Need Consumer Assistance
IF YOU NEED CONSUMER ASSISTANCE CONTENTS Suggestions For Obtaining Service For Your Vehicle ......272 Prepare for the Appointment .
Page 272 272 IF YOU NEED CONSUMER ASSISTANCE SUGGESTIONS FOR OBTAINING SERVICE FOR YOUR VEHICLE Prepare for the Appointment If you’re having warranty work done, be sure to have the right papers with you. Take your warranty folder. All work to be performed may not be covered by the warranty, discuss additional charges with the service manager.
Page 273 • If for some reason you are still not satisfied, talk to the general manager or owner of the dealership. They want to know if you need assistance. • If your dealership is unable to resolve the concern, you may contact the Manufacturer’s Customer Center.
Page 274 274 IF YOU NEED CONSUMER ASSISTANCE Service Contract You may have purchased a service contract for your vehicle to help protect you from the high cost of unexpected repairs after your manufacturer’s new vehicle limited warranty expires. The manufacturer stands behind only the manufacturer’s Service Contracts.
Page 275 WARRANTY INFORMATION See your manufacturer’s Warranty Information Booklet for information on your warranty coverage and transfer of warranty. MOPAR® PARTS Mopar ® fluids, lubricants, parts, and accessories are available from your dealer. They will help you keep your vehicle operating at its best. REPORTING SAFETY DEFECTS In the 50 United States and Washington D.C.: If you believe that your vehicle has a defect which could...
Page 277 A Special Note Concerning Vehicle Alteration..194 Acceleration Skid Control ..... 164 Deactivating....... 168 Indicator Lamp .
Page 278 278 INDEX ASSYST Maintenance Computer ....110 Automatic Lock Feature ......19 Automatic Transmission .
Page 279 Engine Cleaning ......233 Headlamps, Taillamps, Turn Signal Lenses ..234 Vehicle Washing .
Page 280 280 INDEX Clock ........96 Comfort Tire Pressures .
Page 281 Engine Cleaning......233 Engine Control Unit Indicator Lamp ... . 107 Engine Coolant.
Page 282 282 INDEX Headlamp Range Control..... . . 68 Headlamps, taillamps, turn signal lenses ..234 Heated Rear Window .
Page 283 Acceleration Skid Control Warning Lamp . 143, 166 Additional Brake Lamp ..... 252 Anti-Lock Brake System (ABS) Indicator Lamp. 161 Battery Charge Indicator Lamp .
Page 284 284 INDEX Warranty ....... . . 264 With ASSYST Maintenance Computer ..266 Without ASSYST Maintenance Computer .
Page 285 Relay Assignment, Standard Equipment..242 Remote Keyless Entry ......20 Locking .
Page 286 286 INDEX Sliding Door ........30 Snow Chains....... . . 179 Spare Wheel Location .
Page 287 Switching off ....... 24 Towing Protection and Passenger Compartment Protection Switch ......24 Towing the Vehicle .
Page 288 288 INDEX Windows De-Fogging ....... 119 De-Icing ........119 Windshield Heater .

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Dodge 2005 Sprinter Owner's Manual

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