maintenance schedule DODGE SPRINTER 2004 1.G Owners Manual

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INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
UNDERSTANDING THE FEATURES OF YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
UNDERSTANDING YOUR INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
STARTING AND OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
WHAT TO DO IN EMERGENCIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
MAINTAINING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
IF YOU NEED CONSUMER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
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MA INTENA NCE SCHEDULES
CONTENTS
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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Maintenance - Without ASSYST Maintenance
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Maintenance Intervals . . . . . . . . . . . . . . . . . . . . 249

Maintenance - With ASSYST Maintenance
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Regular Check-Ups. . . . . . . . . . . . . . . . . . . . . . . . . 250

Special Maintenance Requirements . . . . . . . . . . . 251Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Dust Filter for Heating/Ventilation
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Engine Oil Change and Filter Replacement . . . . 251Once a Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Scope of Work for Maintenance service . . . . . . . 252Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252Additional Maintenance Work . . . . . . . . . . . . . 254Additional Maintenance Work
After ... Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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248 MAINTENANCE SCHEDULES
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INTRODUCTIONThis is intended as a guide to the service requirements
of your vehicle.
It contains all necessary instructions concerning
service intervals and operations which have to be
carried out.
Scope and frequency of maintenance work primarily
depend on the vehicle's operating conditions.
In the interest of maintaining the vehicle's operating
safety, the specified work should be performed
regularly and in good time.
Our vehicles are subject to ongoing development.
Technical progress may also affect the scope of service
work performed.
"Daily vehicle checks" before starting a journey are the
responsibility of the driver.
WA RRA NTYThe Sprinter Dealer network is at your disposal for
maintenance work. Each of these workshops has the
equipment and tools, the specially trained, skilled and
experienced personnel and receives regular technical
instruction from DaimlerChrysler Corporation to
ensure that your vehicle is inspected and maintained
thoroughly and in accordance with the latest
procedures.
Please follow the instructions given in this Owner’s
Manual and ensure that they are observed, even if you
hand the vehicle over to a third party for use or care. By
not observing these instructions you may void your
warranty rights.
If the specified oil and maintenance services are not
carried out regularly or at the time intervals specified,
a decision as to the validity of a warranty claim can
only be made after DaimlerChrysler Corporation has
investigated your claim.
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MAINTENANCE SCHEDULES 249
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The use of Special lubricant additives is not
recommended. The use of such additives may affect
your warranty rights. With regard to legal stipulations
concerning emissions control, please note that engines
have to be serviced and adjusted in accordance with
special instructions and using special measuring
equipment. Modifications to or interference with the
emissions control systems are not permissible.
All Sprinter Dealer are familiar with the relevant and
appliable regulations.
MA INTENA NCE - WITHOUT A SSYST
MA INTENA NCE COMPUTER
Maintenance IntervalsAdditional work must be carried out at yearly
intervals.
As a general rule, to avoid unnecessary visits to the
workshop you should try to have necessary repair
work performed together with other maintenance
work.Oil service
– Refer to
Normal Operation
every
10,000 miles or
16,000 km or 12 months
Maintenance serviceevery
30,000 miles or
48,000 km
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250 MAINTENANCE SCHEDULES
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MA INTENA NCE - WITH A SSYST MA INTENA NCE
COMPUTERASSYST provides you with information on the best
possible timing for maintenance work.
NOTE: The engine manufacturer strongly
recommends the use of synthetic engine oils, such as
Mobil 1 SAE 0W-40.
When the next maintenance service is due, this will be
indicated in the multi-function display with the
symbol
9 Oil service
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.
REGULA R 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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MAINTENANCE SCHEDULES 251
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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 high 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 CHA NGE A ND 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 intervals 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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252 MAINTENANCE SCHEDULES
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SCOPE OF WORK FOR MA INTENA NCE SERVICE
Oil ServiceOil change
Engine:
Oil change and filter replacement
Check fluid levels of the following system, refill as
necessary.
If fluid is lost, trace and eliminate cause – as a separate
order.
Power-assisted steering
Lubrication work:
Trailer tow hitch (original equipment)
Maintenance
ASSYST maintenance computer resetFunction check
Signalling system,
warning and indicator lamps
Headlamps, exterior lighting
Windscreen wipers,
windscreen washer system
Check for leaks and damage.
Check for abrasion points and ensure that
lines are correctly routed!
All assemblies:
Engine, transmission, transfer case, front axle, rear
axle, steering, power steering pump
All lines and hoses, sensor cables
Rubber boots on front axle drive shafts,
rubber boots on front axle suspension ball joints, shock
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MAINTENANCE SCHEDULES 253
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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
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254 MAINTENANCE SCHEDULES
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A dditional 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
A dditional Maintenance Work A fter ... YearsEvery 3 years
Air cleaner filter element renewal
(note installation date
)
Every 5 years or 100,000 miles
Coolant renewal
Note coolant composition
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268 INDEXLock, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Locking, Central. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55MMaintenance Computer . . . . . . . . . . . . . . . . . . . . . . . 103
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . 249
Maintenance Schedules
Additional Maintenance Work
After ... Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Dust Filter for Heating/Ventilation
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Engine Oil Change and Filter Replacement . . . . 251
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Once a Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Regular Check-Ups. . . . . . . . . . . . . . . . . . . . . . . . . 250
Scope of Work for Maintenance service . . . . . . . 252
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
With ASSYST Maintenance Computer . . . . . . . . 250Without ASSYST Maintenance Computer . . . . . 249
Maximum Engine Speed. . . . . . . . . . . . . . . . . . . . . . . 136
Mechanical Sun Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Mechanical Sun Roof Operation . . . . . . . . . . . . . . . . . 75
Mirror Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Mirrors
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Mopar® Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Multi-Function Indicator . . . . . . . . . . . . . . . . . . . . . . . 87
Multifunction Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
OOccupant Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Opening/Closing doors . . . . . . . . . . . . . . . . . . . . . . . . 23
Operation, Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Ornamental Moldings . . . . . . . . . . . . . . . . . . . . . . . . . 222
Outlet, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Outside Temperature Display . . . . . . . . . . . . . . . . . . . 91
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