2004 DODGE SPRINTER belt

100 UNDERSTANDING YOUR INSTRUMENT PANEL3
Brake fluid level too low and electronic brake
force distribution (EBV) malfunction
(Canada only).
<
Seat belt warning lamp.
-
ABS malfunction and electronic brake force
distribution (EBV) malfunction.
±
Engine control unit malfunction.
k
Acceleration skid control (ASR) malfunction
and brake assist system (BAS)
1 malfunction.
W
Fluid level in windshield washer low.
q
Preheating.
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MAINTAINING YOUR VEHICLE
7
CONTENTS
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . 205

Sprinter Original Parts . . . . . . . . . . . . . . . . . . . . . . 207

Service Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Disposal of Service Products . . . . . . . . . . . . . . 208

Emission Related Component Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Regular Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Windshield Washer System Fluid Reservoir . 209Air Filter Restriction Indicator (Optional) . . . 209Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 210Ribbed V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Hydraulic Brake System, Clutch Mechanism
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Checking Coolant Level . . . . . . . . . . . . . . . . . . 213

Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Disconnecting the Battery . . . . . . . . . . . . . . . . . 216Reconnecting the Battery . . . . . . . . . . . . . . . . . . 217Charging the Battery . . . . . . . . . . . . . . . . . . . . . 217

Replacing Wiper Blades . . . . . . . . . . . . . . . . . . . . . 218Appearance Car and Corrosion Protection . . 219Power Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Automatic Car Wash . . . . . . . . . . . . . . . . . . . . . 221Tar Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Paintwork, Painted Body Components . . . . . . 221Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 221Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . 222Ornamental Moldings . . . . . . . . . . . . . . . . . . . . 222Headlamps, Taillamps, Turn Signal Lenses . . 222Window Cleaning . . . . . . . . . . . . . . . . . . . . . . . 223
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204 MAINTAINING YOUR VEHICLE
Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Light Alloy Wheels . . . . . . . . . . . . . . . . . . . . . . 224Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 224Steering Wheel and Gear Selector Lever . . . . 224Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Headliner and Shelf Below Rear Window . . . 224Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Hard Plastic Trim Items . . . . . . . . . . . . . . . . . . 225Plastic and Rubber Parts . . . . . . . . . . . . . . . . . . 225

Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Standard Fuse and Relay Equipment . . . . . . . 226Relay Assignment, Standard Equipment . . . . 230Fuse and Relay Optional Equipment . . . . . . . 230

Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 233Front Lamp Unit . . . . . . . . . . . . . . . . . . . . . . . . . 233Taillamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
License Plate Lamps
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 240Additional Brake Lamp
(Cargo/Passenger Vans Only) . . . . . . . . . . . . . 240Side-Mounted Turn Signals . . . . . . . . . . . . . . . 241Side-Marker Lamps,
Standing Lamps (Optional) . . . . . . . . . . . . . . . . 241Interior Lighting in Passenger Compartment
and Load Compartment . . . . . . . . . . . . . . . . . . 242Interior Lighting with Reading Lamp . . . . . . . 242Interior Lighting with Interior Sensor
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Exit Lamps (Optional) . . . . . . . . . . . . . . . . . . . . 243

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244Recommended Fluids and Lubricants . . . . . . 245
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206 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).Freightliner-all.book Pag e 206 Monday, December 1, 2003 2:54 PM

208 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 RELA TED COMPONENT WA RRA NTY
STATEMENTThe Manufacturer warrants to the original and each
subsequent owner of a MERCEDES-BENZ 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
(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.
REGULA R 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.
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MAINTAININ G YOUR VEHICLE 211
7
Ribbed V-BeltThe ribbed V-belt drives the accessories, such as
generator, coolant pump and hydraulic steering pump.
The ribbed V-belt is automatically kept tensioned.
Check the state of the ribbed V-belt regularly, such as
at every engine oil level check.
The belt must not be damaged, worn, oiled or glazed.
There must be no cracks in the belt running surface.
Replace damaged belts.
Hydraulic Brake System, Clutch Mechanism Fluid
Level1. Brake fluid reservoir
Brake fluid level must be between the MIN and MAX
marks in the reservoir (1).
If the brake fluid is below the MIN mark, there may be
a fault in the hydraulic system. Have the system
checked as soon as possible by an authorized Sprinter
Dealer.
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222 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, 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).
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224 MAINTAINING YOUR VEHICLELight A lloy 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.
Cup HolderUse 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.Seat BeltsThe webbing must not be treated with chemical
cleaning agents. Use only clear, lukewarm water and
soap. Do not dry the webbing at temperatures above
176
°F (+80
°C) or in direct sunlight.
Headliner and Shelf Below Rear WindowClean with soft bristle brush, or use a dry-shampoo
cleaner in case of excessive dirt.UpholsteryUsing aftermarket seat covers or wearing clothing that
have the tendency to give off coloring (e.g. when wet
WARNING!
Do not bleach or dye seat belts as this may severe-
ly weaken them. In a crash they may not be able to
provide adequate protection.
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