engine DODGE SPRINTER 2006 1.G Repair Manual

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5
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).
The engine’s torque is then no longer
limited and the drive wheels are free
to spin, which can help them cut into
loose surfaces.
The ASR can only be shut off with the engine running.
If the engine is shut off with the ASR deactivated, the
ASR is automatically re-activated after the engine is
started again.Vehicle Type 2500 only:
If there is a danger of skidding, and/or starting at a
speed of 38 mph (60 km/h) ESP
® activates ASR
automatically.
WARNING!
On a slippery road surface if both drive wheels
start to spin there is a risk of skidding. Adapt your
speed and driving style to the prevailing road,
traffic and weather conditions.
P54.25-0294-20
WARNING!
Vehicle type 2500 only:
Even when ASR is deactivated, ESP
® remains
active and regulates braking to improve stability
as necessary. The warning lampv flashes in
the speedometer.
The danger of your vehicle’s brake system
overheating and being damaged is increased
during long, demanding application of the
brakes. Furthermore, an overheated brake system
could result in a longer stopping distance.
Thus, only deactivate ASR if it is absolutely
necessary.

STARTING AND OPERATING 173
5
For the indicator lamp k refer to "Indicator Lamp
Acceleration Skid Control (ASR) and Brake Assist
System (BAS)
".
Indicator Lamp Electronic Stability Program
(ESP®) (vehicle type 2500 only)
When the key is in position 2 in the ignition lock, the
ESP
® indicator lamp will light up in the
instrument cluster as a function check. It goes out
when the engine is running.
If the indicator lamp remains on or lights up when
the engine is running, the electronic stability program
(ESP
®) is malfunctioning and switched off
automatically. The engine’s power output may be then
reduced.
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.
The BAS cannot prevent accidents, including
those resulting from excessive speed in turns,
following another vehicle too closely, or
hydroplaning. Only a safe, attentive, and skillful
driver can prevent accidents.
The capabilities of an BAS equipped vehicle must
never be exploited in a reckless or dangerous
manner which could jeopardize the user’s safety
or the safety of others
.
Adapt your speed and driving style to the
prevailing road, traffic and weather conditions.
Driving too fast increases the risk of an accident.

174 STARTING AND OPERATING
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 – the ESP
®
is then reactivated.Electronic Stability Program (ESP
®) (vehicle type
2500 only)
The Electronic Stability Program (ESP
®) monitors the
vehicle’s traction (force of adhesive friction between
the tires and the road surface) and handling.
The ESP
® recognizes when a wheel is spinning or if the
vehicle starts to skid. By applying brakes to the
appropriate wheel and by limiting engine output, the
ESP
® works to stabilize the vehicle. The ESP® is
especially useful while driving off and on wet or
slippery road surfaces.
The warning lamp v in the speedometer flashes
when the ESP
® is engaged, refer also to "Warning
Lamp Acceleration Skid Control (ASR) and Electronic
Stability Program (ESP
®)".
If wheels with tires of a different size than those offered
by an authorized Sprinter Dealer are used, the correct
operation of the ESP
® cannot be guaranteed.
WARNING!
If the ESP® indicator lamp remains on, the
electronic stability program (ESP®) is malfunc-
tioning. The vehicle stability will no longer be au-
tomatically regulated in good time.
The danger that your vehicle breaks into a skid, is
increased in certain driving situations. Drive with
extra caution.
Have the ESP
® repaired as soon as possible by an
authorized Spinter Dealer.

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5
AUXILIARY DRIVE (OPTIONAL)
Auxiliary drive (1)
Ribbed V-belt (not part of factory package) (2)
Tensioner pulley (3)
Support (4)
Unit (not part of factory package) (5)
NOTE: When retrofitting a unit pay attention to the
running direction of the engine.
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 too closely, or
hydroplaning. Only a safe, attentive, and skillful
driver can prevent accidents.
The capabilities of an ESP
® equipped vehicle
must never be exploited in a reckless or dangerous
manner which could jeopardize the user’s safety
or the safety of others.
If the vehicle is to be towed away with the front
wheels clear of the ground, or if the brakes are to be
tested on a brake dynamometer, do not put the key
in position 2 in the ignition lock because the ESP
®
would engage the brakes to stabilize the vehicle.
If the ESP® function is used for a prolonged
period of time, the rear axle brakes may fail due to
overheating.

176 STARTING AND OPERATING
STEERING
When the engine is not running, there is no power
assistance for the steering. Greater force will be
required to steer the vehicle.
WHEELS AND TIRES
The tires on a new vehicle provide a balance of many
characteristics. They should be inspected regularly for
wear and correct cold tire inflation pressure. The
vehicle manufacturer strongly recommends to use tires
equivalent to the originals in size, quality and
performance when replacement is needed. Refer to the
Tire and Loading Information placard on the driver’s
door B-pillar for the size designation of your tire.
The service description and load identification will be
found on the original equipment tire. Failure to use
equivalent replacement tires may adversely affect the
safety, handling, and ride of your Sprinter vehicle.Contact an authorized Sprinter Dealer or an
authorized tire dealer with any questions you may
have on tire specifications or capability.
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.
WARNING!
Only use tires which have been tested and ap-
proved for your Sprinter vehicle by the vehicle
manufacturer. Tires approved by the vehicle man-
ufacturer are developed to provide best possible
performance in conjunction with the driving safe-
ty systems on your Sprinter vehicle such as ABS or
ESP
®.
Using tires other than those approved by the
vehicle manufacturer may result in damage that is
not covered by Warranty.

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5
To avoid damage to your vehicle, tires or chains,
observe the following precautions:
 Because of limited chain clearance between tires and
other suspension components, it is important that
only chains in good condition are used. Broken
chains can cause serious vehicle damage. Stop the
vehicle immediately if noise occurs that could
suggest chain breakage. Remove the damaged parts
of the chain before further use.
 Install chains as tightly as possible and then
retighten after driving about 1/2 mile (0.8 km).
 Do not exceed 30 mph (50 km/h).
 Drive cautiously and avoid severe turns and large
bumps, especially with a loaded vehicle.
 Do not install tire chains on front wheels.
 Do not drive for a prolonged period on dry
pavement.
 Observe the tire chain manufacturer’s instructions
on method of installation, operating speed, and
conditions for usage. Always use the lower
suggested operating speed of the chain
manufacturer if different than the speed
recommended by the manufacturer.FUEL REQUIREMENTS
Use only commercially available vehicular diesel fuels
No. 2 or No. 1 (ASTM D 975 No. 2-D or No. 1-D).
NOTE: Because of its better quality the manufacturer
recommends the use of commercially available
vehicular diesel fuel No. 2.
For information on cold weather operation, contact
your authorized Sprinter Dealer.
WARNING!
Marine diesel fuel, Bio diesel fuel, heating oil or
the like must not be used.
Do not blend diesel fuel with marine diesel fuel,
Bio diesel fuel or heating oil.
The use of such non-approved fuels or blending
diesel fuel may result in malfunction or cause
engine damage. Damage or malfunctions
resulting from poor fuel quality or from blending
specific fuel additives are not covered by the
Sprinter Warranty.

210 STARTING AND OPERATING
If diesel fuels are used with a sulphur content
exceeding 0.5 % by weight, engine oil change intervals
must be shortened. Please contact your Sprinter Dealer
to obtain the necessary information.
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 Separator
Check the water separator when the fuel indicator
lamp does not go out or comes on while the engine
is running.
The interval for changing the fuel filter is reduced to
10,000 miles (about 15,000 km).
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.

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5
Diesel Fuels for Use at Very Low Temperatures
At very low temperatures the fluidity of No. 2 diesel
fuel may become insufficient due to parraffin
separation. For this reason the vehicle comes equipped
with a fuel preheater. It permits a troublefree engine
operation to a temperature of approximately 14 °F (–
10 °C) when using No. 2 diesel fuel.
To avoid malfunctions, No. 2 diesel fuel of a lowered
cloud point is marketed during the cold season.
At temperatures below 14 °F (–10 °C) use winterized or
No. 1 diesel fuel only. If not available, a certain
quantity of fuel flow improver may be added. Mixing
only to be done within the vehicle’s fuel tank.
Engine power may drop according to the proportion of
fuel flow improver. For this reason, keep percentage of
fuel flow improver added to the minimum
necessitated by the ambient temperature.
Even in extreme climatic conditions, the maximum
mixture ratio should not exceed 50%
Adding of kerosene to diesel fuel is not recommended
even at low temperatures.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)
No. 2 Diesel Fuel: 50 %
Kerosene: 50 %
Even in extreme climatic conditions, the maximum
mixture ratio should not exceed 50 %.
Adding of kerosene to No. 1 diesel fuel is not
recommended even at low temperatures.
Do not blend other specific fuel additives with diesel
fuel except for fuel flow improver. They only result in
unnecessary cost, and may be harmful to the engine
operation.
CAUTION!
Damage or malfunctions resulting from poor fuel
quality or from blending specific fuel additives
are not covered by the Sprinter Warranty.

212 STARTING AND OPERATING
REFUELING
1. Fuel filler neck
2. Fuel filler cap
The fuel filler neck (1) is located behind the fuel filler flap
next to the driver’s door. The fuel filler flap can be opened
when the driver’s door is open. Turn the fuel filler cap (2)
on the fuel filler neck (1) counterclockwise and take it off.
For cargo/passenger vans, place the fuel filler cap (2) in
the holder on the inside of the fuel filler flap.
When you have finished refueling, install the fuel filler
cap (2).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.
Fuel is flammable and explosive. Keep open
flames away from the fuel.
Refrain from smoking as well as use of any
electrical equipment (such as cell phones). This
also applies to places where the characteristic
smell of fuel is evident.
If diesel fumes are noticed inside the vehicle, have
the cause traced and rectified immediately by an
authorized Sprinter Dealer.

214 STARTING AND OPERATING
BLEEDING DIESEL FUEL SYSTEM
If the fuel tank was run empty, the diesel fuel system
must be bled after refueling before starting the engine.
 Turn the key in the ignition lock to position 2 for at
least 30 seconds.
 Return the key to position 0.
 Start the engine three to four times.
The malfunction indicator light (MIL) ± must go
out.
NOTE: Too many attempts to start the engine could
drain the battery. If the engine does not start after
several attempts, consult an authorized Sprinter
Dealer.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 lights up.