service DODGE SPRINTER 2004 1.G User Guide

MAINTAINING YOUR VEHICLE
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CONTENTS
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . 205

Sprinter Original Parts . . . . . . . . . . . . . . . . . . . . . . 207

Service Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Disposal of Service Products . . . . . . . . . . . . . . 208

Emission Related Component Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Regular Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Windshield Washer System Fluid Reservoir . 209Air Filter Restriction Indicator (Optional) . . . 209Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 210Ribbed V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Hydraulic Brake System, Clutch Mechanism
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Checking Coolant Level . . . . . . . . . . . . . . . . . . 213

Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Disconnecting the Battery . . . . . . . . . . . . . . . . . 216Reconnecting the Battery . . . . . . . . . . . . . . . . . . 217Charging the Battery . . . . . . . . . . . . . . . . . . . . . 217

Replacing Wiper Blades . . . . . . . . . . . . . . . . . . . . . 218Appearance Car and Corrosion Protection . . 219Power Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Automatic Car Wash . . . . . . . . . . . . . . . . . . . . . 221Tar Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Paintwork, Painted Body Components . . . . . . 221Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 221Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . 222Ornamental Moldings . . . . . . . . . . . . . . . . . . . . 222Headlamps, Taillamps, Turn Signal Lenses . . 222Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . 223
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MAINTAININ G YOUR VEHICLE 207
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SPRINTER ORIGINAL PARTSEvery authorized Sprinter Dealer maintains a stock of
Sprinter original parts for maintenance and repair
work.
Sprinter original parts are subjected to the most
stringent quality inspections and will ensure that the
vehicle is maintained at a high level of operating
efficiency and safety, and that it maintains its value.
Each part has been specifically designed and
manufactured or selected and approved for use in
Sprinter vehicles.
It is therefore best to use only Sprinter original parts.
For cost-effective repairs in accordance with sound
recycling principles, the use of non-genuine parts and
accessories not authorized by the manufacturer could
damage the vehicle or compromise its durability or
safety.
When ordering original parts, always provide the
vehicle identification number and the engine number.
SERVICE PRODUCTSMechanical elements and the lubricants used for them
must be carefully matched.
For this reason, only brands tested and approved by
the manufacturer should be used. Please contact your
Sprinter Dealer to obtain the necessary information.
No lubricant additives should be used.
The use of such additives could affect your warranty
rights. Information is available from any authorized
Sprinter Dealer.
For specifications of engine oils, coolant and brake
fluid, contact your
authorized
Sprinter
Dealer.
WARNING!
If handled incorrectly, service products can consti-
tute a health risk for people and an environmental
hazard.
Always observe relevant guidelines for handling,
storing and disposing of service products.
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208 MAINTAINING YOUR VEHICLEDisposal of Service ProductsDispose of service products and of parts which come
into contact with them (e.g. filters) in an
environmentally responsible manner. Comply with
applicable bars and regulations.EMISSION RELA TED COMPONENT WA RRA NTY
STATEMENTThe Manufacturer warrants to the original and each
subsequent owner of a MERCEDES-BENZ heavy-duty
on highway diesel engine that:
(1) the engine was designed, built and equipped so as
to conform at the time of sale with the applicable
regulations adopted by the Federal Environmental
Protection Agency
(2) the emission control system of such engine is free
from defects in materials and workmanship which
would cause it not to conform with those regulations
for a period of use of five years or 100 000 miles or
3 000 hours of engine operation, whichever occurs
first.
REGULA R CHECKSThe following checks should be performed at regular
intervals (for example once a week or each time the
vehicle is refueled):
 Windshield cleaner system – fluid reservoir.
 Air strainer, in vehicles with an air strainer element
maintenance indicator (optional equipment).
 Engine oil level.
 Checking ribbed V-belt.
 Hydraulic brake system, clutch mechanism fluid
level.
 Coolant level.
 Tire and spare wheel condition and pressures of the
same. For more information, refer to "Wheels and
Tires".
 Vehicle lighting.
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212 MAINTAINING YOUR VEHICLEBrake fluidUse brake fluid approved to MB 331.0, or a DOT 4
brake fluid with: minimum dry boiling point (ERBP)
500
°F, minimum wet boiling point (WERBP)
356°F, maximum viscosity 1500 mm
2/s,
conforming to FMVSS116 and ISO 4925.
In the course of its service life, the boiling point of the
brake fluid will fall due to the continuous absorption of
moisture from the atmosphere.
If the brakes are placed under heavy loads (e.g., on
steep hills) bubbles of steam can then form in the brake
system.
This will adversely affect the brakes' effectiveness.
Engine CoolantThe coolant is a mixture of water and a corrosion
inhibitor/antifreeze additive. Within the cooling
system, the corrosion inhibitor/antifreeze ensures
 anti-corrosion protection
 antifreeze protection
 a higher boiling point.
The coolant added in the factory ensures adequate
antifreeze and anti-corrosion protection.
Use coolant approved to MB 325.0, such as Valvoline
GO5, or an equivalent Extended Life Coolant.
To avoid damage to the cooling system, only use
manufacturer approved corrosion inhibitor/
antifreeze additives.
Information on the corrosion inhibitor/antifreeze
additive is available from any Sprinter Dealer.
For reasons of anti-corrosion protection and to increase
the boiling point, the coolant added to the cooling
system is designed for all year round operation – even
in countries with high prevailing temperatures.
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MAINTAININ G YOUR VEHICLE 213
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Have the coolant renewed at least every five years or
after 100,000 miles.
When the coolant is renewed, the new coolant should
contain 50% antifreeze/corrosion inhibitor by volume.
This corresponds to antifreeze protection down to -
37 °C/-35°F.
Do not exceed a proportion of about 55 % by volume
(antifreeze protection down to about -45 °C/-49 °F) as
the heat dissipation properties then deteriorate.
In the event of coolant loss, do not add water only, but
sufficient antifreeze/corrosion inhibitor to maintain
the correct concentration.
The water in the coolant must satisfy certain
requirements. These are often met by tap supply
drinking water.
The water must be specially prepared if the water
quality does not come up to the required standards.
Have the corrosion inhibitor/antifreeze concentration
in the coolant checked at the outset of winter,
respectively once a year in countries with high
prevailing temperatures.A regular check is included in the maintenance service.
Checking Coolant LevelCoolant reservoir (1)
The cooling system is pressurized. Only check the
coolant level with the vehicle parking on a level surface
and with the engine switched off.
– Wait until the coolant temperature has dropped
below 194 °F (+90 °C).
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216 MAINTAINING YOUR VEHICLEBA TTERIESThe standard battery is located in the engine
compartment.The auxiliary battery is located underneath the front
passenger seat (optional equipment).
The battery will not achieve its maximum service life
unless it is kept adequately charged at all times. If the
vehicle is used primarily for short distances, or left
parked for lengthy periods, have the battery charge
checked more frequently.
Disconnecting the Battery
WARNING!
Failure to follow these instructions can result in
severe personal injuries and death.
Never lean over batteries while connecting, you
might get injured, if the battery explodes.
Battery fluid contains sulfuric acid. Do not allow
this fluid to come in contact with eyes, skin or
clothing. In case it does, immediately flush
affected area with water and seek medical help if
necessary.
A battery will also produce hydrogen gas, which
is flammable and explosive. Keep flames or
sparks away from battery, avoid improper
connection of jumper cables, smoking etc.
Use only impact-resistant batteries with a central
gas release cover to prevent corrosion damage and
to prevent occupants from caustic burns in the
event of an accident.
CAUTION!
Do not loosen or remove the battery terminal
clamps while the engine is running or the key is in
the ignition lock as this could damage electrical or
electronic equipment beyond repair. All electrical
consumers must be switched off.
Do not place any metal objects on the battery.
Doing so may cause a short-circuit.
Loosen and remove the negative terminal clamp
first, then the positive terminal.
Afterwards disconnect vent tube from the fitting.
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MAINTAININ G YOUR VEHICLE 245
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Recommended Fluids and LubricantsComponent Recommended Fluid
Brake Use brake fluid approved to MB 331.0, or a DOT 4 brake fluid with:
minimum
dry boiling point (ERBP) 500°F, minimum wet boiling point
(WERBP) 356°F, maximum viscosity 1500 mm
2/s, conforming to FMVSS 116
and ISO 4925.
Coolant Use coolant approved to MB 325.0, such as Valvoline GO5, or an equivalent
Extended Life Coolant.
Engine Use engine oils approved to MB 228.3 or MB 228.5 that are also licensed to
API CI-4.
Automatic Transmission Use ATF approved to MB 236.10, MB 236.12. Synthetic Dexron III®
Automatic Transmission Fluid may be substituted.
Power Steering No fluid service required. Use Power Steering Fluid approved to MB 341.
Dexron III® Automatic Transmission Fluid may be substituted.
Rear Axle Use oils approved to MB 235.0, such as Shell Spirax MB 90. Reduced axle
durability may result if an unapproved product is used.
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MA INTENA NCE SCHEDULES
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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Maintenance - Without ASSYST Maintenance
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Maintenance Intervals . . . . . . . . . . . . . . . . . . . . 249

Maintenance - With ASSYST Maintenance
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Regular Check-Ups. . . . . . . . . . . . . . . . . . . . . . . . . 250

Special Maintenance Requirements . . . . . . . . . . . 251Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Dust Filter for Heating/Ventilation
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Engine Oil Change and Filter Replacement . . . . 251Once a Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Scope of Work for Maintenance service . . . . . . . 252Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252Additional Maintenance Work . . . . . . . . . . . . . 254Additional Maintenance Work
After ... Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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248 MAINTENANCE SCHEDULES
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INTRODUCTIONThis is intended as a guide to the service requirements
of your vehicle.
It contains all necessary instructions concerning
service intervals and operations which have to be
carried out.
Scope and frequency of maintenance work primarily
depend on the vehicle's operating conditions.
In the interest of maintaining the vehicle's operating
safety, the specified work should be performed
regularly and in good time.
Our vehicles are subject to ongoing development.
Technical progress may also affect the scope of service
work performed.
"Daily vehicle checks" before starting a journey are the
responsibility of the driver.
WA RRA NTYThe Sprinter Dealer network is at your disposal for
maintenance work. Each of these workshops has the
equipment and tools, the specially trained, skilled and
experienced personnel and receives regular technical
instruction from DaimlerChrysler Corporation to
ensure that your vehicle is inspected and maintained
thoroughly and in accordance with the latest
procedures.
Please follow the instructions given in this Owner’s
Manual and ensure that they are observed, even if you
hand the vehicle over to a third party for use or care. By
not observing these instructions you may void your
warranty rights.
If the specified oil and maintenance services are not
carried out regularly or at the time intervals specified,
a decision as to the validity of a warranty claim can
only be made after DaimlerChrysler Corporation has
investigated your claim.
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MAINTENANCE SCHEDULES 249
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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. Modifications to or interference with the
emissions control systems are not permissible.
All Sprinter Dealer are familiar with the relevant and
appliable regulations.
MA INTENA NCE - WITHOUT A SSYST
MA INTENA NCE COMPUTER
Maintenance IntervalsAdditional work must be carried out at yearly
intervals.
As a general rule, to avoid unnecessary visits to the
workshop you should try to have necessary repair
work performed together with other maintenance
work.Oil service
– Refer to
Normal Operation
every
10,000 miles or
16,000 km or 12 months
Maintenance serviceevery
30,000 miles or
48,000 km
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