Dodge Sprinter. Manual — part 2
HOIST
A vehicle can be lifted with:
• A single-post, frame-contact hoist.
• A twin-post, chassis hoist.
• A 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)
•
DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
•
IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
•
DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
•
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
•
DO NOT USE OPEN FLAME NEAR BATTERY.
•
REMOVE
METALLIC
JEWELRY
WORN
ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
•
WHEN 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:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Yellow or bright color test indicator, if equipped.
• Low battery fluid level.
• Generator drive belt condition and tension.
• Fuel 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
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LUBRICATION & MAINTENANCE
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(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
• Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
• When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
• Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
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 remains locked and the
vehicle cannot be steered. With the engine not run-
ning 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)
If the Engine is Damaged
For towing distances up to 30 miles (about 50
km)
• Shift selector lever in “N” position.
• Do not exceed a towing speed of 30 m.p.h. (50
km/h).
For towing distances greater than 30 mile
(about 50 km)
• Remove the propeller shafts leading to the drive
axles. The vehicle can be towed without restriction.
If the Transmission is Damaged
• Remove the propeller shafts leading to the drive
axles. The vehicle can be towed without restriction.
If the Front Axle is Damaged
• Raise the front axle.
• Observe the same towing restrictions as for
engine damage.
If the Rear Axle is Damaged
• Raise the rear axle.
NOTE: Comply with local legal regulations regard-
ing towing vehicles.
SAFETY PRECAUTIONS
NOTE: The following safety precautions must be
observed when towing a vehicle.
• Secure loose and protruding parts.
• Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
• Do not allow towing equipment to contact the
disabled vehicle’s fuel tank.
• Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
• Do not allow passengers to ride in a vehicle
being towed.
• Always observe state and local laws regarding
towing regulations.
• Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
• Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
• Remove exhaust pipe tips that interfere with the
tow sling and crossbar
• Padding should be placed between the tow sling/
crossbar and any painted surfaces
• When placing tow hooks on the rear axle, posi-
tion them so they do not damage the brake tubing or
hoses
• Do not tow the vehicle by connecting to the front
or rear shock absorbers
• Do not tow a heavily loaded vehicle. Damage to
the vehicle may result. Use a flatbed device to trans-
port a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain, steep rises in the road or if the vehicle
is equipped with air dams, spoilers, and/or ground
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LUBRICATION & MAINTENANCE
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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
• Oil service – Normal Operation every 10,000
miles or 16,000 km or 12 months.
• Maintenance 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.
• One wrench icon showing indicates Oil Service
is necessary.
• Two 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:
• Engine oil level
• Brake system - fluid level
• Battery - acid level
• Windshield washer system and headlamp clean-
ing system - fluid level
• Mechanical assemblies (e.g. engine, transmis-
sion, etc.) - check for leaks
• Condition of tires and tires pressures
• All 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.
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LUBRICATION & MAINTENANCE
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SCOPE OF WORK FOR MAINTENANCE SERVICE
Oil Service
• Engine: Oil change and filter replacement
Check fluid levels of the following system, refill as neces-
sary.
• If fluid is lost, trace and eliminate cause - as a
separate order.
• Power-assisted steering
Lubrication work:
• Trailer tow hitch (original equipment)
Maintenance
• ASSYST maintenance computer reset
Function check
• Signalling system, warning and indicator lamps
• Headlamps, exterior lighting
• Windshield wipers, windshield washer system
Check for leaks and damage
• Check for abrasion points and ensure that lines
are correctly routed!
• All lines and hoses, sensor cables
• Rubber boots on front axle drive shafts, rubber
boots on front axle suspension ball joints, shock
absorbers
• Check fluid levels for the following systems, cor-
rect as necessary
NOTE: Should there be a loss of fluid which cannot
be explained by regular use, trace and eliminate the
cause.
• Engine cooling system. Check corrosion inhibi-
tor/antifreeze, refill as necessary.
• Hydraulic brake system
• Battery
• Windshield washer system
Engine
• Fuel filter renewal - Every oil service
• Air cleaner with maintenance indicator:
• Check degree of contamination.
• Air cleaner filter element renewed as necessary.
Chassis and body
• Trailer coupling: Check operation, play and
retaining fixtures
• Secondary rubber springs: Visual check
• Tire pressures: Correct as necessary, including
spare tire
• Check thickness of brake pads
• Brake test
• Check condition of steering mechanism
• Heating/ventilation dust filter renewal
ADDITIONAL MAINTENANCE WORK
Automatic transmission once only at 80,000 miles / 128000
km
• Oil and filter change
During every second maintenance service
• Air cleaner without maintenance indicator:
• Air cleaner filter element renewal
• Check poly-V-belt for wear and signs of damage
During every fourth maintenance service
• Change rear axle fluid
ADDITIONAL MAINTENANCE WORK AFTER YEARS
Every 2 years
• Change brake fluid.
Every 3 years
• Air cleaner filter element renewal (note installa-
tion date)
Every 15 years or 100,000 miles
• Coolant renewal
• Note coolant composition
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 3).
Fig. 3 INTERNATIONAL SYMBOLS
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LUBRICATION & MAINTENANCE
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