engine DODGE SPRINTER 2006 1.G Workshop Manual

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5
NOTE: Coasting the vehicle, or driving with gear
selector lever in "N" can result in transmission damage
that is not covered by the Sprinter Warranty.
wThe transmission automatically upshifts through
5th gear. Position "D" provides optimum driving
characteristics under all normal operating
conditions.
Gear Selection for Special Circumstances
The transmission gear ranges for special circumstances can
be selected by pushing the gear selector lever to the right or
the left with the gear selector lever in position "D".
The gear range currently selected is indicated in the
instrument cluster display.
Briefly press gear selector lever in the ç direction:
The transmission downshifts, one gear range at a time,
in the order "4", "3", "2", "1".
Press and hold gear selector lever in the ç direction:
The transmission will shift to a gear range which
favorably accelerates or decelerates the vehicle. This
way downshiftings can be caused.Briefly press gear selector lever in the æ direction:
The transmission will shift from the current gear range
to the next higher gear range. If the transmission is
already in gear range "D", an additional upshift of one
gear is not possible.
Press and hold gear selector lever in the æ direction:
The transmission will shift from the current gear range
directly to gear range "D".
NOTE: With transmission in gear range "D", "4" or "3",
upshifting from 1st to 2nd to 3rd gear is delayed
depending on vehicle speed and engine temperature.
This allows the catalytic converter to heat up more
quickly to operating temperatures.
During the brief warm-up period this delayed upshift
and increased engine noise might be perceived as a
malfunction. However, neither the engine nor
WARNING!
On slippery road surfaces, never downshift in order
to slow the vehicle down. This could result in drive
wheel slip and reduced vehicle control. Your vehi-
cle’s ABS will not prevent this type of loss of control.

152 STARTING AND OPERATING
transmission are negatively affected by this mode of
operation.
The delayed upshift is effective with vehicle speeds
below 31 mph (50 km / h) at partial throttle and engine
temperatures below 95 °F (+35 °C).
To avoid overrevving the engine when the gear
selector lever is moved to a lower gear, the
transmission will not shift to a lower gear if the
engine’s revolutions per minute limit would be
exceeded. In this case there will be no downshift, even
when the vehicle speed reaches the engine’s rpm limit
of that gear, for example by applying the service
brakes.
To prevent the engine from laboring at low rpm when
driving uphill grades or with your vehicle heavily
loaded, the automatic transmission will downshift
when necessary to maintain engine rpm within the best
torque range.Gear
qUpshift through 4th gear only. Suitable for
performance driving.
pUpshift through 3rd gear only. Suitable for
moderately steep hills. Since the transmission
does not shift higher than 3rd gear, this gear
selection will allow use of the engine’s braking
power downhill.
oUpshift through 2nd gear only. For driving in
mountainous regions or under extreme
operating conditions. This gear selection will
allow use of the engine’s braking power when
descending steep grades.
nUse this position, which makes maximum use of
the engine’s braking effect, while descending
very steep or lengthy downgrades and only at
speeds below 25 mph (38 km / h).

158 STARTING AND OPERATING
Protect sharp edges with padding.
 Check the tire pressures after loading the vehicle.
For passenger vans:
 Do not stack loads higher than the upper edge of the
backrests.
 Always place the load against the backrests of the
seat benches.
 Whenever possible, transport loads behind seats
that are not occupied.
 Distribute the load in such a way that the
permissible axle loads are not exceeded when the
vehicle is equipped with the maximum number of
seats. Loading the luggage compartment up to the
maximum payload would cause the permissible
rear axle load to be exceeded.BRAKES
Service Brake
WARNING!
When the engine is not running, the brake and
steering systems are without power assistance.
Under these circumstances, a much greater effort
is necessary to stop or steer the vehicle.
After driving in heavy rain for some time without
applying the brakes or through water deep
enough to wet brake components, the first
braking action may be somewhat reduced and
increased pedal pressure may be necessary. Be
sure to maintain a safe distance from vehicles in
front.
Resting your foot on the brake pedal will cause
excessive and premature wear of the brake pads.
It can also result in the brakes overheating,
thereby significantly reducing their effectiveness.
It may not be possible to stop the vehicle in
sufficient time to avoid an accident.

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5
NOTE: On long and steep downhill slopes, reduce the
load on the brakes by shifting down a gear to utilize the
braking effect of the engine.
To prevent corrosion on the brake pads, after driving
on very wet roads, especially if road salts have been
used, apply brakes before parking the vehicle. The heat
generated will help to dry the brake disks.Brake Pad Wear Indicator
When the key is turned to position 2 in the ignition
lock, the indicator lamp2 in the instrument cluster
lights up for about 2 seconds. It must go out when the
engine is running.
If the 2indicator lamp lights up while the engine is
running, the brake pads are worn almost to their limit.
Have the brake system examined as soon as possible
by an authorized Sprinter Dealer.

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5
NOTE: If you find that the minimum mark on the
brake fluid reservoir is reached, have the brake system
checked for pad thickness and leaks.Parking Brake Indicator Lamp
With the key in position 2 in the ignition lock and the
parking brake released, the indicator lamp lights
up for about 2 seconds.
If the parking brake is on, the indicator lamp does
not go out before the parking brake is released.
WARNING!
Driving with the brake indicator lamp; (3)
illuminated can result in an accident. There may
be a malfunction in the brake system or in the
electronic brake force distribution. The braking
characteristics are affected and the vehicle could
skid if it is braked hard.
Have your brake system checked immediately if
the brake indicator lamp; (3) stays on. Do
not add brake fluid before checking the brake
system. Overfilling the brake fluid reservoir can
result in spilling brake fluid on hot engine parts
and the brake fluid catching fire. There is a risk of
injury due to hot engine parts or hot steam.

164 STARTING AND OPERATING
Anti-Lock Brake System (ABS) Indicator Lamp
When the key is in position 2 in the ignition lock, the
ABS indicator lamp- will light up in the
instrument cluster. It goes out after about 2 seconds.
If the ABS indicator lamp- remains on or lights up
when the engine is running, the ABS is malfunctioning.
NOTE: If the voltage in the vehicle’s electrical system
drops below 10 volts, the ABS indicator lamp- will
also light up in the instrument cluster and the ABS will
be deactivated. The indicator lamp will go out as soon
WARNING!
The following factors increase the risk of acci-
dents:
 Excessive speed, especially in turns
 Wet and slippery road surfaces
 Following another vehicle too closely
The ABS, EBV, ASR, BAS and ESP
® cannot reduce
this risk nor can they prevent the natural laws of
physics from acting on the vehicle.
Always adapt your speed and driving style to the
prevailing road, traffic and weather conditions
and maintain a safe distance between your vehicle
and other road users as well as objects on the road.

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5
Electronic Brake Force Distribution (EBD)
The electronic brake force distribution (EBD) prevents
the rear wheels from being overbraked when there is
little load on the rear axle or if there is not much friction
between the tires and road (e.g., if the road is wet).Acceleration Skid Control Indicator Lamp (ASR)
and Brake Assist System (BAS)1 if equipped
When the key is in position 2 in the ignition lock, the
indicator lampk will light up in the instrument
cluster as a function check. It goes out when the engine
is running.
1Vehicle type 2500 only
WARNING!
If the brake indicator lamp ;(-) does not
go out or lights up again while driving, the brake
fluid level may not necessarily have dropped be-
low the minimum filling capacity but a malfunc-
tion may have occurred in the EBD. In this case
continue driving, but with even greater care.
The wheels of the rear axle could lock if the
vehicle is braked hard. This could lead to a
skidding of the vehicle. Have the malfunction
traced and repaired without delay by an
authorized Sprinter Dealer.
Adapt your speed and driving style to the
prevailing road, traffic and weather conditions.
Driving too fast increases the risk of an accident.

168 STARTING AND OPERATING
If the indicator lampk remains on or lights up
when the engine is running, the acceleration skid
control (ASR) or the brake assist system (BAS)
1 is
malfunctioning.
Then the ASR will be switched off automatically.
NOTE: If the ABS is malfunctioning or the voltage in
the vehicle’s electrical system drops below 10 volts, the
indicator lampk will also light up in the instrument
cluster and the ASR and the BAS
1 will be deactivated.
The indicator lamp will go out as soon as the voltage
reaches this level again or the ABS is operational again
– the ASR and the BAS
1 are then reactivated.
If a malfunction is present in the acceleration skid
control (ASR), the engine’s power output may be
reduced.
1Vehicle type 2500 only
WARNING!
If the indicator lampk remains on, the acceler-
ation skid control (ASR) or the brake assist system
(BAS)
1 is malfunctioning.
Your vehicle’s handling characteristics can
change. Drive with extra caution.
Have the malfunction traced and repaired as soon
as possible by an authorized Sprinter Dealer.

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5
Acceleration Skid Control (ASR) Warning Lamp
and Electronic Stability Program (ESP®)* – if
equipped
When the key is in position 2 in the ignition lock, the
warning lampv in the speedometer will light up
for about 2 seconds. It must go out when the engine is
running.
The warning lampv flashes when:
The ASR or ESP
®* is activated.
 The drive wheels spin with the ASR shut off.
*Vehicle type 2500 onlyThe warning lamp v lights up when the ASR is
shut off.
Deactivate the acceleration skid control, refer to
"Deactivating Acceleration Skid Control (ASR)".
WARNING!
If the warning lampv in the speedometer
lights up or flashes:
 Do not deactivate the acceleration skid control
(ASR).
 Only depress the accelerator pedal as far as
necessary when pulling away.
 Ease off on the accelerator pedal when driving at
a steady speed.
 Adapt your speed and driving style to the
prevailing road, traffic and weather conditions.
Failure to heed these warnings could cause the
vehicle to enter a skid and may result in an
accident.

170 STARTING AND OPERATING
Acceleration Skid Control (ASR)
ASR makes it possible to pull away and accelerate on a
slippery surface. A spinning wheel is braked and its
tractive power is transferred to the wheel with full
grip.
The acceleration skid control (ASR) improves driving
stability at all speeds only on vehicles of the chassis
and cargo/passenger vans type 3500 C/HC/SHC
(without ESP
®).
The engine’s torque is limited to improve driving
stability. When this is happening, the warning
lampv in the speedometer flashes.
If the road surface is not capable of providing traction,
bearing in mind the tires, load and grade, it may not be
possible to pull away even with ASR.
If wheels with tires of a different size than those offered
by an authorized Sprinter Dealer are used, the correct
operation of the ASR cannot be guaranteed.
WARNING!
ASR cannot prevent the natural laws of physics
from acting on the vehicle, nor can it increase the
traction afforded.
The ASR cannot prevent accidents, including
those resulting from excessive speed in turns,
following another vehicle too closely, or
hydroplaning. Only a safe, attentive, and skillful
driver can prevent accidents.
The capabilities of an ASR equipped vehicle must
never be exploited in a reckless or dangerous
manner which could jeopardize the user’s safety
or the safety of others.
If the ASR function is used for a prolonged period
of time, the rear axle brakes may fail due to
overheating.
If the vehicle is to be towed away with the front
wheels clear of the ground, or if the brakes are to
be tested on a brake dynamometer, do not pull the
key in position 2 in the ignition lock, because the
drive wheels could lock.