engine DODGE SPRINTER 2004 1.G Manual PDF

176 STARTING AND OPERATING 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.
Bleeding the Diesel Fuel SystemThe diesel fuel system is 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.
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STARTING AND OPERATING 181
5
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.
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STARTING AND OPERATING 183
5
EMISSIONS CONTROL SYSTEM (CATALYTIC
CONVERTER)
FORDING (WA DING CA PA BILITY)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.
BODY BUILDER GUIDELINEIf you intend on making any alterations to the vehicle,
we strongly recommend that you call DaimlerChrysler
Corporation at telephone 704-655-1050 or 704-655-1054
to request a copy of the Sprinter Body Builder
Guideline.
Body 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.
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!
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.
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WHAT TO DO IN EMERGENCIES
6
CONTENTS
Hazard Warning Flasher Switch . . . . . . . . . . . . . 186

Vehicle Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . 187Spare Wheel Location . . . . . . . . . . . . . . . . . . . . 189

Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Using the Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Removing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 195

Installing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 200If the Engine is Damaged . . . . . . . . . . . . . . . . . 201If the Transmission is Damaged . . . . . . . . . . . . 201If the Front Axle is Damaged . . . . . . . . . . . . . . 202If the Rear Axle is Damaged . . . . . . . . . . . . . . . 202
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192 WHAT TO DO IN EMERGENCIESSpare Wheel Location for Chassis
1. Loosen thumb nuts by hand and remove.
2. Use wrench to loosen fixing nut to the thread end.
3. Lift spare wheel holder.
4. Turn hooks to the side and lower spare wheel
holder. Remove the spare wheel.
JA CK
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.
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198 WHAT TO DO IN EMERGENCIES
Tightening torque for 9,990 lbs (4,530 kgs)
(vehicle type 3500 C/HC/SHC):
Steel wheel – 138 lbf.ft ±14 lbf.ft (190 N.m ±20 N.m)
 Remove jack and stow it in the vehicle tool kit.
 Check the tire pressure.
 Re-tighten the wheel bolts to the specified torque
with a torque wrench after a distance of 30 miles
(about 50 km).
JUMP STA RTINGIf 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 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).
 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 also 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.
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WHAT TO DO IN EMERGENCIES 199
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. 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.
The battery housing could be damaged. Never
lean over batteries while connecting or jump-
starting. You might get injured.
Read all instructions before proceeding.
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200 WHAT TO DO IN EMERGENCIES1. 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
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WHAT TO DO IN EMERGENCIES 201
6
If the Engine is DamagedFor towing distances up to 30 miles (about 50 km)
 Shift selector lever to "N" position.
 Do not exceed a towing speed of 30 mph (50 km / h).
For towing distances greater than 30 miles (about
50 km)
 Remove the propeller shafts leading to the drive
axles.
The vehicle can be towed without restriction.If the Transmission is Damaged Remove the propeller shafts leading to the drive
axles.
WARNING!
Do not tow the vehicle if the key cannot be turned
in the ignition lock.
If the key cannot be turned, the ignition lock re-
mains locked and the vehicle cannot be steered.
With the engine not running there is no power
assistance for the braking and steering systems.
In this case, it is important to keep in mind that a
considerably higher degree of effort is necessary
to brake and steer the vehicle.
The vehicle must not be towed with the front axle
raised and the key in position 2 in the ignition
lock as the drive wheels could then lock due to the
acceleration skid control (ASR) or the optional
Electronic Stability Program (ESP).
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202 WHAT TO DO IN EMERGENCIESIf the Front Axle is DamagedRaise the front axle.
 Observe the same towing restrictions as for engine
damage.
If the Rear Axle is Damaged  Raise the rear axle.
NOTE: Comply with local legal regulations regarding
towing vehicles.
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