weight DODGE SPRINTER 2004 1.G Owners Manual

I N TRO D U CTI O N 5
1
VEHICLE IDENTIFICA TION NUMBER, SA MPLE
A ND LOCA TIONVehicle identification number, visible (location: lower
edge of windshield)
VEHICLE SA FETY CERTIFICA TION LA BEL,
SA MPLE A ND LOCA TIONLocation: below the driver’s seat on an outwardfacing
position of the mounting pillar.
1. Incomplete vehicle certification label for
chassis-cab.
2. Type plate (vehicle identification number,
permissible weights)
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134 STARTING AND OPERATING
Deactivating the Acceleration Skid Control
(ASR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Brake Assist System (BAS) (Cargo/passenger
vans type 2500 C/HC/SHC only) . . . . . . . . . . 160Indicator Lamp Electronic Stability
Program (ESP) (Cargo/passenger vans
type 2500 C/HC/SHC only) . . . . . . . . . . . . . . 161Electronic Stability Program (ESP) (Cargo/
passenger vans type 2500 C/HC/SHC only) . . 162

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 163Tire Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Hydroplaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Tire Pressures of Loaded Vehicle in PSI (kPa) . 167Tire Pressures of Loaded Vehicle in PSI (kPa) . 168Comfort Tire Pressures in PSI (kPa) . . . . . . . . 169Comfort Tire Pressures in PSI (kPa) . . . . . . . . 169

Snow Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Fuel Filter with Water Separator . . . . . . . . . . . 170Diesel Fuels for Use at Very Low
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Programmed Top Speed (Optional) . . . . . . . . . . 173

Bleeding Diesel Fuel System . . . . . . . . . . . . . . . . . 174

Draining Fuel Filter with Water Separator . . . . . 175Bleeding the Diesel Fuel System . . . . . . . . . . . 176

Permissible Roof Load . . . . . . . . . . . . . . . . . . . . . . 177

Trailer Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Trailer Hitches (Optional) . . . . . . . . . . . . . . . . . 177Electrical Connections (Optional) . . . . . . . . . . 177Vehicle and Trailer Weights and Ratings . . . . 178Loading a Trailer . . . . . . . . . . . . . . . . . . . . . . . . 178Checking Weights of Vehicle and Trailer . . . . 179Attaching a Trailer . . . . . . . . . . . . . . . . . . . . . . . 179Towing a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 180Parking a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 182

Emissions Control System (Catalytic Converter) . 183

Fording (Wading Capability) . . . . . . . . . . . . . . . . 183

Body Builder Guideline . . . . . . . . . . . . . . . . . . . . . 183A Special Note Concerning Vehicle
Alteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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144 STARTING AND OPERATINGTRANSMISSION SELECTOR LEVER, MANUALLY
UNLOCKINGIn the case of power failure the transmission selector
lever can be manually unlocked (for vehicle towing).
To do so, insert a pin (1) (ball point pen), into the
covered opening below the position "D" of the shift
pattern. While pushing the pin down, move selector
lever from position "P".
After removal of the pin from the opening, the cover
will not close fully. Only after moving the selector lever
to positions "D+" and "D–" does the cover return to its
closed position.
LOADING THE VEHICLE
WARNING!
Do not overload the tires by exceeding the specified
vehicle capacity weight (as indicated by the label on
the base of the driver’s seat). Overloading the tires
can overheat them, possibly causing a blowout,
which could cause an accident and personal injury.
In addition, braking and stopping distances can be
significantly longer if the vehicle is overloaded.
WARNING!
Always close the sliding and rear doors when
driving.
Otherwise exhaust fumes could enter the vehicle
interior and poison you.
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STARTING AND OPERATING 145
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The handling characteristics of a vehicle when laden
are dependent on the type of load and the distribution
of the load within the vehicle.
Carrying heavy or bulky loads may alter the vehicle’s
handling characteristic.Loading GuidelinesPlease note and comply with the following information
when loading and transporting goods.
 Do not allow the load, including passengers, to
exceed the permitted gross vehicle weight or the
permitted axle loads for the vehicle. Bear in mind
that the unladen weight could be increased by
installing items of optional equipment and
accessories.
 Distribute the load uniformly. Excessive loads on
individual points of the load surface could cause
damage to the floor covering.
 Transport heavy loads between the axles near the
rear axle as low as possible in the vehicle.
 Secure any kind of load with sufficient wear and
tear-resistant load restraints. Lashing rings.
WARNING!
Unsecure or poorly secured loads, and seats that
have been removed, could move around the vehi-
cle interior uncontrollably in the event of sudden
braking, a rapid change in direction or an acci-
dent. This increases the risk of injury to occu-
pants in these situations.
Secure and position a load as described in the
following loading guidelines.
Piling up heavy objects or placing them on upper
shelves or loading them otherwise high up in the
vehicle will significantly raise the center of
gravity of the vehicle. Placing excessive loads on
individual points of the load surface or behind
the rear axle will also adversely affect the
handling characteristics of your vehicle and may
lead to loss of control over the vehicle.
Road safety and tire durability are adversely
affected if the permissible axle loads or gross
vehicle weight are exceeded due to the vehicle’s
load. Braking and stopping distances can be
significantly longer.
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STARTING AND OPERATING 165
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Tire GripTire 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.HydroplaningDepending on the depth of the water layer on the road,
hydroplaning may occur, even at low speeds and with
new tires. Reduce vehicle speed, avoid grooves in the
road, and apply brakes cautiously in the rain.
TIRE PRESSURES
WARNING!
If tire pressures are too low, there is a risk of the
tire’s tread deteriorating and sudden loss of pres-
sure due to the excessive temperature of the tire.
This has an adverse effect on road safety and in-
creases the risk of an accident.
The limiting speed for the tires (tires and tire
pressure) must not be exceeded. Exceeding the
permissible maximum speed causes tire damage,
which can lead to loss of control of the vehicle.
Do not overinflate tires. Overinflating tires can
result in sudden deflation (blowout) because they
are more likely to become punctured or damaged by
road debris, potholes, etc. Follow recommended
inflation pressures.
Do not overload the tires by exceeding the specified
vehicle capacity weight as indicated by the label on
the base of the driver’s seat. Overloading the tires
can overheat them, possibly causing a blowout,
which could cause an accident resulting in severe
personal injuries, death and property damage.
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170 STARTING AND OPERATINGSNOW CHA INSInstall snow chains on rear wheels only. Install snow
chains on exterior wheel in vehicles with double tires.
Comply with the manufacturer’s installation
instructions.
NOTE: Vehicles with snow chains installed are only to
be driven on a snow-covered surface. The snow chains
must be removed on road surfaces free of snow.FUELSUse only commercially available vehicular diesel fuels
No. 2 or No. 1 (ASTM D 975 No. 2-D or No. 1-D).
If diesel fuels are used with a sulphur content
exceeding 0.05 % by weight, engine oil change
intervals must be shortened. Please contact your
Sprinter Dealer to obtain the necessary information.
Marine diesel fuel, heating oil or the like must not be
used.
Refueling from drums or canisters may lead to the fuel
becoming contaminated. This in turn can cause faults
in the fuel system. Always filter the fuel before adding
it to the vehicle’s tank.
Fuel Filter with Water SeparatorCheck the water separator when the fuel indicator
lamp does not go out or comes on while the engine
is running. For more information on the indicator
lamp .
The interval for changing the fuel filter is reduced to
10,000 miles (about 15,000 km).
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STARTING AND OPERATING 177
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PERMISSIBLE ROOF LOADThe 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.TRA I LER TOWI NGTrailer Hitches (Optional)
Only install a trailer hitch receiver approved for your
vehicle. For information on availability and
installation, please see your authorized Sprinter
Dealer.
The bumpers on your vehicle are not designed for use
with clamp-type hitches. Do not attach rental hitches
or other bumper-type hitches to them.
To reduce the possibility of damage, remove the hitch
ball adaptor from the receiver when not in use.Electrical Connections (Optional)The Sprinter is available with a variety of pre-installed
conditions (lines and turn signal indicator and brake
module installed and / or not installed). Make sure that
the correct trailer hitch receiver kit is used. For further
information, please see your authorized Sprinter
Dealer.
In order to prevent possible damage to the vehicle’s
electrical system by incorrectly installing the trailer
wiring plug, we recommend having the harness
connected at an authorized Sprinter Dealer.
WARNING!
Failure to use proper equipment and driving tech-
nique can result in a loss of vehicle control when
towing a trailer.
Improper towing or failure to follow the
instructions contained in this guide can result in
serious injury. Follow the guidelines below
carefully to assure safe trailer operation.
Ask your authorized Sprinter Dealer, if you
require an explanation of information contained
in this guide.
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178 STARTING AND OPERATINGVehicle and Trailer Weights and RatingsGross Vehicle Weight Rating (GVWR) is the maximum
permissible vehicle weight:
8,550 lbs (3,878 kgs) or
9,990 lbs (4,531 kgs)
NOTE: The weight of your Sprinter is indicated on the
type plate. For type plate, see Identification Labels.
Gross Vehicle Weight (GVW): comprises weight of
vehicle including fuel, tools, spare wheel, installed
accessories, passengers, cargo and trailer tongue. It
must never exceed the GVWR.
Gross Axle Weight Rating (GAWR) is the maximum
permissible axle weight:Gross Trailer Weight (GTW) is the maximum
permissible trailer weight to be towed:
5,000 lbs. (2,260 kgs)
Trailer Tongue Weight Rating (TWR) is the maximum
permissible weight of the trailer tongue:
500 lbs. (225 kgs) limit for Sprinter approved hitch
receiver.
Loading a TrailerWhen loading a trailer, you should observe that
neither the permissible GTW, nor the GVWR are
exceeded.
Maximum permissible values are listed on the safety
compliance certification labels for the vehicle and for
the trailer to be towed. The lowest value listed must be
selected when determining how the vehicle and trailer
are loaded.
We recommend loading the trailer in such a manner
that it has a tongue weight (TW) between 10% and 15%
of the GTW.
The tongue weight at the hitch ball must be added to
the GVW to prevent exceeding your Sprinter tow
vehicle’s rear GAWR.
Type GVWR GAWR (FA) GAWR (RA)
2500
C/HC /
SHC8,550 lbs
3,878 kgs3,860 lbs
(1,751 kgs)5,360 lbs
(2,431 kgs)
3500
C/HC /
SHC9,990 lbs
4,531 kgs3,860 lbs
(1,751 kgs)7,060 lbs
(3,202 kgs)
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STARTING AND OPERATING 179
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Checking Weights of Vehicle and TrailerTo assure that the tow vehicle and trailer are in
compliance with the maximum permissible weight
limits, and to know the actual weights, have the loaded
vehicle-trailer combination (tow vehicle including
driver, passengers and cargo, trailer fully loaded)
weighed on a commercial scale.
Check the vehicle’s front and rear Gross Axle Weight
(GAW), the GTW and TW. The values as measured
must not be exceeded, according to the weight listed
under “Vehicle and trailer weight and ratings”.A ttaching a TrailerPlease observe maximum permitted trailer dimensions
(width and length).
Most states and all Canadian provinces require safety
chains between your tow vehicle and the trailer. The
chains should be crisscrossed under the trailer tongue.
They must be attached to the hitch receiver, and not to
the vehicle’s bumper or axle. Be sure to leave enough
slack in the chains to permit turning corners.
Most states and all Canadian provinces require a
separate brake system at various trailer weights.
WARNING!
Do not connect a trailer brake system (if trailer is
so equipped) directly to the vehicle’s hydraulic
brake system as your vehicle is equipped with an-
tilock brakes. If you do, neither the vehicle’s
brakes nor the trailer’s brakes will function prop-
erly. This could cause an accident resulting in
property damage, injury or death to you or others.
The provided vehicle electrical wiring harness for
trailer towing has a brake signal wire for hook-up
to a brake controller.
Most states and all Canadian provinces require a
break-away switch on trailers with a separate
brake system. The switch activates the trailer
brakes in the possible event that the trailer might
separate from the tow vehicle.
You should consider using a trailer sway control
system. For further information see your
authorized Sprinter Dealer.
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MAINTENANCE SCHEDULES 251
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SPECIAL MAINTENANCE REQUIREMENTSIf bodies built by manufacturers other than
DaimlerChrysler Corporation are fitted to the vehicle, the
maintenance requirements and lubrication intervals
specified by the body manufacturer must be adhered to,
in addition to all standard maintenance requirements.Brake FluidOnly use brake fluids approved by the manufacturer
(DOT 4 plus). Information about brake fluids is
available from your Sprinter Dealer.CoolantHave the corrosion inhibitor/antifreeze concentration
in the coolant checked before the onset of winter (once
a year in countries with high prevailing temperatures).
Have the coolant renewed every five years or 100,000
miles.Dust Filter for Heating/Ventilation ReplacementThe dust filter and the tailgate interior filter are
renewed during routine maintenance service.
However, if operating conditions are dusty, these
filters should be renewed more frequently.
ENGINE OIL CHA NGE A ND FILTER
REPLACEMENTIn a minimum, change the engine oil and oil filter once
a year - even if the vehicle mileage per year is extremly
low. For standard oil service schedules, please see the
chapter oil service and maintenance service.Once a YearSelect the viscosity of the engine oil (SAE classes)
according to the outside air temperature.
Only use engine oil approved by DaimlerChrysler
Corporation if following the ASSYST system
guidelines.
Information is available from your Sprinter Dealer.
If the fuel used has a sulphur content exceeding 0.05 %
by weight, the service intervals should be split in half.
If the sulphur content of the fuel used is between 0.3%
and 0.8% by weight, the service intervals should be
split in half (i.e. every 5,000 miles instead of every
10,000 miles).
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