brake DODGE SPRINTER 2005 1.G Repair Manual

MAINTENANCE SCHEDULES
CONTENTS
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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
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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

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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 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).

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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

270 MAINTENANCE SCHEDULES
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Additional Maintenance WorkAutomatic 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 ... YearsEvery 2 years
Change brake fluid
Every 3 years
Air cleaner filter element renewal
(note installation date
)
Every 15 years or 100,000 miles
Coolant renewal
Note coolant composition

INDEX
10
AA Special Note Concerning Vehicle Alteration . . . . 194
Acceleration Skid Control . . . . . . . . . . . . . . . . . . . . . 164 Deactivating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . 143, 166
Acceleration Skid Control (ASR) . . . . . . . . . . . . 166, 167
Air Conditioner for the Rear Passenger Compartment
125 Air Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Air Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Air Conditioning Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Rear Passenger Compartment . . . . . . . . . . . . . . . 124
Air Conditioning, Regulated . . . . . . . . . . . . . . . . . . . 122
Air Filter Restriction Indicator. . . . . . . . . . . . . . . . . . 219 Air Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Air Vents
Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Airbag and Belt Tensioners . . . . . . . . . . . . . . . . . . . . . 49
Airbag Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Alarm Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Anti-Lock Brake System (ABS) Indicator Lamp . . . 161
Appearance and Care . . . . . . . . . . . . . . . . . . . . . . . . . 231
Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ASSYST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

278 INDEXASSYST Maintenance Computer . . . . . . . . . . . . . . . 110
Automatic Lock Feature . . . . . . . . . . . . . . . . . . . . . . . . 19
Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . 145Accelerator Position . . . . . . . . . . . . . . . . . . . . . . . . 146
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Gear Selector Lever Position . . . . . . . . . . . . . . . . . 147
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Selector Lever Manually Unlocking. . . . . . . . . . . 150
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Auxiliary Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Auxiliary Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 137
Auxiliary Heater Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Timer Auxiliary Heater (Water and Air Heater) 132
Tips for Coping with Problems . . . . . . . . . . . . . . 138BBatteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . 228
Disconnecting the Battery . . . . . . . . . . . . . . . . . . . 227
Reconnecting the Battery . . . . . . . . . . . . . . . . . . . . 228
Replacing Batteries in Remote Keyless Entry . . . . 22
Battery Charge Indicator Lamp . . . . . . . . . . . . . . . . . 104 Belt Tensioners
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Belt Tensioners and Airbag . . . . . . . . . . . . . . . . . . . . . 49
Bleeding the Diesel Fuel System . . . . . . . . . . . . . . . . 185
Body Builder Guideline . . . . . . . . . . . . . . . . . . . . . . . 193
Brake Assist System (BAS) . . . . . . . . . . . . . . . . . . . . . 169
Brake fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Brake Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 222
Brake Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 157
Brake Pad Wear Indicator. . . . . . . . . . . . . . . . . . . . . . 156
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Brake System, Anti-Lock . . . . . . . . . . . . . . . . . . . . . . 162
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Bulbs Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
CCapacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Care of Vehicle

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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

280 INDEXClock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Comfort Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . 178
Compartments in Front Doors. . . . . . . . . . . . . . . . . . . 86
Constant RPMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Consumer Assistance Be Reasonable with Request . . . . . . . . . . . . . . . . . 272
If You Need Assistance . . . . . . . . . . . . . . . . . . . . . 272
Prepare a List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Prepare for the Appointment . . . . . . . . . . . . . . . . 272
Coolant Level Indicator Lamp . . . . . . . . . . . . . . . . . . 106
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . 101
Coolant, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Cooling System, Engine . . . . . . . . . . . . . . . . . . . . . . . 223
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85DDe-Fogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
De-Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Diesel Fuels for Use at Very Low Temperatures . . 180
Displaying Engine Oil Level . . . . . . . . . . . . . . . . . . . 113
Doors Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Cargo Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Sliding Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Draining Fuel Filter with Water Separator . . . . . . . 184
Driver’s Airbag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Driving Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . 160
EElectric Sun Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Fuse and Relay Optional Equipment . . . . . . . . . . 242
Fuse, Relay, and Diode Assignments - Optional
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Relay Assignment, Standard Equipment . . . . . . 242
Standard Fuse and Relay Equipment. . . . . . . . . . 239
Electrical Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Electronic Brake Force Distribution . . . . . . . . . . . . . 164
Electronic Brake Force Distribution Lamp . . . . . . . . 157
Electronic Stability Program . . . . . . . . . . . . . . . . . . . 166
Emission Label, Vehicle/Engine . . . . . . . . . . . . . . . . . . 7
Emission Related Component . . . . . . . . . . . . . . . . . . 218
Emissions Control System . . . . . . . . . . . . . . . . . . . . . 192
Engine Break-in Recommendations . . . . . . . . . . . . . . 52

INDEX 283
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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