engine MERCEDES-BENZ SPRINTER 2010 MY10 Operator’s Manual

Modifying the engine power output
Having the engine power output of your
vehicle increased by tampering with the
electronic engine management system will
invalidate the vehicle's general operating
permit and insurance coverage, as well as
your New Vehicle Limited Warranty and
warranty entitlement.
Modifications to the output of the engine
must be reported to the insurance provider
and require the vehicle to be recertified. The
tires, chassis, brake and cooling systems
must be adapted to the increased engine
power output.
Tampering with the electronic engine
management system modifies emission
values and it
will not be possible to guarantee
the operating safety of the engine in every
case. Increases in performance may lead to
malfunctions and consequential damage to
other assemblies.
If you sell the vehicle, failing to inform the
buyer of the modified engine power output
could constitute an offense punishable by
law, depending on the country concerned. Diesel particle filter
! If the vehicle is predominantly used for
short-distance driving, this could lead to a
malfunction in the automatic cleaning
function for the diesel particle filter. As a
result, fuel may accumulate in the engine
oil and cause engine failure.
Therefore, if you mainly drive short
distances, you should

drive on a highway or
on rural roads for 20 minutes every
310 miles (500 km). This ensures sufficient
regeneration of the diesel particle filter. Vehicle alterations
We recommend the use of genuine Sprinter
parts and conversion parts as well as accessories that have been expressly
approved for your vehicle model.
These parts have been subjected to special
tests in order to determine their safety,
reliability and suitability.
!
For safety reasons, have add-on
equipment prepared and installed
according to the

Sprinter body/equipment
mounting directives in force. These body/
equipment mounting directives guarantee
that the chassis and add-on equipment
form a cohesive whole and that the highest
possible level of operating and driving
safety is reached.
We recommend for safety reasons that:
R you carry out no other modifications to
the vehicle.
R you obtain the agreement of the
distributor named on the inside of the
front cover for any deviations from the
approved body/equipment mounting
directives.
Approval by official testing centers or
permission given by authorities do not
eliminate safety risks.
! The wooden or plastic cargo area floor
fitted at the factory is an integral
component of the vehicle structure. The
vehicle body could be damaged if you have
the load area floor removed. This then
affects the securing of loads and the
maximum loading capacity of the lashing
points is no longer guaranteed.
Therefore, do not have the load area floor
removed.
Even seemingly small changes to the vehicle,
such as attaching a radiator cover for winter
driving or as protection against insects, are
not allowed. These could cause the engine
diagnostics to register incorrect data. The
recording of engine diagnostic data is a legal
requirement, and must always be verifiable
and accurate. 18
Introduction

Sprinter body builder guideline
If you intend on making any alterations to the
vehicle, we strongly recommend that you
contact the distributor named on the inside
of the front cover in order to obtain all
necessary information (there may be a
charge).
Body builders and dealers who make 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.
They are responsible for ensuring that
modifications or equipment installation do
not affect the safety of the vehicle. G
Warning
Any modifications or alterations of the
Sprinter 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 injury or death.
Consult the Sprinter Body Builder Guideline
and the Sprinter Operator's Manual prior to
initiating any alterations or modifications.
We are not responsible for any final
certification or claims regarding product
liability, or warranty claims, which result from
any component, assembly, or system being
altered, or which cause non-compliance with
any of the emission control standards or
motor vehicle safety standards, or which
would otherwise cause the vehicle to be or to
become defective or unsafe.
We do not assume responsibility as the final-
stage manufacturer or the consequential
product liability. Correct use
Observe the following

information when using
your vehicle:
R the safety notes in this manual
R the "Technical data" section in this manual
R traffic rules and regulations
R motor vehicle laws and safety standards
Substances constituting a health
hazard Do not store or transport in the cab any
substances that
constitute

a health hazard or
react aggressively.
These include:
R solvents
R fuels
R oils and greases
R cleaning agents
R acids G
Warning
Do not store or transport in the cab any
substances that constitute

a health hazard or
react aggressively. Gases and liquids may
escape from containers that are completely
sealed.
The driver's ability to concentrate while the
vehicle is in motion and the driver's health
could be affected. In addition, electrical
components (e. g. control units and
connectors) could be damaged. This can
result in malfunctions, system failures, or
short circuits which can start a fire.
You could cause an accident, thereby
endangering yourself and others.
Stickers and warning labels G
Warning!
Various warning labels are attached to your
vehicle. These warning

labels are intended to
make you and others aware of various risks.
Do not remove any of these warning labels Introduction
19 Z

Instrument cluster variants
Function Page
0046
Instrument cluster on
vehicles without
steering-wheel buttons
70
0047
Indicator and warning
lamps
008A
0069, 006A Brightens/dims the
instrument cluster lighting 72
0088
Tachometer with indicator
and warning lamps
71
0086
Display 73
0087
Fuel gauge with fuel filler
flap location indicator
72
006E
Speedometer with
indicator and warning
lamps
71
006F
Reset button 0048
70
0070
007B Menu button:
• changes standard display 73
• selects menus 73 Function Page
0071
Instrument cluster on
vehicles with steering-
wheel buttons
70
0072
Indicator and warning
lamps
0073
Display 74
0074
Tachometer with indicator
and warning lamps
71
0075
Fuel gauge with fuel filler
flap location indicator
72
0076
0069, 006A Brightens/dims the
instrument cluster lighting 72
0077
Speedometer with
indicator and warning
lamps
71
0078
Reset button 0048
70
0079
00A4 Service button
Checks the engine oil level 171
Indicator and warning
lamps24
Instrument cluster variants
At a glance

Function Page
0067
ESP
®
warning lamp 50,
187 ASR warning lamp 48,
187 0041
Coolant level too low 193
00AE
Coolant temperature too
high
193
008A
Restraint systems
malfunction
191
0065
Brake fluid level too low 188
EBD malfunction 187
Trailer brake force booster
malfunction
188
00B4
Engine oil level warning 192
00BB
Engine diagnostics
indicator lamp
194
Exhaust gas aftertreatment
malfunction
195
0028
Preglow system 194
004A
Left-hand turn signal 90
0077
Tire pressure loss or the tire
pressure monitor is
malfunctioning (USA only)
195
Tire pressure loss (Canada
only)
195
00BD
Fluid level too low in
windshield washer/
headlamp cleaning system
196
003E
Door open 197
0026
Brake pads/linings worn 191
004D
Right-hand turn signal 90
0031
ABS malfunction 189
003D
ASR malfunction 189
BAS malfunction 189
009E
ESP
®
malfunction 187 Function Page
00E4
DEF supply low or
contaminated/thinned
199
Exhaust gas aftertreatment
malfunction
200
00AB
Dirt accumulation in air
filter
195
00B6
Reserve fuel 193
Fuel filler cap open 194
00BA
Water in the fuel 196
003F
Battery charging
malfunction
191
0055
Bulb defective 197
0066
Parking brake applied 112
0064
Low-beam headlamps on 89
004E
Working speed governor
(ADR) on
117
0063
High-beam headlamps on 90
0080
Reserve fuel 193
Fuel filler cap open 194
0082
Fasten seat belt 196
i
Vehicles with steering-wheel buttons:
Corresponding messages may also be
shown in display 0073(Y page 24). Instrument cluster variants
25At a glance

X
Without twisting it, place the shoulder
section of the seat belt over the center of
the shoulder and the lap section across the
hips.
X Engage belt tongue 0047 in buckle 0088.
X If necessary, adjust the seat belt to the
appropriate height ( Y
page 35).
X If necessary, pull upwards on the shoulder
section of the seat belt to tighten the belt
across your body.
All seat belts in the vehicle, except the
driver's seat
belt, are equipped with a special
seat belt retractor to secure child restraint
systems properly. For further information on
"Special seat belt retractors", see
(Y page 43).
For more information about releasing the seat
belt with release button 0088, see "Releasing
seat belts" ( Y page 35).
Adjusting the seat belt height
You can adjust the seat belt height on the
driver's seat and the outer co-driver's seat.
Adjust the belt to a height that allows the
upper part

of the seat belt to be routed across
the center of your shoulder. X
To raise: slide belt sash guide 0046 upwards.
The belt sash guide engages in various
positions. X
To lower: press and hold belt sash guide
release 0086.
X Slide belt sash guide 0046
downwards.
X Release belt sash guide release 0086 and
make sure that belt sash guide 0046 has
engaged.
Releasing seat belts
X Press release button 008A and guide belt
tongue 0047

back towards belt sash
guide 0046.
! Make sure

that the seat belt retracts fully.
The seat belt or belt buckle may otherwise
become trapped in the door or the seat
adjustment mechanism. This could
damage the door, door trim panels and the
seat belt. Damaged seat belts can no
longer provide the intended degree of
protection and must be replaced. Contact
an authorized Sprinter Dealer.
Belt warning for drivers and co-drivers Regardless of whether the driver's and co-
driver's seat belts have already been
fastened, the 0082 seat belt warning lamp
lights up for six seconds each time the engine
is started. It then goes out once the driver and
the front passenger have fastened their seat
belts.
If the driver's seat belt is not fastened after
the engine is started, an additional warning
tone will sound. The warning tone goes out
after approximately six seconds or once the
driver's seat belt is fastened.
Emergency Tensioning Devices, seat
belt force limiters
If the vehicle is equipped with a driver's front
air bag, the seat belts on the driver's and co-
driver's seats have ETDs.
!
If the front-passenger seat is not
occupied, do not engage the seat belt
tongue in the buckle on the front-
passenger seat. Otherwise, the Emergency Occupant safety
35
Safety Z

Tensioning Device could be triggered in the
event of an accident.
ETDs help remove
slack in the seat belts in an
accident, pulling the seat belt close against
the occupant's body.
ETDs do not correct incorrect seat positions
or incorrectly fastened seat belts.
ETDs do not pull vehicle occupants back
towards the backrest.
If the seat belt is also equipped with a seat
belt force limiter and this is triggered, the
force exerted by the seat belt on the vehicle
occupant is reduced.
The seat belt force limiters are synchronized
with the front air bags, which take on a part
of the deceleration force in an accident. Thus,
the force exerted on the occupant is
distributed over a greater area.
The ETDs can only be triggered if the ignition
is switched on and the restraint systems are
operational, see "SRS warning lamp" .
The ETDs are triggered depending on the type
and severity of an accident:
R in the event of a head-on or rear-end
collision, if the vehicle decelerates or
accelerates rapidly in a longitudinal
direction during the initial stages of the
impact
R in the event of a side impact if the vehicle
decelerates or accelerates rapidly in a
lateral direction and the vehicle is equipped
with side impact air bags and/or window
curtain air bags
R in certain situations, if the system detects
that the vehicle will overturn
If the ETDs are triggered, you will hear a bang
and powder may also be released. In rare
cases the bang may temporarily affect your
hearing. The power emitted is generally not
hazardous to health. The 008A SRS indicator
lamp lights up. G
Warning
Pyrotechnic ETDs that were activated must be
replaced. For your safety, when disposing of the
pyrotechnic ETDs always follow our safety
instructions. These are available at any
authorized Sprinter Dealer.
SRS (Supplemental Restraint System)
Introduction SRS reduces the risk of occupants hitting the
vehicle interior
in

the event of an accident. In
addition, it can reduce the forces the
occupants are subjected to during an
accident.
SRS consists of:
R the 008A SRS indicator lamp
R air bags
R air bag control unit (with crash sensors)
R ETDs for the driver's and co-driver's seat
R seat belt force limiters, for the driver's and
co-driver's seat
008A indicator lamp The SRS system conducts a self-test when
the ignition is switched on and in regular
intervals while the engine is running. This
facilitates detection of system malfunctions.
The 008A SRS indicator lamp in the
instrument cluster comes on when the
ignition is switched on.
It goes out no later than a few seconds after
the engine has been started.
The SRS components are in operational
readiness when
the 008A

SRS indicator lamp
is not lit while the engine is running. G
Warning
The SRS self-check has detected a
malfunction if the 008A SRS indicator lamp:
R does not come on at all
R fails to go out approximately 4 seconds
after the engine was started
R comes on after the engine was started or
while driving36
Occupant safety
Safety

X
Turn both handles 0046 to a horizontal
position. Make sure that locks 008A are in
front of the window frame on the inside.
The window is locked.
X Replace locking pins 0047 before
beginning a
new journey at the latest.
You may obtain information about this from
any authorized Sprinter Dealer. Driving safety systems
Important safety notes
G
Warning
The following factors increase the risk of
accidents:
R Excessive speed, especially in turns
R Wet and slippery road surfaces
R Following another vehicle too closely
The driving safety systems described in this
section cannot reduce these risks or prevent
the natural laws

of physics from acting on the
vehicle. They cannot increase braking or
steering efficiency beyond that afforded by
the condition of the vehicle brakes and tires
or the traction afforded.
Only a safe, attentive, and skillful driver can
prevent accidents.
The capabilities of a vehicle equipped with the
driving safety systems described in this
section must never be exploited in a reckless
or dangerous manner which could jeopardize
the user's safety or the safety of others.
Always adjust your driving style to the
prevailing road and weather conditions and
keep a safe distance to other road users and
objects on the street.
If a driving system malfunctions, other driving
safety systems may also switch off. Observe
indicator and warning lamps that may come
on as well as messages in the multifunction
display that may appear.
i In wintry driving conditions, always use
winter tires (M+S tires) and if necessary, snow chains. Only in this way will the
driving safety systems described in this
section work as effectively as possible.
Overview
In this section,

you will find information about
the following driving safety systems:
R ABS ( Anti-lock Braking System)
R BAS ( Brake Assist System)
R ESP ®
(Electronic Stability Program)
R ASR (Acceleration Skid Control)
R EBD ( Electronic Brake force Distribution) ABS (Anti-lock Braking System)
Important safety notes G
Warning
Observe "Important safety notes"
(Y page 47). G
Warning!
Do not pump the brake pedal. Use firm, steady
brake pedal pressure instead. Pumping the
brake pedal reduces the braking effect.
ABS regulates brake pressure in such a way
that the wheels do not lock during braking.
This allows you

to maintain the ability to steer
your vehicle.
ABS works from a speed of about 3 mph
(5 km/h) upwards, regardless of road-surface
conditions. ABS works on slippery surfaces,
even when you only brake gently.
The 0031 warning lamp in the instrument
cluster lights up when the ignition is switched
on. It goes out when the engine is running.
Braking If ABS intervenes when braking, you will feel
a pulsating in the brake pedal.
If the
0067 warning lamp flashes, this may
indicate dangerous road conditions and Driving safety systems
47
Safety Z

serves as a reminder to take extra care while
driving.
X
If ABS intervenes: continue to depress the
brake pedal with force until the braking
situation is over.
X To make a full brake application:
depress the brake pedal with full force. G
Warning
If the ABS malfunctions, other driving systems
such as the

BAS or the ESP ®
are also switched
off. Observe indicator and warning lamps that
may come on as well as messages in the
multifunction display that may appear.
If the ABS malfunctions, the wheels may lock
during hard braking, reducing the steering
capability and extending the braking distance. BAS (Brake Assist System)
G
Warning
Observe "Important safety notes"
(Y page 47).
BAS operates in emergency braking
situations. If you depress the brake pedal
quickly, BAS automatically

boosts the braking
force, potentially reducing the stopping
distance.
X Keep the brake pedal firmly depressed until
the emergency braking situation is over.
ABS prevents the wheels from locking.
The brakes will function as usual once you
release the brake pedal. BAS is deactivated. G
Warning
If the BAS malfunctions, the brake system still
functions, but without the additional brake
boost available that the BAS would normally
provide in an emergency braking maneuver.
Therefore, the braking

distance may increase. EBD (Electronic Brake force
Distribution)
G
Warning
Observe "Important safety notes"
(Y page 47).
EBD monitors and controls the brake
pressure on the rear wheels to improve
driving stability while braking. G
Warning
If the 009E, 003D, 0031 and 0065 indicator
lamps light up while the vehicle is in motion,
EBD may be defective.
If EBD malfunctions,

the brake system will still
function with full brake boost. However, the
rear wheels could lock up during emergency
braking situations, for example. You could
lose control of the vehicle and cause an
accident.
Adapt your driving style to the changed
driving characteristics. ASR (acceleration skid control)
Important safety notes G
Warning
Observe "Important safety notes"
(Y page 47).
ASR can significantly improve traction, i.e.
the transmission of power from the tires to
the road surface, and thus may increase the
vehicle's driving stability. ASR assists in
pulling away and

accelerating, particularly on
smooth and slippery surfaces.
ASR can brake individual wheels and limits
the engine torque to help prevent the drive
wheels from spinning.
If ASR intervenes, the 0067 warning lamp
flashes in the instrument cluster. 48
Driving safety systems
Safety

G
Warning
Never switch off ASR when you see the
0067 warning lamp
flashing in the instrument
cluster. In this case proceed as follows:
R when driving off, apply as little throttle as
possible.
R while driving, ease off the accelerator
pedal.
R adapt your speed and driving style to the
prevailing road conditions.
Failure to observe these guidelines could
cause the vehicle to skid. ESP ®
cannot
prevent accidents resulting from excessive
speed.
If, taking tires, cargo load and gradient into
consideration, the surface driven on still
provides insufficient traction, you may
experience difficulties in pulling away despite
ASR.
Vehicles without steering-wheel buttons:
the 003D indicator lamp in the instrument
cluster lights up when you switch on the
ignition. It goes out when the engine is
running.
Activating/deactivating ASR G
Warning
ASR should
not be switched off during normal
driving other than in the circumstances
described below. Deactivating

the system will
reduce vehicle stability in driving maneuvers.
Do not switch off ASR when a spare wheel is
mounted.
ASR is activated automatically when the
engine is running.
It may be best to deactivate ASR briefly in the
following situations:
R when using snow chains
R in deep snow
R on sand or gravel If you deactivate ASR:
R
the engine's torque

is no longer limited and
the drive wheels can spin. The spinning of
the wheels results in a cutting action, which
provides better grip.
R brake intervention will continue to improve
traction where a drive wheel begins to spin,
e.g. if only the side of the road is slippery.
The wheel will be braked to increase
traction under such circumstances.
R active brake intervention by ESP ®
to
increase driving stability remains active. G
Warning
Even with ASR deactivated, ESP ®
remains
active and continues to perform brake
interventions where this is necessary to
improve driving stability. The 0067 warning
lamp flashes.
With ASR deactivated, there is an increased
risk of your vehicle's brake system
overheating and suffering damage due to
prolonged application. A

hot brake system will
also result in increased stopping distance.
Therefore, only deactivate ASR when
absolutely necessary. X
Press button 0046
.
When ASR is

deactivated, the 0067 warning
lamp in the instrument cluster lights up. Driving safety systems
49
Safety Z

ESP
®
(Electronic Stability Program) G
Warning
Observe "Important safety notes"
(Y page 47).
If ESP ®
detects that the vehicle is deviating
from the direction desired by the driver, one
or more wheels are braked to help stabilize
the vehicle. If

necessary, the engine output is
also modified to help keep the vehicle on the
desired course within physical limits. ESP ®
assists the driver when pulling away on wet
or slippery roads. ESP ®
can also help stabilize
the vehicle during braking.
If ESP ®
intervenes, the 0067 warning lamp
flashes in the instrument cluster. G
Warning
If the 009E

indicator lamp remains lit, ESP ®
is
not available due to a malfunction. Vehicle
stability in standard driving maneuvers is
reduced.
Adapt your speed and driving style to the
prevailing road conditions and to the non-
operating status of ESP ®
.
If ESP ®
is malfunctioning, the engine output
may be reduced.
! Only operate the vehicle for a maximum
of ten seconds on a brake test
dynamometer. Switch off the ignition.
Application of the brakes by ESP ®
may
otherwise destroy the brake system.
! Do not operate the vehicle on a
dynamometer

(e.g. for a performance test).
If you would like to operate the vehicle on
a dynamometer, consult an authorized
Sprinter Dealer beforehand. The drive train
or brake system could otherwise be
damaged.
i Only use wheels with the recommended
tire sizes. Only then will ESP ®
function
properly. 50
Driving safety systems
Safety