wheel DODGE SPRINTER 2005 1.G Service Manual

208 WHAT TO DO IN EMERGENCIESCentering wheels with wheel bolts
 If dual assemblies are used, before placement the inner wheel should be inspected to ensure that all
ball bearing rings are in proper position.
 Install the wheel and snug the wheel bolts.
 Slightly tighten wheel bolts.
 Slowly open jack release va lve to lower vehicle until
tire is resting on ground.
 Tighten the wheel bolts in a crosswise pattern to the specified torque with a torque wrench.
Tightening torque for 8,550 lbs (3,880 kgs)
(vehicle type 2500 C/HC/SHC):
Steel wheel – 177 lbf.ft ±7 lbf.ft (240 N.m ±10 N.m)
Light alloy wheel – 138 lbf.ft ±14 lbf.ft
(190 N.m ±20 N.m) Tightening torque for 9,990 lbs (4,530 kgs)
(vehicle type 3500 C/HC/SHC):
Steel wheel – 138lbf.ft ±14lbf.ft (190N.m ±20N.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).
WARNING!
Do not tighten the wheel bolts and wheel nuts
completely while the vehicle is still jacked up.
The vehicle could tip.
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.

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)
*.

214 MAINTAINING YOUR VEHICLE

Headlamps, Taillamps, Identification Lamps,
Turn Signal Lenses . . . . . . . . . . . . . . . . . . . . . . . 234
Reversing Aid Sensors . . . . . . . . . . . . . . . . . . . . 235
Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . 235
Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . 236
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 236
Steering Wheel and Gear Selector Lever . . . . 236
Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Headliner and Shelf Below Rear Window . . . 237
Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . 237
Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . 238


Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Standard Fuse and Relay Equipment . . . . . . . 239
Relay Assignment, Standard Equipment . . . . 242
Fuse and Relay Optional Equipment . . . . . . . 242


Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . 245
Taillamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
License Plate Lamps
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252
Additional Brake Lamp
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 252
Side-Mounted Turn Signals . . . . . . . . . . . . . . . 253
Side-Marker Lamps,
Standing Lamps (Optional) . . . . . . . . . . . . . . . . 253
Identification Lamps (Cargo/
passenger vans only) . . . . . . . . . . . . . . . . . . . . . 254
Interior Lighting in Passenger Compartment
and Load Compartment . . . . . . . . . . . . . . . . . . 254
Interior Lighting with Reading Lamp . . . . . . . 255
Interior Lighting with Interior Sensor
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Exit Lamps (Optional) . . . . . . . . . . . . . . . . . . . . 256


Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Recommended Fluids and Lubricants . . . . . . 258

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.

234 MAINTAINING YOUR VEHICLECorrosion protection, such as anticorrosion wax
should be applied to the engine compartment after
every engine cleaning. Before applying, all control
linkage bushings and joints should be lubricated. The
poly-V-belt and all pulleys should be protected from
any wax.Vehicle WashingDo not use hot water or wash your vehicle in direct
sunlight. Use only a mild car wash detergent.
Thoroughly spray the vehicle with a diffused jet of
water. Direct only a very weak spray towards the
ventilation intake. Use plenty of water and rinse the
sponge and chamois frequently.
Rinse with clear water and thoroughly wipe dry with a
chamois. Do not allow cleaning agents to dry on the
finish.
Due to the width of the vehicle, prior to running the
vehicle through an automatic car wash, fold back the
outside mirrors to prevent them from getting
damaged.
In the winter, thoroughly remove all traces of road salt
as soon as possible. When washing the underbody, do not forget to clean
the inner sides of the wheels.
Ornamental MoldingsFor regular cleaning and care of very dirty chrome-
plated parts, use a chrome cleaner.Headlamps, Taillamps, Identification Lamps, Turn
Signal LensesUse a mild car wash detergent with plenty of water.
To prevent scratches, never apply strong force and use
only a soft, non-scratchy cloth when cleaning the
lenses. Do not attempt to wipe dirty lenses with a dry
cloth or sponge.
WARNING!
Dirty or iced-up steps and entrances create a risk
of slipping or falling.
Keep steps, entrances and footwear free from dirt
(e.g. mud, clay, snow and ice).

236 MAINTAINING YOUR VEHICLEWiper BladeClean the wiper blade rubber with a clean cloth and
detergent solution.
Light Alloy WheelsA wheel care product should be used for regular
cleaning of the light alloy wheels.
If possible, clean wheels once a week, using a soft
bristle brush and a strong spray of water.
Follow instructions on container.
NOTE: Use only acid-free cleaning materials. The acid
could lead to corrosion.Instrument ClusterUse a gentle dishwashing detergent or mild detergent
for delicate fabrics as a washing solution. Wipe with a
cloth moistened in lukewarm solution. Do not use
scouring agents.Steering Wheel and Gear Selector LeverWipe with a damp cloth and dry thoroughly or clean
with a leather care product.
WARNING!
For safety reasons, remove key from ignition lock
before cleaning the windshield, otherwise the
wiper motor can suddenly turn on and cause in-
jury.
Dirty or iced-up steps create a risk of slipping or
falling. Do not use the step in the front bumper
when it is icy or dirty.
WARNING!
For safety reasons, remove key from ignition lock
before cleaning the wiper blade, otherwise the
wiper motor can suddenly turn on and cause se-
vere personal injuries and death.

INDEX 279
10
Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Headlamps, Taillamps, Turn Signal Lenses . . . . 234
Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Care of vehicle
Paintwork, painted body components . . . . . . . . 233
Power washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Tar stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Central Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Central Locking Switch. . . . . . . . . . . . . . . . . . . . . . . . . 17 Locking and Unlocking . . . . . . . . . . . . . . . . . . . . . . 19
Locking Status Display . . . . . . . . . . . . . . . . . . . . . . 18
To Program the Automatic Lock Feature . . . . . . . 19
Chains, Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Changing a Bulb
Additional Brake Lamp . . . . . . . . . . . . . . . . . . . . . 252
Exit Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Interior Lighting with Interior Sensor Protection 255 License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 252
Reading Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Side-Marker Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 253
Side-Mounted Turn Signal . . . . . . . . . . . . . . . . . . 253
Taillamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 224
Checking Weights of Vehicle and Trailer. . . . . . . . . 188
Cigar Lighter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Cleaning Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . . . . 237
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . 236
Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 236
Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . . . 238
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Steering Wheel and Gear Selector Lever . . . . . . . 236
Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

282 INDEXHeadlamp Range Control. . . . . . . . . . . . . . . . . . . . . . . 68
Headlamps, taillamps, turn signal lenses . . . . . . . . 234
Heated Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . 121
Heater, Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116, 118
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Hydroplaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175IIgnitionLock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Indicator Lamp Symbols . . . . . . . . . . . . . . . . . . . . . . 108
Inhalation of Exhaust Gas . . . . . . . . . . . . . . . . . . . . . . 54
Installing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Instrument and Display Lighting . . . . . . . . . . . . . . . . 97
Instrument Cluster Battery Charge Indicator Lamp . . . . . . . . . . . . . . 104
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Coolant Level Indicator Lamp . . . . . . . . . . . . . . . 106
Coolant Temperature Gauge. . . . . . . . . . . . . . . . . 101
Engine Control Unit Indicator Lamp . . . . . . . . . . 107 Engine Oil Level Indicator Lamp . . . . . . . . . . . . . 105
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Trip Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Water in Fuel Indicator Lamp . . . . . . . . . . . . . . . . 104
Instrument Cluster and Indicator Lamps. . . . . . . . . . 91
Instruments and Controls . . . . . . . . . . . . . . . . . . . . . . . 89
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Cargo Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Driver and Rear-Seat Passenger/Cargo Area. . . . 69
Interior Sensor Protection . . . . . . . . . . . . . . . . . . . . 69
Reading Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Intervals, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 265
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intrument Cluster Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
JJack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209LLamps Acceleration Skid Control . . . . . . . . . . . . . . . . . . . 164

INDEX 285
10
Relay Assignment, Standard Equipment . . . . . . . . . 242
Remote Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removing a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Replacing Wiper Blades . . . . . . . . . . . . . . . . . . . . . . . 230
Reporting safety Defects . . . . . . . . . . . . . . . . . . . . . . . 275
Reserve Fuel Indicator Lamp . . . . . . . . . . . . . . . . . . . 103
Residual Engine Heat Utilization . . . . . . . . . . . . . . . 122
Residual Engine Heat Utilization (REST) . . . . . . . . 122
Restraints, Occupant . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Retrofitting Seat Mounting Cups . . . . . . . . . . . . . . . . 65
Reversing Aid Audible Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Ribbed V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Roof Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
RPMs, Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143SSafety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Seat Belt Warning Lamp and Airbag Malfunction . . 44
Seat Belts Belt Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Fastening and Removing . . . . . . . . . . . . . . . . . . . . . 45
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Seats Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Driver’s and Front Passenger’s Seat . . . . . . . . . . . . 60
Folding Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Head Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Rear Seat Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Security System with Towing and Passenger
Compartment Protection . . . . . . . . . . . . . . . . . . . . . . . 23 Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Switching off the Alarm . . . . . . . . . . . . . . . . . . . . . . 24
Visual Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Service Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Disposal of Service Products . . . . . . . . . . . . . . . . . 218
Skid Control, Acceleration . . . . . . . . . . . . . . . . . . . . . 164

286 INDEXSliding Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Snow Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Spare Wheel Location . . . . . . . . . . . . . . . . . . . . . . . . . 200
Special Maintenance Requirements . . . . . . . . . . . . . 267
Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Sprinter Original Parts . . . . . . . . . . . . . . . . . . . . . . . . 217
SRS Malfunction Indicator Lamp . . . . . . . . . . . . . . . . 49
Standard Fuse and Relay Equipment . . . . . . . . . . . . 239
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Suggestions For Obtaining Service For Your Vehicle .
272
Sun RoofElectrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . 81
Sun Roof, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Switch,Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13TTachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99, 101
Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Tie Down Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Tire Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Tire Pressure Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tires
Changing the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Comfort Tire Pressures. . . . . . . . . . . . . . . . . . . . . . 178
Hydroplaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Pressure Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Snow Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Spare Wheel Location . . . . . . . . . . . . . . . . . . . . . . . 200
Tire Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tire Pressures Table . . . . . . . . . . . . . . . . . . . . . . . . 177
Tires, Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Towing a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Towing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24