check engine DODGE SPRINTER 2005 1.G Owner's Manual

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
Dealer.
For coolant composition and water quality, contact
your Sprinter Dealer.
WINTER OPERATIONHave your vehicle winterized by an authorized
Sprinter Dealer before the onset of winter.
 Have the engine oil changed, if the engine oil filled is not approved for winter use.
 Coolant: antifreeze/anti-corrosion concentration in the coolant checked.
 Windshield washer system: add winter concentrate to the washer fluid.
 Battery: the battery will lose capacity as temperatures drop. Only a well-charged battery will
ensure reliable engine starting even at low outside
temperatures.
 Tires: fit M+S radial tires, taking note of the maximum permissible speed of the tires fitted.

MAINTAINING YOUR VEHICLE 227
7
BATTERIESThe standard battery is located in the engine
compartment. The auxiliary battery is lo
cated 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.

MAINTENANCE SCHEDULES
CONTENTS
8M A
I
N T
E
N A
N CE
S
C
H E
D
U L
E
S


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264


Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264


Maintenance - Without ASSYST Maintenance
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . 265


Maintenance - With ASSYST Maintenance
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266


Regular Check-Ups. . . . . . . . . . . . . . . . . . . . . . . . . 266


Special Maintenance Requirements . . . . . . . . . . . 267
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Dust Filter for Heating/Ventilation
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267


Engine Oil Change and Filter Replacement . . . . 267
Once a Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267


Scope of Work for Maintenance service . . . . . . . 268
Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Additional Maintenance Work . . . . . . . . . . . . . 270
Additional Maintenance Work After ... Years . . . 270

266 MAINTENANCE SCHEDULES
M A I
N T
E
N A
N
C E
S
C
H
E
D
U L
E
S8
MAINTENANCE - WITH ASSYST MAINTENANCE
COMPUTERASSYST 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.
9
If the display shows the number of days, the symbol
È will also appear in the multi-function display.
You should have the maintenance performed within
the stated period/distance.
The service indicator will be reset by your Sprinter
Dealer after an oil service and/or maintenance service
has been performed.
REGULAR CHECK-UPSTo maintain the safe operation of your vehicle, it is
recommended that you perform the following tasks on
a regular basis (i.e., weekly or whenever the vehicle is
refueled). Check:
 Engine oil level
 Brake system, clutch mechanism – fluid level
 Battery – acid level
 Windshield washer system and headlamp cleaning
system – fluid level
 Mechanical assemblies (e. g. ,engine, transmission, etc.) – check for leaks
 Condition of tires and tire pressures
 All exterior lights

MAINTENANCE SCHEDULES 267
8M A
I
N T
E
N A
N CE
S
C
H E
D
U L
E
S
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 h igh 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 CHANGE AND 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 interval s 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).

268 MAINTENANCE SCHEDULES
M A I
N T
E
N A
N
C E
S
C
H
E
D
U L
E
S8
SCOPE OF WORK FOR MAINTENANCE SERVICE
Oil ServiceOil 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.
Power-assisted steering
Lubrication work:
Trailer tow hitch (original equipment)
Maintenance
ASSYST maintenance computer reset Function check
Signalling system,
warning and indicator lamps
Headlamps, exterior lighting
Windscreen wipers,
windscreen washer system
Check for leaks and damage.
Check for abrasion points and ensure that
lines are correctly routed!
All assemblies:
Engine, transmission, transfer case, front axle, rear
axle, steering, power steering pump
All lines and hoses, sensor cables
Rubber boots on front axle drive shafts,
rubber boots on front axle suspension ball joints, shock
absorbers

MAINTENANCE SCHEDULES 269
8M A
I
N T
E
N A
N CE
S
C
H E
D
U L
E
S
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
Fuel filter renewal
Air cleaner with maintenance indicator:
Check degree of contamination.
Air cleaner filter element renewed as
necessary. Chassis and body
Trailer coupling:
Check operation, play and retaining fixtures
Secondary rubber springs:
Visual check
Tire pressures:
Correct as necessary, including spare tyre
Check thickness of brake pads
Brake test
Check condition of brake disks. Brake disks renewal as
necessary
– as a separate order
Check condition of steering mechanism
Heating/ventilation dust filter renewal

INDEX 279
10
Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Headlamps, Taillamps, Turn Signal Lenses . . . . 234
Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Care of vehicle
Paintwork, painted body components . . . . . . . . 233
Power washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Tar stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Central Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Central Locking Switch. . . . . . . . . . . . . . . . . . . . . . . . . 17 Locking and Unlocking . . . . . . . . . . . . . . . . . . . . . . 19
Locking Status Display . . . . . . . . . . . . . . . . . . . . . . 18
To Program the Automatic Lock Feature . . . . . . . 19
Chains, Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Changing a Bulb
Additional Brake Lamp . . . . . . . . . . . . . . . . . . . . . 252
Exit Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Interior Lighting with Interior Sensor Protection 255 License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 252
Reading Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Side-Marker Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 253
Side-Mounted Turn Signal . . . . . . . . . . . . . . . . . . 253
Taillamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 224
Checking Weights of Vehicle and Trailer. . . . . . . . . 188
Cigar Lighter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Cleaning Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . . . . 237
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . 236
Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 236
Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . . . 238
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Steering Wheel and Gear Selector Lever . . . . . . . 236
Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

INDEX 283
10
Acceleration Skid Control Warning Lamp . 143, 166
Additional Brake Lamp . . . . . . . . . . . . . . . . . . . . . 252
Anti-Lock Brake System (ABS) Indicator Lamp. 161
Battery Charge Indicator Lamp . . . . . . . . . . . . . . 104
Brake Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Coolant Level Indicator Lamp . . . . . . . . . . . . . . . 106
Electronic Brake Force Distribution . . . . . . . . . . . 157
Engine Control Unit Indicator Lamp . . . . . . . . . . 107
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Engine Oil Level Indicator Lamp . . . . . . . . . . . . . 105
Exit Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 252
Reading Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Reserve Fuel Indicator Lamp . . . . . . . . . . . . . . . . 103
Seat Belt Warning Lamp . . . . . . . . . . . . . . . . . . . . . 44
Side-Marker Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 253
SRS Malfunction Indicator Lamp . . . . . . . . . . . . . . 49
Taillamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Water in Fuel Indicator Lamp . . . . . . . . . . . . . . . . 104 Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Lighter, Cigar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Lighting, Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Lock, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Locking, Central . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
MMaintenance Computer . . . . . . . . . . . . . . . . . . . . . . . 110
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . 265
Maintenance Schedules
Additional Maintenance Work After ... Years . . 270
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Dust Filter for Heating/Ventilation Replacement . .
267
Engine Oil Change and Filter Replacement . . . . 267
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Once a Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Regular Check-Ups . . . . . . . . . . . . . . . . . . . . . . . . . 266
Scope of Work for Maintenance service . . . . . . . 268

284 INDEX
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
With ASSYST Maintenance Computer . . . . . . . . 266
Without ASSYST Maintenance Computer . . . . . 265
Maximum Engine Speed . . . . . . . . . . . . . . . . . . . . . . 142
Mechanical Sun Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Mechanical Sun Roof Operation . . . . . . . . . . . . . . . . . 81
Mirror Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Mirrors Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Mobile Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Mopar® Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Multi-Function Indicator . . . . . . . . . . . . . . . . . . . . . . . 94
Multifunction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 72
OOccupant Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Opening/Closing doors . . . . . . . . . . . . . . . . . . . . . . . . 27
Operation, Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ornamental Moldings . . . . . . . . . . . . . . . . . . . . . . . . . 234
Outlet, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Outside Temperature Display . . . . . . . . . . . . . . . . . . . 98
Overheating (Air Heater) . . . . . . . . . . . . . . . . . . . . . . 138
PPassenger Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Passenger Airbag, Front Seat . . . . . . . . . . . . . . . . . . . . 48
Passenger Compartment Protection . . . . . . . . . . . . . . 25
Alarm Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pedals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Permissible Roof Load . . . . . . . . . . . . . . . . . . . . . . . . 186
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Power Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Programmed Top Speed . . . . . . . . . . . . . . . . . . . . . . . 182RRadio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Radio Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Rear Cargo Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rear Seat Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Removal and Installation . . . . . . . . . . . . . . . . . . . . . 64
Recommended Fluids and Lubricants . . . . . . . . . . . 258
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Regular Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218