brake DODGE SPRINTER 2005 1.G Service Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 2005, Model line: SPRINTER, Model: DODGE SPRINTER 2005 1.GPages: 288, PDF Size: 27.89 MB
Page 190 of 288
190 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.
Page 191 of 288
STARTING AND OPERATING 191
5
Parking a Trailer
CAUTION!
Extreme care must be exercised since your vehicle
with a trailer will require additional passing
distance ahead than when driving without a
trailer. Because your vehicle and trailer is longer
than your vehicle alone, you will also need to go
much farther ahead of the passed vehicle before
you can return to your lane.
WARNING!
To reduce the risk of personal injury, or damage to
the vehicle powertrain, as a result of vehicle/trail-
er movement, always:
Keep right foot on brake pedal.
Shift gear selector lever to position
"N".
Have a second person place wheel chocks on
downhill side of left and right trailer wheels.
Slowly release brake pedal and let vehicle and
trailer roll into chocks until stopped.
Firmly depress parking brake pedal.
Move gear selector lever to position
"P".
On inclines turn front wheels towards the road
curb.
Page 198 of 288
198 WHAT TO DO IN EMERGENCIESCHANGING THE TIREIf you get a flat tire while driving, gradually decrease
your speed. Hold the steering wheel firmly and slowly
move to a safe place on the side of the road. The
pressure of the spare wheel always has to be checked
regularly (at least after every tenth time at the filling
station).
WARNING!
Only certain tires meeting the tire size/load/speed
rating specifications contained in the Tire Pres-
sure Tables are certified to conform to FMVSS 120
for the Sprinter vehicle at this time. Please check
your side walls of your originally equipped tires
for specific makes/sizes, and speed load ratings
when you need to replace your tires.
To prevent accident, injury or possible death, use
only the correct tires for your tire replacement.
WARNING!
The jack is designed exclusively for jacking up the
vehicle at the jack take-up brackets built into ei-
ther side of the vehicle. To help avoid personal in-
jury, use the jack only to lift the vehicle during a
wheel change. Never get beneath the vehicle
while it is supported by the jack only.
Keep hands and feet away from the area under the
lifted vehicle. Always firmly set parking brake
and block wheels before raising vehicle with jack.
Do not disengage parking brake while the vehicle
is raised.
Always use the jack on a level surface.
Do not change wheels on either steep uphill or
downhill grades. Be sure that the jack arm end is
fully seated in the jack take-up bracket. The
vehicle may begin to move and fall from the jack
which could cause serious or fatal personal injury
and property damage.
Always lower the vehicle onto sufficient capacity
jack stands before working under the vehicle.
Page 199 of 288
WHAT TO DO IN EMERGENCIES 199
6
Procedure:
1. Park the vehicle on a firm, level, non-slippery surface.
2. Switch on the hazard warning flasher switch, apply the parking brake, and place the transmission
selector in "P".
3. Everyone must leave the vehicle before you jack it up.
4. Everyone must leave the danger zone, before jacking the vehicle. 5. The vehicle must be safeguarded in accordance
with legal regulations (such as using a warning
triangle).
6. Prevent vehicle from rolling away by blocking wheels with wheel chocks (not supplied with
vehicle) or sizable wood block or stone.
On a level road, place one chock in front of and one
behind the wheel that is diagonally opposite to the
wheel being changed.
When changing a wheel on mild uphill or downhill
grades, place chocks on the downhill side blocking
both wheels of the other axle.
Do not jack the vehicle up more than 1.2 in (30
mm) between the tire and the surface. Otherwise,
the vehicle may tip over and may cause serious
injury or death to you or others.
Precautions when changing a wheel:
For the torque, refer to
"Installing a wheel ";
Do not damage, grease or oil wheel bolts or their
threads.
WARNING!
Do not change wheels on either steep uphill or
downhill grades. The vehicle may begin to move
and fall from the jack which could cause personal
injury and property damage.
Page 211 of 288
WHAT TO DO IN EMERGENCIES 211
6
TOWING THE VEHICLE
*Vehicle Type 2500 only
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)
*.
Page 213 of 288
MAINTAINING YOUR VEHICLE
7
CONTENTS
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . 215
Sprinter Original Parts . . . . . . . . . . . . . . . . . . . . . . 217
Service Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Disposal of Service Products . . . . . . . . . . . . . . 218
Emission Related Component Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Regular Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Windshield Washer System Fluid Reservoir . 219Air Filter Restriction Indicator (Optional) . . . 219Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 221Ribbed V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Hydraulic Brake System, Clutch
Mechanism Fluid Level . . . . . . . . . . . . . . . . . . . 222Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Engine Cooling System . . . . . . . . . . . . . . . . . . . 223
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 223Checking Coolant Level . . . . . . . . . . . . . . . . . . 224
Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227Disconnecting the Battery . . . . . . . . . . . . . . . . . 227Reconnecting the Battery . . . . . . . . . . . . . . . . . . 228Charging the Battery . . . . . . . . . . . . . . . . . . . . . 228
Replacing Wiper Blades . . . . . . . . . . . . . . . . . . . . . 230Appearance Care and Corrosion Protection . 231Power Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Automatic Car Wash . . . . . . . . . . . . . . . . . . . . . 233Tar Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Paintwork, Painted Body Components . . . . . . 233Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 233Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . 234Ornamental Moldings . . . . . . . . . . . . . . . . . . . . 234
Page 214 of 288
214 MAINTAINING YOUR VEHICLE
Headlamps, Taillamps, Identification Lamps,
Turn Signal Lenses . . . . . . . . . . . . . . . . . . . . . . . 234Reversing Aid Sensors . . . . . . . . . . . . . . . . . . . . 235Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . 235Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . 236Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 236Steering Wheel and Gear Selector Lever . . . . 236Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Headliner and Shelf Below Rear Window . . . 237Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . 237Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . 238
Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Standard Fuse and Relay Equipment . . . . . . . 239Relay Assignment, Standard Equipment . . . . 242Fuse and Relay Optional Equipment . . . . . . . 242
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 245Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . 245Taillamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250License Plate Lamps
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252Additional Brake Lamp
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252Side-Mounted Turn Signals . . . . . . . . . . . . . . . 253Side-Marker Lamps,
Standing Lamps (Optional) . . . . . . . . . . . . . . . . 253Identification Lamps (Cargo/
passenger vans only) . . . . . . . . . . . . . . . . . . . . . 254Interior Lighting in Passenger Compartment
and Load Compartment . . . . . . . . . . . . . . . . . . 254Interior Lighting with Reading Lamp . . . . . . . 255Interior Lighting with Interior Sensor
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255Exit Lamps (Optional) . . . . . . . . . . . . . . . . . . . . 256
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257Recommended Fluids and Lubricants . . . . . . 258
Page 216 of 288
216 MAINTAINING YOUR VEHICLELegend For Engine Compartment
1. Windshield washer system fluid reservoir.
2. Maintenance indicator for air cleaner element (Optional).
3. Oil dipstick.
4. Oil filler neck.
5. Ribbed V-belt. Auxiliary drive (Optional) refer to “Auxiliary
drive“. 6. Fuel filter with water separator.
7. Hydraulic brake fluid reservoir.
8. Coolant reservoir.
9. Battery
The auxiliary battery is located underneath the
front passenger seat (optional equipment).
10. Fuse box (These special fuses should only be replaced at by
an authorized Sprinter Dealer).
Page 217 of 288
MAINTAINING YOUR VEHICLE 217
7
SPRINTER ORIGINAL PARTSEvery authorized Sprinter Dealer maintains a stock of
Sprinter original parts for maintenance and repair work.Over 6,000 retailers around the world guarantee that
you can be supplied with Sprinter original parts
wherever you are. Over 300,000 different parts and
assemblies, including parts for older vehicle models,
are distributed from a central parts warehouse using
an optimally tuned logistics concept.
Sprinter original parts are subjected to the most
stringent quality inspections and will ensure that the
vehicle is maintained at a high level of operating
efficiency and safety, and that it maintains its value.
Each part has been specifically designed and
manufactured or selected and approved for use in
Sprinter vehicles.
It is therefore best to use only Sprinter original parts.For cost-effective repairs in accordance with sound
recycling principles, the use of non-genuine parts and
accessories not authorized by the manufacturer could
damage the vehicle or compromise its durability or safety. When ordering original parts, always provide the
vehicle identification number and the engine number.
SERVICE PRODUCTSMechanical elements and the lubricants used for them
must be carefully matched.
For this reason, only brands tested and approved by
the manufacturer should be used. Please contact your
Sprinter Dealer to obtain the necessary information.
No lubricant additives should be used.
The use of such additives could affect your warranty
rights. Information is available from any authorized
Sprinter Dealer.
For specifications of engine oils, coolant and brake
fluid, contact your authorized Sprinter Dealer.
WARNING!
If handled incorrectly, service products can consti-
tute a health risk for people and an environmental
hazard.
Always observe relevant guidelines for handling,
storing and disposing of service products.
Page 218 of 288
218 MAINTAINING YOUR VEHICLEDisposal of Service ProductsDispose of service products and of parts which come
into contact with them (e.g. filters) in an
environmentally responsible manner. Comply with
applicable bars and regulations.EMISSION RELATED COMPONENT WARRANTY
STATEMENTThe Manufacturer warrants to the original and each
subsequent owner of a Sprinter heavy-duty on
highway diesel engine that:
(1) the engine was designed, built and equipped so as
to conform at the time of sale with the applicable
regulations adopted by the Federal Environmental
Protection Agency, and
(2) the emission control system of such engine is free
from defects in materials and workmanship which
would cause it not to conform with those regulations
for a period of use of five years or 100 000 miles or
3 000 hours of engine operation, whichever occurs
first.
REGULAR CHECKSThe following checks should be performed at regular
intervals (for example once a week or each time the
vehicle is refueled):
Windshield cleaner system – fluid reservoir.
Air strainer, in vehicles with an air strainer element maintenance indicator (optional equipment).
Engine oil level.
Checking ribbed V-belt.
Hydraulic brake system, clutch mechanism fluid level.
Coolant level.
Tire and spare wheel condition and pressures of the same. For more information, refer to "Wheels and
Tires".
Vehicle lighting.