fuel type MERCEDES-BENZ SPRINTER 2006 Service Manual

TABLE OF CONTENTS - Continued
A/C COMPRESSOR CONTROL SHORTED LOW (ACTIVE)....................132
AIR OUTLET TEMP SENSOR HIGH OR OPEN (ACTIVE).....................134
AIR OUTLET TEMP SENSOR SHORTED LOW (ACTIVE).....................136
ATC FUNCTION TEST COOL FAILURE....................................138
ATC FUNCTION TEST FAILURE..........................................138
ATC FUNCTION TEST HEAT FAILURE.....................................138
AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE)......................140
AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE)......................142
BLOWER STAGE 1 HIGH OR OPEN (ACTIVE)..............................144
BLOWER STAGE 1 SHORTED LOW (ACTIVE)..............................146
CABIN HEATER CONTROL HIGH OR OPEN (ACTIVE).......................148
CABIN HEATER CONTROL SHORTED LOW (ACTIVE).......................150
CIRC PUMP CONTROL HIGH OR OPEN (ACTIVE)..........................152
CIRC PUMP CONTROL SHORTED LOW (ACTIVE)..........................154
EVAP TEMP SENSOR HIGH OR OPEN (ACTIVE)...........................156
EVAP TEMP SENSOR SHORTED LOW (ACTIVE)...........................158
NO COMMUNICATION BUS (ACTIVE).....................................160
NO COMMUNICATION WITH ECM (ACTIVE)...............................163
NO COMMUNICATION WITH IC (ACTIVE)..................................165
RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (ACTIVE)................167
RECIRC AIR SOLENOID CONTROL SHORTED LOW (ACTIVE)................169
REFRIG PRESS SENSOR HIGH OR OPEN (ACTIVE)........................171
REFRIG PRESS SENSOR SHORTED LOW (ACTIVE)........................173
WATER CYCLE VALVE CONTROL HIGH OR OPEN (ACTIVE).................175
WATER CYCLE VALVE CONTROL SHORTED LOW (ACTIVE).................177
INSTRUMENT CLUSTER
AMBIENT TEMP SENSOR OPEN/SHORT TO BATTERY......................179
AMBIENT TEMP SENSOR SHORT TO GROUND............................181
FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY.........................182
FUEL LEVEL SENSOR SHORT TO GROUND...............................184
INSTRUMENT CLUSTER INTERNAL FAILURE B1043........................185
INSTRUMENT CLUSTER INTERNAL FAILURE B1053........................186
INSTRUMENT CLUSTER OVERVOLTAGE..................................187
NO CAN COMMUNICATION WITH ABS....................................188
NO CAN COMMUNICATION WITH ECM...................................190
NO CAN COMMUNICATION WITH TCM....................................192
PREGLOW INDICATOR LAMP FAILURE...................................194
SRS INDICATOR LAMP FAILURE.........................................195
POWER DOOR LOCKS/RKE
DRIVER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND......196
PASSENGER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND .198
REPLACE CONTROL MODULE..........................................200
RKE INTERFACE CIRCUIT SHORT TO GROUND - CTM......................201
RKE INTERFACE CIRCUIT SHORT TO GROUND - SKREEM..................203
RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - CTM.....................205
RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - SKREEM..................206
THE ACM HAS UNLOCKED THE DOORS..................................208
UNKNOWN TROUBLE CODE UNKNOWN DTC TYPE 2......................209
*RKE INOPERATIVE....................................................210
*RKE POOR RANGE...................................................211
iv

Compres SO Accel (Compressor Shut Off - Due
To Acceleration)
The Engine Control Module transmits this data. A
status of9YES9indicates that the compressor shut
off because of an acceleration request. A status of
9NO9indicates that there is no acceleration request.
If shut off due to an acceleration request, the
compress will switch on again after 20 seconds. In
addition, the original acceleration request can no
longer exist for the ECM to acknowledge a subse-
quent request. In the event of a CAN Bus commu-
nication failure,9NO9is displayed as a substitute
value.
Compres SO W/E-Off (Compressor Shut Off -
Due to Emergency Off)
The Engine Control Module transmits this data. A
status of9YES9indicates that the compressor shut
off because of an emergency off request. A status of
9NO9indicates that there is no emergency off re-
quest. In the event of a CAN Bus communication
failure, the last stored value is displayed as a
substitute value.
Auxiliary Fan
The ATC Module transmits this data. A status of
9ON9indicates that the auxiliary fan is operational.
A status of9OFF9indicates that the auxiliary fan is
not operational. The Auxiliary Fan normally oper-
ates when refrigerant head pressure exceeds 290
PSI and coolant temperature exceeds 221ÉF. In the
event of a CAN Bus communication failure, 257ÉF is
displayed for coolant temperature (in Sensors) and
the Auxiliary Fan will run continuously.
Light PB CTRL Module
This input displays a status of9Bright9for positive
dimmer switch operation and9Dimmed9for nega-
tive dimmer switch operation. In the event of a CAN
Bus communication failure,9Bright9is displayed.
3.3.2 CABIN HEATER MODULE (CHM) &
HEATER BOOSTER MODULE (HBM)
3.3.2.1 SYSTEM DESCRIPTION
WARNING: NEVER OPERATE THE HEATER
IN AN ENCLOSED AREA THAT DOES NOT
HAVE EXHAUST VENTILATION FACILITIES.
ALWAYS VENT THE HEATER'S EXHAUST
WHEN OPERATING THE HEATER. REFER TO
(VENTING THE HEATER'S EXHAUST(
BELOW FOR PROPER EXHAUST VENTING
INSTRUCTIONS. FAILURE TO FOLLOW
THESE INSTRUCTIONS CAN RESULT IN
PERSONAL INJURY OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO
COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR/REPLACEMENT. FAILURE
TO FOLLOW THESE INSTRUCTIONS CAN
RESULT IN PERSONAL INJURY OR DEATH.
WARNING: ALWAYS DISCONNECT THE
VEHICLE'S BATTERY PRIOR TO
PERFORMING ANY TYPE OF WORK ON THE
HEATER ASSEMBLY. FAILURE TO FOLLOW
THESE INSTRUCTIONS CAN RESULT IN
PERSONAL INJURY OR DEATH.
WARNING: NEVER ATTEMPT TO REPAIR THE
HEATER ASSEMBLY OR ANY OF ITS
INTERNAL COMPONENTS. ALWAYS
PERFORM HEATER COMPONENT
REPLACEMENT IN ACCORDANCE WITH THE
SERVICE INFORMATION. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN
RESULT IN PERSONAL INJURY OR DEATH.
CAUTION: Always Perform The Heater
Pre-Test (In The Diagnostic Procedures) Prior
To Performing Any Other Test On The Heater
For The Test Result To Be Valid.
NOTE: Do not disconnect the vehicle's
battery or the heater's main power-supply
while the heater is in operation or in
run-down mode. Failure to follow these
instructions may result in excess emissions
from the heater.
NOTE: Failure to prime the Dosing Pump
after draining the fuel line will prevent heater
activation during the first attempt to start the
unit. This may also set a Diagnostic Trouble
Code (DTC) in the control unit's memory. Do
not perform the Dosing Pump Priming
Procedure if an attempt was made to start the
heater without priming the Dosing Pump
first. This will put excess fuel in the heater
module and cause smoke to emit from the
heater's exhaust pipe when heater activation
occurs.
NOTE: Waxed fuel can obstruct the fuel line
and reduce flow. Check for the appropriate
winter grade fuel and replace as necessary.
The Cabin Heater Assembly and Heater Booster
Assembly are supplemental type heaters designed
to pre-heat the engine's coolant in order to supply
the vehicle's occupants with heat prior to the engine
7
GENERAL INFORMATION

Static Heater Signal
A status of9ON9indicates that the heater module
sees the9Stationary Heating Mode ON9signal after
switching on the heater with the heater timer or the
auxiliary heater switch. A status of9OFF9indicates
that the9Stationary Heating Mode ON9signal is
not present at the heater module.
Heater Booster Mode Signal
A status of9ON9indicates that the heater module
sees the9Heater Booster Mode ON9signal after
switching on the heater with the auxiliary heater
switch. A status of9OFF9indicates that the9Heater
Booster Mode ON9signal is not present at the
heater module.
3.4 INSTRUMENT CLUSTER
The Instrument Cluster has easy-to-read instru-
ments, is capable of CAN bus communication and
provides a diagnostic function. The Instrument
Cluster with analog speedometer, tachometer, fuel
and coolant temperature gauges comes in two ver-
sions.
²Speedometer with outer miles-per-hour (mph)
scale and inner kilometers-per-hour (km/h) scale.
Coolant temperature is indicated in Fahrenheit
(for US).
²Speedometer with outer kilometers-per-hour
(km/h) scale and inner miles-per-hours (mph)
scale. Coolant temperature is indicated in de-
grees Celsius (for Canada).
Below the speedometer, there is a LCD multi-
function indicator in clear view of the driver. Warn-
ing and indicator lights (based on colored light
emitting diodes) are located in the bottom of the
instrument cluster with the exception of the turn
signal indicator lights, ASR warning light and re-
serve fuel warning light. The warning lights for the
seat belt usage and parking brake/brake fluid level
are located in the line above the bottom line. The
indicator that illuminates up when the parking
brake is applied or the brake fluid level is low is
different for U.S. and Canada.
When the key is turned to the 2nd position in the
ignition, the function of the following indicator
lights is checked automatically: High Beam ON,
Preheating, airbag malfunction. In case of a broken
LED of the airbag malfunction light, the seat belt
usage warning light will flash for 6 seconds after
the function check is finished. The Instrument
Cluster is operated with the help of 4 buttons
located below the multifunction indicator. The back-
lighting for the instrument cluster uses yellow
LED's and can be adjusted electronically to daylight
and darkness.The instrument cluster includes a warning
buzzer, which sounds (in addition to a warning light
in some cases) when:
²The headlights are on with the ignition off and
the door opened.
²The driver 's seat belt is not fastened with the
ignition on.
²The key is in the ignition and the door is open.
²Critical ASSYST information is displayed in the
multifunction indicator.
3.5 POWER DOOR LOCKS/RKE
3.5.1 CENTRAL LOCKING
The Central Locking System locks all vehicle
doors if any door is locked from the inside or
mechanically locked with the key from the outside.
However, unlocking any door, in that manner, will
only unlock that particular door. The Master Door
Lock Switch on the dash enables the operator to
lock/unlock all doors. By pressing the top of the
rocker type switch once, all doors will lock. Pressing
the switch again will unlock all doors. Pressing the
lower part of the switch once will lock all doors
except the driver door. Pressing the lower part
again will unlock all doors except the driver door. If
the Central Locking System automatically unlocks
after the vehicle was attempted to be locked, at
least one door is not properly closed.
There are two LED indicators in the Master Door
Lock Switch. The left indicator is for the driver door
and the right indicator is for all passenger/cargo
doors. These will indicate if a door is ajar or if the
doors are locked. The door ajar switches are part of
the door lock motor and are mounted in the door
latch assembly.
Inside each door lock motor there is a command
switch. The command switch is operated by the
plunger and signals any change in the lock status,
locked or unlocked. Each command switch is wired
to the Central Timer Module (CTM) sometimes
referred to as the Central Locking Module. If all
doors are closed and are unlocked, and any door is
locked by the key or the interior handle, thereby
changing the command switch, all doors will be
locked. If one of the door lock motors does not reach
the end position after a locking command, it will be
detected by the CTM (command switch not in
9Locked9position) and the vehicle will be unlocked.
3.5.2 REMOTE KEYLESS ENTRY (RKE)
The SKREEM is a combination of the Remote
Keyless Entry Module and the SKIM (Sentry Key
Immobilizer Module). It is located behind the In-
strument Cluster and has an antenna that goes up
9
GENERAL INFORMATION

1.0 INTRODUCTION
The procedures contained in this manual include
all specifications, instructions and graphics needed
to diagnose engine control module (ECM) and sen-
try key remote entry module (SKREEM) problems;
they are no start, diagnostic trouble code (DTC) and
no trouble code problems for the ECM. The diagnos-
tics in this manual are based on the trouble condi-
tion or symptom being present at the time of diag-
nosis.
When repairs are required, refer to the appropri-
ate service information for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added; carryover sys-
tems may be enhanced. IT IS RECOMMENDED
THAT YOU REVIEW THE ENTIRE MANUAL TO
BECOME FAMILIAR WITH ALL NEW AND
CHANGED DIAGNOSTIC PROCEDURES.
This manual will cover all the necessary require-
ments to begin a logical diagnostic path for each
problem. If there is a diagnostic trouble code (DTC)
detected, go to the trouble code test. If there are no
DTCs present, go to a no trouble code (*), symptom
based test.
This book reflects many suggested changes from
readers of past issues. After using this book, if you
have any comments or recommendations, please fill
out the form at the back of the book and mail it back
to us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers 2005
Sprinter vehicles equipped with the 2.7L common
rail diesel engine.
1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the engine control module (ECM)
and sentry key immobilizer system (SKREEM) is
done in six basic steps:
²verification of complaint
²verification of any related symptom
²symptom analysis
²problem isolation
²repair of isolated problem
²verification of proper operation
NOTE: All tests in this manual should be per-
formed with the engine at operating temperature,
unless otherwise specified within a particular test.
2.0 IDENTIFICATION OF
SYSTEM
The ECM is located to the left of the steering
column behind the steering column opening cover.
The sentry remote entry module (SKREEM) is
attached to the rear of the instrument cluster.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
The 2.7L direct injection diesel engine system is
equipped with the latest technical advances. The
on-board diagnostics incorporated in the engine
control module and SKREEM are intended to assist
the field technician in repairing vehicle problems by
the quickest means.
The engine system incorporates a common rail
fuel delivery design with exhaust emission feed-
back. This design utilizes electronically controlled
solenoid valve type fuel injectors. Each injector is
controlled individually by the ECM. Injector timing
and fuel quantity are controlled by the ECM based
on inputs from various sensors. The precision con-
trol of the injectors by the ECM helps to reduce the
engine noise, odor and smoke.
3.2 FUNCTIONAL OPERATION
3.2.1 ECM ON-BOARD DIAGNOSTICS
The ECM is programmed to monitor different
circuits of the diesel fuel injection system. This
monitoring is called on-board diagnostics.
Certain criteria must be met for a diagnostic
trouble code to be entered into the ECM memory.
The criteria may be a range of: engine rpm, engine
temperature, time or other input signals to the
ECM. If all of the criteria for monitoring a system or
circuit are met, and a problem is sensed, then a
DTC will be stored in the ECM memory.
It is possible that a DTC for a monitored circuit
may not be entered into the ECM memory, even
though a malfunction has occurred. This may hap-
pen when the monitoring criteria have not been
met.
The ECM compares input signal voltages from
each input device with specifications (the estab-
lished high and low limits of the input range) that
are programmed into it for that device. If the input
voltage is not within the specifications and other
trouble code criteria are met, a DTC will be stored
in the ECM memory.
1
GENERAL INFORMATION

3.2.2 ECM OPERATING MODES
As input signals to the ECM change, the ECM
adjusts its response to the output devices. For
example, the ECM must calculate a different fuel
quantity and fuel timing for engine idle condition
than it would for a wide open throttle condition.
There are several different modes of operation that
determine how the ECM responds to the various
input signals.
Ignition Switch On (Engine Off)
When the ignition is turned on the ECM activates
the glow plug relay for a time period that is deter-
mined by engine coolant temperature, intake air
temperature and battery voltage.
Engine Start-Up Mode
The ECM uses the intake air temperature sensor,
engine temperature sensor and the crankshaft po-
sition sensor (engine speed) inputs to determine
fuel injection quantity.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration
and wide open throttle modes are controlled based
on all of the sensor inputs to the ECM. The ECM
uses these sensor inputs to adjust fuel quantity and
fuel injector timing. EGR valve control is performed
using feedback from the oxygen sensor. An oxygen
sensor is located in the exhaust manifold to sample
oxygen content exiting the engine cylinders. The
ECM uses the O2 sensor, along with other sensor
inputs, to govern the amount of exhaust gas recir-
culation to reduce HC (HydroCarbons) and CO
(Carbon Monoxide). Engine coolant is routed
through the base of the EGR valve to provide
additional cooling of the exhaust gas, which further
helps the reductions of emissions. The EGR valve
has a self-cleaning function. When the engine is
shut off, the EGR valve rotates twice to reduce
carbon deposits at the valve seat.
Overheat Production Mode
If the engine temperature is above 105ÉC (221ÉF)
and vehicle speed is above 40 km/h (25 MPH) the
ECM will limit fuel quantity for engine protection.
Limp-In Mode
The ECM utilizes different degrees of engine
limp-in. The ECM is able to limit engine rpm,
engine power output (turbo boost reduction), acti-
vate engine cooling fan or all of these functions
based on the type of fault that is detected. Critical
engine performance faults such as accelerator pedal
position sensor fault will result in a fixed idle speed
of approximately 680 rpm regardless of actual pedalposition. Other less critical faults will result in
power reduction throughout the full range of driv-
ing conditions.
Overspeed Detection Mode
If the ECM detects engine RPM that exceeds
5200 RPM, the ECM will set a DTC in memory,
limit engine RPM to no more than 2500 RPM, and
illuminate the MIL until the DTC is cleared.
After-Run Mode
The ECM transfers RAM information to ROM
and performs an Input/Output state check.
3.2.3 MONITORED CIRCUITS
The ECM is able to monitor and identify most
driveability related trouble conditions. Some cir-
cuits are directly monitored through ECM feedback
circuitry. In addition, the ECM monitors the voltage
state of some circuits and compares those states
with expected values. Other systems are monitored
indirectly when the ECM conducts a rationality test
to identify problems.
Although most subsystems of the engine control
module are either directly or indirectly monitored,
there may be occasions when diagnostic trouble
codes are not immediately identified. For a trouble
code to set, a specific set of conditions must occur
and unless these conditions occur, a DTC will not
set.
3.2.4 SKREEM OVERVIEW
The sentry key remote entry module system
(SKREEM) is designed to prevent unauthorized
vehicle operation. The system consists of a sentry
key remote entry module (SKREEM), ignition
key(s) equipped with a transponder chip and the
ECM. When the ignition switch is turned on, the
SKREEM interrogates the ignition key. If the igni-
tion key is Valid or Invalid, the SKREEM sends a
message to the ECM indicating ignition key status.
Upon receiving this message the ECM will termi-
nate engine operation or allow the engine to con-
tinue to operate.
3.2.5 SKREEM ON-BOARD DIAGNOSTICS
The SKREEM has been programmed to transmit
and monitor many different coded messages as well
as CAN Bus messages. This monitoring is called
On-Board Diagnostics. Certain criteria must be met
for a DTC to be entered into SKREEM memory. The
criteria may be a range of; input voltage, CAN Bus
message or coded messages to the SKREEM. If all
the criteria for monitoring a circuit or function are
met and a fault is detected, a DTC will be stored in
the SKREEM memory and the START ERROR indi-
cator will be turned on in the instrument cluster.
2
GENERAL INFORMATION

TEST ACTION APPLICABILITY
1NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL
INJECTORS. THIS MAY BE AS HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL
LEAKS.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN
SERVICING FUEL SYSTEM.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Start the engine several times, turning the ignition off for at least 30 seconds
between each run cycle.
Monitor the DRB for ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 8
2NOTE: Check the ECM for other ECM DTC's related to circuits that are
open, shorted to ground or low voltage problems.
Does the DRB also display these type of DTC's?All
Ye s!Go To 3
No!Go To 4
3 Turn the ignition off.
Disconnect the ECM harness connectors.
Turn the ignition on.
Connect a jumper wire between ground and the Engine Control Relay Signal circuit
in ECM C2 harness connector cavity 44.
Using a 12-volt test light connected to ground, check the Fused Engine Control Relay
Output circuits at the ECM C1 harness connector cavities 1, 3 and 5.
Does the test light illuminate brightly for each circuit?All
Ye s!Go To 4
No!Refer to symptom list and perform Checking the ECM Power and
Grounds.
Perform ROAD TEST VERIFICATION - VER-2.
174
DRIVEABILITY - DIESEL
P2151-FUEL PRESS SOLENOID SIGNAL PLAUSIBILITY HIGH Ð
Continued

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT
RECOMMENDATIONS...................1
AUTOMATIC TRANSMISSION FLUID - NAG1 . 1
AXLE FLUID..........................2
BRAKE FLUID.........................2
HOAT COOLANT.......................2
ENGINE OIL - DIESEL ENGINES...........3
FUEL REQUIREMENTS - DIESEL ENGINE . . . 4
POWER STEERING FLUID...............5
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......5FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................5
HOISTING
STANDARD PROCEDURE - HOISTING........5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 6
TOWING
STANDARD PROCEDURE - TOWING.........7
MAINTENANCE SCHEDULES
DESCRIPTION..........................8
INTERNATIONAL SYMBOLS
DESCRIPTION..........................9
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT RECOMMENDATIONS
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 1) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
When service is required, DaimlerChrysler Corpo-
ration recommends that only MOPARtbrand parts,
lubricants and chemicals be used. MOPARtprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
AUTOMATIC TRANSMISSION FLUID - NAG1
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Use ATF approved to MB 236.10, MB 236.12, such
as Shell ATF 3403/M-115, MOPARtpart number
05127382AA, Fuchs/Shell ATF 3353, or equivalent.
Automatic Transmission Fluid (ATF) is red in color
when new. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine
oil or antifreeze. The red color is not permanent and
is not an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
Fig. 1 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
VALUBRICATION & MAINTENANCE 0 - 1

Do not blend other specific fuel additives with die-
sel fuel. They only result in unnecessary cost, and
may be harmful to the engine operation.
POWER STEERING FLUID
No fluid service required. Filled with Power Steer-
ing Fluid approved to MB 236.3, such as Mobil
ATF-D (Exxon Mobil Corporation) or equivalent.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
ENGINE COOLANT
10 Liters 10.5 Quarts
ENGINE OIL
9.0L without Filter Re-
placement9.5 Quarts with Filter
Replacement
AUTOMATIC TRANSMISSION
Service Fill - NAG1 5.0 L (10.6 pts.)
O-haul Fill - NAG1 7.7 L (16.3 pts.)
Dry fill capacity Depending on type and size of inter-
nal cooler, length and inside diameter of cooler lines,
or use of an auxiliary cooler, these figures may vary.
(Refer to appropriate 21 - TRANSMISSION/AUTO-
MATIC/FLUID - STANDARD PROCEDURE).
REAR AXLE  .03L (1 oz.)
8 1/2 1.8 L (4.0 pts.)
FUEL TANK
Primary 100 L (26.4 gal.)*
Reserve 10.5 L (2.8 gal.)*
*Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to manufac-
turing tolerance and refill procedure
DESCRIPTION SPECIFICATION
POWER STEERING SYSTEM
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cool-
er options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed proce-
dures.
FLUID FILL / CHECK LOCA-
TIONS
INSPECTION - FLUID FILL / CHECK LOCA-
TIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle. Support the vehicle in the raised
position with jack stands at the front and rear ends
of the frame rails.
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
VALUBRICATION & MAINTENANCE 0 - 5

HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
The forward lifting pads should be positioned
against the forward flange of the transmission
crossmember brackets at the bottom of the frame
rail. The real lifting pads should be wedged
between the forward flange of the leaf spring
bracket and the frame rail. Safety stands should be
placed under the frame rails at the front and rear
ends.
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.²IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible.
Fig. 2 HOIST LOCATIONS
1 - TRANSMISSION CROSSMEMBER SUPPORT
2 - REAR LEAF SPRING MOUNT - FRONT
3 - TRANSMISSION CROSSMEMBER
0 - 6 LUBRICATION & MAINTENANCEVA

effect panels. If necessary, remove the wheels from
the lifted end of the vehicle and lower the vehicle
closer to the ground, to increase the ground clearance
at the opposite end of the vehicle. Install lug nuts on
wheel attaching studs to retain brake drums.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used provided all the wheels are lifted
off the ground using tow dollies.
MAINTENANCE SCHEDULES
DESCRIPTION
The use of special lubricant additives is not recom-
mended. The use of such additives may affect the
warranty rights. With regard to legal stipulations
concerning emissions control, please note that
engines have to be serviced and adjusted in accor-
dance with special instructions and using special
measuring equipment. Modifications to or interfer-
ence with the emissions control systems are not per-
missible.
MAINTENANCE - WITHOUT ASSYST MAINTE-
NANCE COMPUTER
Maintenance Intervals
²Oil service ±Normal Operationevery 10,000
miles or 16,000 km or 12 months.
²Maintenance service every 30,000 miles or
48,000 km.
Additional work must be carried out at yearly
intervals.
MAINTENANCE - WITH ASSYST MAINTENANCE
COMPUTER
ASSYST provides information on the best possible
timing for maintenance work.
When the next maintenance service is due, this
will be indicated in the multi-function display with
the wrench icon symbol displayed in km/miles or
days.
²One wrench icon showing indicates Oil Service
is necessary.
²Two wrench icons showing indicates Mainte-
nance Service is necessary ± displayed in km/miles or
days.
If the display shows the number of days, a clock
symbol 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 after an oil ser-
vice and/or maintenance service has been performed.
REGULAR CHECK - UPS
To maintain the safe operation of the vehicle, it is
recommended that the following tasks be performed
on a regular basis (i.e. weekly or whenever the vehi-
cle is refueled). Check:
²Engine oil level
²Brake system - fluid level
²Battery - acid level
²Windshield washer system and headlamp clean-
ing system - fluid level
²Mechanical assemblies (e.g. engine, transmis-
sion, etc.) - check for leaks
²Condition of tires and tires pressures
²All exterior lights
SPECIAL MAINTENANCE REQUIREMENTS
If bodies built by manufacturers other than
DaimlerChrysler Corporation are fitted to the vehi-
cle, the maintenance requirements and lubrication
intervals specified by the body manufacturer must be
adhered to, in addition to all standard maintenance
requirements.
Coolant
Corrosion inhibitor/antifreeze concentration in the
coolant should be checked before the onset of winter
(once year in countries with high prevailing temper-
atures).
Replace the coolant every five years or 100,000
miles.
Dust Filter for Heating / Ventilation Replacement
The dust filter and the tailgate interior filter are to
be renewed during routine maintenance service. If
operating conditions are dusty, these filters should be
renewed more frequently.
ENGINE OIL CHANGE AND FILTER REPLACEMENT
At a minimum, change the engine oil and oil filter
once a year ± even if the vehicle mileage per year is
extremely low. For standard oil service schedules
refer to the chapter oil service and maintenance ser-
vice.
Once a Year
Select 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 guide-
lines.
0 - 8 LUBRICATION & MAINTENANCEVA