maintenance DODGE SPRINTER 2005 1.G Owners Manual

TABLE OF CONTENTS
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10SECTIONPAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
UNDERSTANDING THE FEATURES OF YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
UNDERSTANDING YOUR INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
STARTING AND OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
WHAT TO DO IN EMERGENCIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
MAINTAINING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
IF YOU NEED CONSUMER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

UNDERSTANDING YOUR INSTRUMENT PANEL
4
CONTENTS

Instruments and Controls . . . . . . . . . . . . . . . . . . . . 89


Instrument Cluster and Indicator Lamps . . . . . . . 91
Indicator Lamp Symbols . . . . . . . . . . . . . . . . . . . 93
Multi-Function Indicator . . . . . . . . . . . . . . . . . . . 94
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Odometer and Trip Meter . . . . . . . . . . . . . . . . . . 97
Instrument and Display Lighting . . . . . . . . . . . 97
Outside Temperature Display . . . . . . . . . . . . . . 98
Reversing Aid Distance Display (Optional) . . . 99
Tachometer (Engine rpm) . . . . . . . . . . . . . . . . . 101
Coolant Temperature Gauge . . . . . . . . . . . . . . 101
Fuel Gauge with Reserve Fuel Indicator
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Battery Charge Indicator Lamp . . . . . . . . . . . . 104
Water in Fuel Indicator Lamp . . . . . . . . . . . . . 104
Engine Oil Level Indicator Lamp . . . . . . . . . . . 105
Coolant Level Indicator Lamp . . . . . . . . . . . . . 106
Engine Control Unit Indicator Lamp . . . . . . . 107


Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 108


ASSYST Maintenance Computer (Optional). . . . 110
Engine Oil Level – Display in Instrument
Cluster (Vehicles with ASSYST Maintenance
Computer only) . . . . . . . . . . . . . . . . . . . . . . . . . 112
Displaying Engine Oil Level with
Engine Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113


Engine Oil Level Indicator in Instrument
Cluster (Vehicles without ASSYST Maintenance
Computer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115


Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . 116
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Air Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . 117
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
De-Fogging and De-Icing The Front
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Side Air Vents and Center Air Vents . . . . . . . . 120

UNDERSTANDING YOUR INSTRUMENT PANEL 95
4
The multi-function indicator can be used to call up the
odometer, trip meter, clock and outside temperature,
or information such as remaining time/distance until
the next service is due, or the engine oil level.
If your vehicle is equipped with reversing aid, the
multi-function indicator also displays the distance
between your vehicle and a detected obstacle.
The multi-function indicator is activated by:
Turning the key to position 2 in the ignition lock,
opening the driver’s door,
pressing one of the buttons ( ‘), I , ç or
æ ,
switching the side lights on, refer to "Combination
Switch". 1. Press the button (
‘) to switch between the
odometer and the trip meter, and to reset the trip
meter.
Press the button ( ‘) to activate the ASSYST
maintenance computer.
2. Press the I button to switch between the time
and outside temperature and to activate the time
adjustment.
3. Press the ç to adjust (dim) the display and
instrument lighting and to adjust the clock.
4. Press the æ to adjust (brighten) the display and
instrument lighting and to adjust the clock.

110 UNDERSTANDING YOUR INSTRUMENT PANELASSYST MAINTENANCE COMPUTER (OPTIONAL)Function button (‘) (1)
Approximately one month or 2,000 miles (3,000 km)
before a service is due, the maintenance symbol or
lights up when the key is turned to position 2 in the
ignition lock.If the remaining time (in days) is shown, the additional
symbol
È
also appears in the multi-function indicator.
If additional maintenance operations are due, the
maintenance indicator or
lights up when the key is turned to position 2 in the
ignition lock.
For additional maintenance operations, see Sprinter
Service Booklet.
If a service deadline is exceeded, the display will flash
with a minus sign in front when the key is turned to
position 2 in the ignition lock.
The display will be cancelled when the
button ( ‘) is pressed, or automatically after
10 seconds.
The remaining time or remaining distance can also be
called up manually.
To manually call up the remaining time/distance:
Activate the multi-function indicator, refer to "Multi-
Function Indicator".
Briefly press the button ( ‘) twice.
Symb
N00.00-2387-00
Symb
N00.00-2156-00
Symb
N00.00-2388-00
Symb
N00.00-2157-00

UNDERSTANDING YOUR INSTRUMENT PANEL 111
4
Depending on the driving style, the mileage covered
and the operating conditions, the next service due is
displayed either as a remaining distance in "mi"
(in km) or as a remaining time in "days". The length of
time between services should not exceed 2 years.
The display will be cancelled when the
button ( ‘) is pressed, or automatically after
10 seconds.
When a service has been performed, have the ASSYST
maintenance computer reset by an authorized Sprinter
Dealer.
Should your Sprinter for any reason not be serviced by
an authorized Sprinter Dealer, the ASSYST
maintenance computer can, in exceptional
circumstances, be reset as follows:
Turn the key to position 2 in the ignition lock and
immediately press the button ( ‘) twice.
Within 10 seconds, return the key to position 0 in the
ignition lock.
Press and hold the button ( ‘). Turn the key to
position 2 in the ignition lock. Keep the
button ( ‘) pressed. The maintenance indicator with the current remaining
time/distance is shown.
After about 10 seconds, an acoustic signal will sound
and the maintenance indicator is displayed with the
new remaining time/distance.
Release the button (
‘).
NOTE:
The ASSYST maintenance computer provides
information on the optimum maintenance requirements.
If maintenance intervals are not observed, resulting
damage will not be covered by Warranty.
The ASSYST maintenance computer is not an engine
oil gauge.
Engine oil level – for display in instrument cluster, see
next page.
If the engine oil level indicator lamp lights up, refer to
"Engine Oil Level Indicator Lamp".
If the battery is disconnected, the time is not recorded
by the ASSYST maintenance computer. Such periods
must be considered if maintenance intervals are
measured by time.

112 UNDERSTANDING YOUR INSTRUMENT PANELEngine Oil Level – Display in Instrument Cluster
(Vehicles with ASSYST Maintenance Computer only)If the : indicator lamp lights up briefly when the
engine is running, the engine oil level has dropped to
the minimum mark. Check the engine oil level without
delay and add oil to the upper mark on the dipstick. If no engine oil is added and the engine oil level drops
further, a warning buzzer will also sound and
will appear in the multi-function indicator. 2.0 quarts
(about 1.9 liters) of oil must be added.
NOTE:
Engine oil level display
– "qt" in USA only.
– "l" in Canada only.
CAUTION!
If the : indicator lamp lights up, the warning
symbol in the multi-function indicator appears
and the warning buzzer sounds, the operating
safety of the engine is endangered (possibility of
engine damage).
A sudden decrease or absence of oil pressure may
indicate a mechanical failure. Bring the vehicle to
a safe stop, and investigate the cause to prevent
further damage. Do not operate the engine until
the cause has been determined and corrected.
Symb
N00.00-2384-00
qt

UNDERSTANDING YOUR INSTRUMENT PANEL 115
4
ENGINE OIL LEVEL INDICATOR IN INSTRUMENT
CLUSTER
(VEHICLES WITHOUT ASSYST MAINTENANCE
COMPUTER)If the : indicator lamp lights up when the engine is
running, the engine oil level has dropped to the
minimum mark. Check the engine oil level without
delay and add engine oil up to the upper mark on the
dipstick.
If there is no engine oil in the oil sump, a warning
buzzer will sound if the key is turned to position 2 in
the ignition lock or if the vehicle is being driven, and
the warning
will appear in the multi-function indicator. About 2
quarts (1.9 liters) of oil must be added.
Check the engine oil level without delay and add
engine oil to the upper mark on the dipstick.
NOTE: Engine oil level display– "qt" in USA only.
– "l" in Canada only.
Symb
N00.00-2384-00
qt
CAUTION!
If the : indicator lamp lights up, the warning
symbol in the multi-function indicator appears
and the warning buzzer sounds, the operating
safety of the engine is endangered (possibility of
engine damage).
Safely pull off the road and turn off the engine (do
not restart the engine). Determine the cause of the
problem. If there are no obvious signs of leakage,
add engine oil. The engine oil level must be
between the lower and upper marks on the
dipstick. Only add engine oil up to the upper
mark – do not overfill.
If the engine oil level is above maximum, there is
a danger of damage to the engine or catalytic
converter.

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).

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.

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.