engine DODGE SPRINTER 2006 1.G Manual PDF

STARTING AND OPERATING 215
5
NOTE: Prior to opening water drain screw (3), place a
suitable receptacle underneath the drain hose (2). Turn
water drain screw (3) on and off only by hand.
Diesel fuels and diesel fuel mixtures must be disposed
of properly; we recommend water be drained from fuel
filters by an authorized Sprinter Dealer.
Draining Fuel Filter
 Stop the engine.
 Shift gear selector lever to ‘‘P’’ position.
 Open the hood.
 Place a suitable receptacle underneath the drain
hose (2).
 Turn the key in the ignition lock to position 2. Open immediately the water drain screw (3) about 1
turn (counterclockwise) until fluid emerges. Ensure
that the fluid is collected in the receptacle.
 Close the water drain screw (3) as soon as about 0.25
US qt (0.2 liters) are emerged.
 After draining, return the key in the ignition lock to
position 0.
 Dispose of the collected fluid in an environmentally
responsible manner.
 If the filter is still saturated, drain the filter once
more.
After draining, the engine may run briefly but stall for
lack of fuel. If this occurs, bleed the system.
NOTE: Should the water in the fuel indicator lamp
still not go out after the fuel filter has been drained
twice, the cause should be examined by an authorized
Sprinter Dealer.
CAUTION!
Delaying draining of the fuel filter for a
considerable time after the indicator lamp lights
up may lead to engine damage.

216 STARTING AND OPERATING
Bleeding the Diesel Fuel System
The diesel fuel system must be bled before starting the
engine.
 Turn the key in the ignition lock position 2 for at
least 30 seconds.
 Return the key to position 0.
 Start the engine three to four times. The engine
control unit indicator lamp± 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.PERMISSIBLE ROOF LOAD
The 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.
LOADING THE VEHICLE
Two labels on the vehicle show how much weight it
may properly carry.
 The Tire and Loading Information placard can be
found on the driver’s door B-pillar. This placard
tells you important information about the number
of people that can be in the vehicle and the total
weight that can be carried in the vehicle. It also
contains information on the proper size and
recommended tire inflation pressures for the
original equipment tires on the vehicle.
 The Certification Label can be found below the
driver’s seat on an outward facing position of the
mounting pillar. It tells you about the gross weight

226 STARTING AND OPERATING
WARNING!
Take into consideration that when towing a trail-
er, the handling characteristics are different and
less stable from those when operating the vehicle
without a trailer.
It is important to avoid sudden maneuvers.
Sudden maneuvers may lead to loss of control
over the vehicle-trailer combination. This could
cause an accident resulting in property damage or
injury to you or others.
CAUTION!
If the transmission hunts between gears on
inclines, manually shift to a lower gear (select
"4",
"3", "2" or"1"). A lower gear and reduction of
speed reduces the chance of engine overloading
and / or overheating.
When going down a long hill, shift into a lower
gear and use the engine’s braking effect. Avoid
riding the brakes, thus overheating the vehicle
and trailer brakes.
If the engine coolant rises to an extremely high
temperature (coolant temperature needle
approaching the red zone) when the air
conditioner is on, turn off the air conditioner.
Engine coolant heat can be additionally vented by
opening the windows, switching the climate
control fan speed to high and setting the
temperature control to the maximum hot position.

228 STARTING AND OPERATING
EMISSIONS CONTROL SYSTEM (CATALYTIC
CONVERTER)
INHALATION OF EXHAUST GASFORDING (WADING CAPABILITY)
Avoid fording flooded roads or passing through water
unless you are certain as to how deep it is. Driving
through deep water can cause damage to the vehicle,
including but not limited to the electrical components,
engine, transmission, etc. This type of damage is not
covered under the Warranty.
WARNING!
When driving or parking the vehicle, make sure
that its exhaust system does not come into contact
with flammable material (such as dry leaves) as
these materials may otherwise catch fire.
WARNING!
Inhalation of exhaust gas is hazardous to your
health. All exhaust gas contains carbon monoxide
and inhaling it can cause unconsciousness and
lead to death.
Do not run the engine in confined areas (such as a
garage) which are not properly ventilated. If you
think that exhaust gas fumes are entering the
vehicle while driving, have the cause determined
and corrected immediately. If you must drive
under these conditions, drive only with at least
o
ne window fully open.

STARTING AND OPERATING 229
5
BODY BUILDER GUIDELINE
If you intend on making any alterations to the vehicle,
we strongly recommend that you select one of the
following options in order to obtain all necessary
information:
1. Contact the authorized Sprinter Dealer nearest you
to obtain a copy of the Sprinter Body Builder
Guideline.
2. Call DaimlerChrysler Vans LLC at telephone (800)
992-1997 to request a copy of the Sprinter Body
Builder Guideline (there may be a charge).
3. Write to the following address and order the
Sprinter Body Builder Guideline (there may be a
charge).
DaimlerChrysler Vans LLC
P.O. Box 21-8004
Auburn Hills, MI 48321-8004
United States of AmericaBody Builders and Dealers who makes any
modifications which may affect the final certification of
the engine, vehicle or equipment assume the sole
responsibility for the vehicle, including labeling and
documentation, affected by their modifications.
It is their responsibility to certify that the altered
vehicle conforms to all applicable standards and
regulations affected by the vehicle alteration or
continues to comply with the Motor Vehicle Safety
standards and Emissions regulations.
WARNING!
Any modifications or alterations of the Sprinter
vehicle not in compliance with the Sprinter Body
Builder Guideline and the Sprinter Operator’s
Manual may seriously inhibit its roadworthiness
and safety and may lead to an accident resulting in
serious personal injury or death. Consult the
Sprinter Body Builder Guideline and the Sprinter
Operator’s Manual prior to initiating any alter-
ations or modifications.

WHAT TO DO IN EMERGENCIES 231
6
Q Hazard Warning Flasher Switch . . . . . . . . . . . . . 232
Q Fire Extinguisher (Optional) . . . . . . . . . . . . . . . . . 233
Q Vehicle Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Q Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . 234
…Spare Wheel Location . . . . . . . . . . . . . . . . . . . . 236
Q Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
…Using the Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Q Removing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 242
Q Installing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Q Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Q Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 248
…If the Engine is Damaged . . . . . . . . . . . . . . . . . 249
…If the Transmission is Damaged . . . . . . . . . . . . 249
…If the Front Axle is Damaged . . . . . . . . . . . . . . 249
…If the Rear Axle is Damaged . . . . . . . . . . . . . . . 249

WHAT TO DO IN EMERGENCIES 239
6
JACK Using the Jack
The jack is located together with the vehicle tool kit
under the hatch in the front passenger footwell, refer to
"Vehicle Tool Kit".
1. Loosen the wheel bolts before raising the vehicle.
2. Close the release valve on the jack.
3. Assemble the pump lever provided and insert it
into the socket on the jack.
4. Secure the lever by turning it clockwise in the
socket.
Position the jack under the appropriate jack point and
raise the vehicle by pumping the lever.
WARNING!
To avoid the risk of serious or fatal injuries or vehicle
damage, please bear the following points in mind:
 The jack is intended only for raising the vehicle
briefly, for instance, when changing a wheel. If it is
not designed to enable work to be carried out
underneath the vehicle.
Do not crawl under the jacked-up vehicle. For work
under the vehicle, stands must be used.
 The jack must be placed on a firm, flat surface only.
 Do not change wheels on uphill or downhill
gradients under any circumstances.
 Make sure that no persons are present in the vehicle
when jacking up the vehicle.
 Do not start the engine while the vehicle is raised.
 Make sure that the distance between the underside
of the tires and the ground does not exceed 1.2 in (30
mm). Otherwise the vehicle may tip over.

246 WHAT TO DO IN EMERGENCIES
JUMP STARTING
If the battery is dead, the engine can be started with
jumper cables from another vehicle’s battery.
WARNING!
After changing a wheel, you must, for safety reasons,
 have the specified tightening torque checked. The
wheels could otherwise work loose.
 check the tire inflation pressure and correct it if
necessary.
 retighten the wheel bolts and wheel nuts to the
specified tightening torque once the vehicle has
been driven for 30 miles (50 km). If new or
repainted wheels are fitted, the wheel bolts or nuts
must be retightened again after about 600 to 3,000
miles (about 1,000 to 5,000 km).
 have a reversed direction of tire rotation corrected
as soon as possible at a qualified specialist
workshop. The vehicle handling characteristics
could otherwise be affected.WARNING!
A battery will produce hydrogen gas, which is
flammable and very explosive. Avoid open flames
and the formation of sparks in the vicinity of the
batteries. Refrain from smoking or cell phone use.
Avoid improper connection of jumper cables.
Observe safety precautions when handling
batteries.
Exercise care near moving engine components and
electrical cables.
Failure to follow these directions will cause
damage to the electronic components and can lead
to a battery explosion and severe injury or death.

WHAT TO DO IN EMERGENCIES 247
6
 A dead battery can freeze at a temperature of 14°F
(–10°C). Never try to start the engine if the battery
is frozen. Thaw the battery out first.
 Only use a battery of the same rated voltage and of
approximately the same capacity for jump-starting.
 The two vehicles must not touch.
 Switch off all electrical accessories.
 Run the vehicle with the booster battery at idle.
 Connect the jumper cables in the sequence given in
the illustration.
WARNING!
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 affect-
ed area with water, and seek medical help.
The battery housing could be damaged. Never
lean over batteries while connecting or jump-
starting. You might get injured.
Read all instructions before proceeding.

248 WHAT TO DO IN EMERGENCIES
1. First connect the positive terminals of the two
batteries (see illustration, Items 1 + 2). Start with the
booster battery.
2. Then connect the negative terminal of the vehicle
with the booster battery to a vehicle ground point
of the vehicle with the discharged battery, such as
to the engine block (see illustration, Items 3 + 4).
Start with the booster battery.
3. Start the engine in the customary manner.
4. Allow the engine to run for a short time.
5. Before disconnecting the jumper cables from the
vehicle with the booster battery, switch on an
electrical consumer (e.g. the blower, but not the
lamps).
6. Disconnect the jumper cables in the reverse order to
that in which they were connected.
7. Disconnect the jumper cable from negative
terminal and vehicle ground point first (see
illustration, items 3 + 4), then from positive
terminals of the batteries (see illustration 1 + 2).
NOTE: Never try to start the engine with the aid of a
battery quick-charge unit.TOWING THE VEHICLE