Dodge 2004 Freightliner User manual

TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
1
3
4
5
6
7
8
9
2
10
10
SECTION PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
UNDERSTANDING THE FEATURES OF YOUR VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
UNDERSTANDING YOUR INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
STARTING AND OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
WHAT TO DO IN EMERGENCIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
MAINTAINING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
IF YOU NEED CONSUMER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Freightliner-all.book Page 1 Monday, December 1, 2003 2:54 PM

Freightliner-all.book Page 2 Monday, December 1, 2003 2:54 PM

1
CONTENTS
INTRODUCTION
 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
 How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . 4
 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . 4
 Vehicle Identification Number, Sample
and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
 Vehicle Safety Certification Label, Sample
and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
 Vehicle/Engine Emission Label, Sample
and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Freightliner-all.book Page 3 Monday, December 1, 2003 2:54 PM

4 INTRODUCTION
INTRODUCTION
This manual has been prepared with the assistance of
service and engineering specialists to acquaint you
with the operation and maintenance of your new
vehicle. It is supplemented by a Warranty Information
Booklet and various customer oriented documents.
You are urged to read these publications carefully.
Following the instructions and recommendations in
this manual will help assure safe and enjoyable
operation of your vehicle.
NOTE: After you read the manual, it should be stored
in the vehicle for convenient reference and remain with
the vehicle when sold.
When it comes to service, remember that your dealer
knows your vehicle best, has the factory-trained
technicians and genuine Mopar
® parts, and is
interested in your satisfaction.
HOW TO USE THIS MANUAL
Consult the table of contents to determine which
section contains the information you desire.
The detailed index, at the rear of this manual, contains
a complete listing of all subjects.
WARNINGS AND CAUTIONS
This manual contains WARNINGS against operating
procedures which could result in an accident or bodily
injury. It also contains CAUTIONS against procedures
which could result in damage to your vehicle. If you do
not read this entire manual you may miss important
information. Observe all Warnings and Cautions.
WARNING!
Engine exhaust, some of its constituents, and cer-
tain vehicle components contain or emit chemi-
cals known to the State of California to cause
cancer and birth defects or other reproduction
harm. In addition, certain fluids contained in ve-
hicles, and certain products of component wear,
contain chemicals known to the State of Califor-
nia to cause cancer and birth defects or other re-
productive harm.
Freightliner-all.book Page 4 Monday, December 1, 2003 2:54 PM

INTRODUCTION 5
1
VEHICLE IDENTIFICATION NUMBER, SAMPLE
AND LOCATION
Vehicle identification number, visible (location: lower
edge of windshield)
VEHICLE SAFETY CERTIFICATION LABEL,
SAMPLE AND LOCATION
Location: below the driver’s seat on an outwardfacing
position of the mounting pillar.
1. Incomplete vehicle certification label for
chassis-cab.
2. Type plate (vehicle identification number,
permissible weights)
Freightliner-all.book Page 5 Monday, December 1, 2003 2:54 PM

6 INTRODUCTION
Sample Incomplete Vehicle Certification Label
(Label 1)
Sample Type Plate (Label 2)
VEHICLE/ENGINE EMISSION LABEL, SAMPLE
AND LOCATION
Location: on valve cover of the engine
Sample:
Important Engine Information
DaimlerChrysler AG, Stuttgart, Germany
Mercedes-Benz Engine, Model
Engine Family / Engine Code
Exhaust Emission Control System
OM 612 LA CID 164
2 MBXH2.69DJB / Code I
TC, EMC, CAC, CAT, EGR
Date of engine manufacture
Advertised output (SAE gr.)
Fuel rate at adv. Output
Valve lash cold (ins.)
Basic injection timing
Idle speed
2002
115 kW (154 HP) /3800 rpm
58 - 62 mm3/ stroke
hydr. int. tappet exh.
14.5 ± 1 degrees BTDC
680 ± 50 rpm
This engine conforms to US EPA and Canada regulations applicable
to 2004 Model Year.
This engine has a primary intended service application as a light HD
diesel engine.
This engine is not certified for use in an urban bus as defined at 40
CFR 86.093.-2. Sales of this engine for use in an urban bus is a
violation of Federal Law under the Clean Air Act.
This engine is certified to be operated on diesel fuel.
Freightliner-all.book Page 6 Monday, December 1, 2003 2:54 PM

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
2
CONTENTS
 Ignition Lock /Starter Switch . . . . . . . . . . . . . . . . . . 9
 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
 Central Locking (Optional) . . . . . . . . . . . . . . . . . . 11
 Unlocking: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
 Locking: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
 Central Locking Switch . . . . . . . . . . . . . . . . . . . . 13
 Locking Status Display . . . . . . . . . . . . . . . . . . . . 14
 Locking and Unlocking . . . . . . . . . . . . . . . . . . . . 15
 To Program the Automatic Lock Feature when
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . 15
 Remote Keyless Entry (Optional) . . . . . . . . . . . . . 16
 Unlocking with Remote Keyless Entry . . . . . . . 17
 Locking with Remote Keyless Entry . . . . . . . . . 18
 Replacing Batteries in Remote Keyless Entry . . . 18
 Security System with Towing and Passenger
Compartment Protection (Optional) . . . . . . . . . . . 19
 Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 Visual Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 Switching off the Alarm . . . . . . . . . . . . . . . . . . . 20
 Towing Protection and Passenger Compartment
Protection Switch (Optional). . . . . . . . . . . . . . . . . . 20
 Towing Protection . . . . . . . . . . . . . . . . . . . . . . . . 20
 Switching off the Towing Protection . . . . . . . . . 20
 Passenger Compartment Protection . . . . . . . . . 21
 Switching off the Passenger Compartment
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
 Alarm Pushbutton (Vehicles with Security
Systems only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
 Opening/Closing doors . . . . . . . . . . . . . . . . . . . . . 23
 Sliding Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
 Rear Cargo Doors . . . . . . . . . . . . . . . . . . . . . . . . . 29
 Passenger/Cargo Area Door . . . . . . . . . . . . . . . 33
 Occupant Restraints . . . . . . . . . . . . . . . . . . . . . . . . . 35
Freightliner-all.book Page 7 Monday, December 1, 2003 2:54 PM

8 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
 Seat Belt Warning Lamp and Airbag
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
 Fastening and Removing . . . . . . . . . . . . . . . . . . 38
 Belt Height Adjustment . . . . . . . . . . . . . . . . . . . . 40
 Airbag and Belt Tensioners . . . . . . . . . . . . . . . . . . 40
 SRS Malfunction Indicator Lamp . . . . . . . . . . . 40
 Driver’s Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
 Front Seat Passenger Airbag
(not in conjunction with folding seat in
partition wall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
 Belt Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
 Safety Precautions for the Airbag . . . . . . . . . . . 44
 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
 Engine Break-In Specifications . . . . . . . . . . . . . . . . 46
 The first 1,000 miles (about 1,500 km) . . . . . . . . 46
 Engine Oil Consumption . . . . . . . . . . . . . . . . . . . 47
 Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
 Inhalation of Exhaust Gas . . . . . . . . . . . . . . . . . . . . 48
 Tie Down Rings (Optional) . . . . . . . . . . . . . . . . . . . 48
Freightliner-all.book Page 8 Monday, December 1, 2003 2:54 PM

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 9
2
IGNITION LOCK/STARTER SWITCH
0 The steering wheel is locked when the key is
removed
To remove the key, place the selector lever in
position "P"; rotate the key in the ignition lock to
position 0; and remove the key.
1 The steering wheel is unlocked
2 Preheating and driving position
3Startposition
To engage the steering wheel lock:
After removing the key, turn the steering wheel until
the steering wheel lock engages.
To release the steering wheel lock:
Turn the steering wheel slightly while turning the key
to position 1.
NOTE: If the driver’s or passenger’s door is opened
with the key in position 0 or 1 in the ignition lock, a
warning buzzer sounds.
WARNING!
Do not remove the key from the ignition lock un-
less the vehicle is stationary. Always remove the
key from the ignition lock when leaving the ve-
hicle to prevent children or unauthorized per-
sons from starting the engine.
Freightliner-all.book Page 9 Monday, December 1, 2003 2:54 PM

10 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Immobilizer
The immobilizer is automatically activated when the
key is removed from the ignition lock. The engine
cannot be started. As soon as the correct key is inserted
into the ignition lock, the immobilizer is deactivated.
For notes on the remote keyless entry, refer to "Remote
Keyless Entry".
NOTE: If the engine cannot be started and the displays
Áand îappear alternately in the multi-function
indicator when the key is in position 2 in the ignition
lock, a fault has developed or the key used has not been
activated.
Remove the key and repeat the starting procedure. If
the engine still cannot be started, consult an authorized
Sprinter Dealer.
Freightliner-all.book Page 10 Monday, December 1, 2003 2:54 PM

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 11
2
CENTRAL LOCKING (OPTIONAL)
To unlock (1)
To lock (2)
To unlock (1)
To lock (2)
CAUTION!
An unlocked vehicle is an invitation to thieves.
Always remove the key from the ignition and lock
all doors when leaving the vehicle unattended.
WARNING!
For personal security and safety in the event of an
accident, lock the vehicle doors when you drive
as well as when you park and leave the vehicle.
Freightliner-all.book Page 11 Monday, December 1, 2003 2:54 PM

12 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Unlocking:
If a door lock or interior handle on the driver or front-
seat passenger door is unlocked, only the driver or
front-seat passenger door will be unlocked.
NOTE: If a door lock or interior handle on the sliding
door or tailgate is unlocked, only the sliding door or
tailgate will be unlocked.
Locking:
All doors are automatically locked if a door lock or
interior handle is locked.
NOTE: If the central locking automatically unlocks
again after having been locked, at least one door is
closed incorrectly.
If it then locks again within about 5 seconds, then all
closed doors are locked.
The central locking displays vehicle locking with one
or more open doors by means of a special function
sequence (locking, unlocking, locking). Once closing
has been completed, an open door will not
automatically be locked.
WARNING!
When leaving the vehicle always remove the key
from the ignition lock, and lock your vehicle.
Do not leave children unsupervised in the vehicle,
even if they are secured by a child restraint system.
The children could
• injure themselves on parts of the vehicles
• release the child-proof locks by pressing the
central locking button and could thereby open
the doors and
• cause injury to others as a result
• get out of the vehicle and could either injure
themselves when doing so or they could be
injured by the traffic approaching from the rear
• suffer serious or fatal effects in the event of long
periods of hot weather
• release the parking brake. The vehicle could
then start moving of its own accord.
Unsupervised use of vehicle equipment may cause
severe personal injuries, death and property damage.
Freightliner-all.book Page 12 Monday, December 1, 2003 2:54 PM

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 13
2
After the engine is started (about 1 second), all doors
with the exception of the driver-side door are locked
automatically.
Central Locking Switch
The central locking switch is located
on the center section of the
dashboard.
The entire vehicle or just the
passenger door and the cargo doors
can be locked or unlocked from
inside the vehicle with the central locking switch.
After the engine is started (about 1 second), all doors
with the exception of the driver-side door are locked
(standard setting).
CAUTION!
In case of an accident, rescue from the outside may
be more difficult if the vehicle is locked.
To unlock the vehicle after the engine is started,
refer to "Central Locking Switch".
Freightliner-all.book Page 13 Monday, December 1, 2003 2:54 PM

14 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Locking Status Display
Left-hand indicator lamp is illuminated:
The driver’s door is locked.
Right-hand indicator lamp is illuminated:
Front-seat passenger door and rear-seat passenger
area/cargo area are locked.
Both indicator lamps are illuminated:
The entire vehicle is locked.
If an indicator lamp flashes:
At least one door has not been properly closed.
NOTE: The indicator lamps go out,
once the remote keyless entry transmitter has been
used to completely lock the vehicle;
if the ignition lock is in the position 0, and once the
interior handles/closing cylinders have been used to
completely lock the vehicle;
after about 15 minutes in position 0 in the ignition lock.
The display can be reactivated by pressing the central
locking switch, located on the center section of the
dashboard.
WARNING!
When leaving the vehicle always remove the key
from the ignition lock, and lock your vehicle.
Do not leave children unsupervised in the vehicle,
even if they are secured by a child restraint system.
The children could
• injure themselves on parts of the vehicles
• release the child-proof locks by pressing the
central locking button and could thereby open
the doors and
• cause injury to others as a result
• get out of the vehicle and could either injure
themselves when doing so or they could be
injured by the traffic approaching from the rear
• suffer serious or fatal effects in the event of long
periods of hot weather
• release the parking brake. The vehicle could
then start moving of its own accord.
Unsupervised use of vehicle equipment may cause
severe personal injuries, death and property damage.
Freightliner-all.book Page 14 Monday, December 1, 2003 2:54 PM

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 15
2
Locking and Unlocking
To lock entire vehicle:
Press top of central locking switch.
The left and the right indicator lamp in the switch
illuminate. If one of the two indicator lamps blinks, at
least one door is not closed properly.
To unlock entire vehicle:
Press top of central locking switch again.
To lock the front-seat passenger door and the rear-seat
passenger area/cargo area:
Press bottom of central locking switch.
The right indicator lamp in the switch illuminates. If
the indicator lamp blinks, at least one door is not closed
properly.
To unlock the front-seat passenger door and the rear-
seat passenger area/cargo area:
Press bottom of central locking switch again.
To Program the Automatic Lock Feature when
Starting the Engine
Place the key in position 2 in the ignition lock and close
all doors.
To switch off automatic locking of the front-seat passenger
door and the rear-seat passenger area/cargo area:
Press the central locking switch at the bottom and hold
it there for about 5 seconds. The right indicator lamp
flashes twice. Automatic locking when the engine is
started is switched off.
To switch on automatic locking of the front-seat passenger
door and the rear-seat passenger area/cargo area:
Press the central locking switch at the bottom and hold
it there for about 5 seconds. The right indicator lamp
flashes four times. Automatic locking when the engine
is started is switched on (standard setting).
NOTE: A door which is closed after the engine has
been started will not be locked automatically.
Freightliner-all.book Page 15 Monday, December 1, 2003 2:54 PM

16 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Au
Automatic Unlocking in Case of an Accident
The doors will unlock in the event of certain accidents,
provided that the power supply is still maintained.
REMOTE KEYLESS ENTRY (OPTIONAL)
This transmitter complies with FCC rules part 15 and
with RS-210 of Industry Canada. Operation is subject
to the following two conditions: (1) this device may not
cause harmful interference and (2) this device must
accept any interference that may be received, including
interference that may cause undesired operation.
NOTE: Any unauthorized modification to this device
could void the user’s authority to operate the
equipment.
NOTE: Included with your vehicle are2 remote
keyless entry transmitters plus removable mechanical
key.
Keys which were not included with delivery must be
activated at an authorized Sprinter Dealer before they
can be used.
If a non-activated key is used, after the fourth attempt
to start, the starting process will be blocked for 1
minute.
The multi-function display will alternately show Á
and î, refer to "Immobilizer".
Malfunctions could occur if the remote keyless entry
transmitter is exposed to moisture. As a precaution,
both remote keyless entry transmitters should always
be carried.
The remote keyless entry transmitter transmits in all
directions. It does not have to be pointed at the vehicle.
Do not expose the remote keyless entry transmitter to
high levels of electromagnetic radiation in order to
avoid the risk of malfunctions.
The remote keyless entry transmitter has an average
range of about 32 ft (about 10 m). Always verify the
CAUTION!
In case of an accident, rescue from the outside may
be more difficult if the vehicle is locked.
To unlock the vehicle after the engine is started,
refer to ‘‘Central Locking Switch’’.
Freightliner-all.book Page 16 Monday, December 1, 2003 2:54 PM

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 17
2
correct operation of the remote keyless entry
transmitter by listening for the locking noise and by
checking that the white patch on the interior door
handle is visible.
When pressing the Œor ‹buttons, the indicator
lamp illuminates. If the indicator lamp does not
illuminate, the batteries must be replaced. For
instructions on replacing the batteries in the remote
keyless entry transmitter.
The remote keyless entry transmitter will not function
when there is a vehicle key inserted in the ignition lock.
Release button for mechanical key (1)
Indicator lamp (2)
Lock button ‹ (3)
Unlock button Π(4)
Unlocking with Remote Keyless Entry
Press the Œbutton once. The driver’s door is
unlocked and the hazard warning lamp, as well as the
remote keyless entry transmitter indicator lamp, blink
once.
Freightliner-all.book Page 17 Monday, December 1, 2003 2:54 PM

18 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Press the Œbutton a second time. The passenger
door and cargo doors are unlocked and the turn signal
lamps, as well as the remote keyless entry transmitter
indicator lamp, blink once again. The button must be
pressed a second time within about 2.5 seconds,
otherwise the second request to open can not be
performed.
NOTE: The vehicle is automatically locked again, if
within about 40 seconds of unlocking with the remote
keyless entry transmitter, none of the doors are
opened. The hazard warning lamp does not blink.
Locking with Remote Keyless Entry
Press the ‹button. The entire vehicle is locked and
the hazard warning lamp blinks three times. The
remote keyless entry transmitter indicator lamp blinks
once.
If the hazard warning lamp does not blink, at least one
door is improperly closed. Check to see if there is a
door that is not properly closed or if there is a key in the
ignition lock. Remove key from ignition lock and/or
close doors properly and press the ‹button again.
REPLACING BATTERIES IN REMOTE KEYLESS
ENTRY
Do not touch the battery contact surfaces (insert the
batteries with a lint-free cloth).
NOTE: Do not operate the remote control while the
battery is being replaced.
WARNING!
Keep batteries away from children.
Consult a doctor immediately if a battery is
swallowed.
Dispose of used batteries in an environmentally
responsible manner.
Danger of explosion if the battery is not correctly
replaced. Replacements should always be either
of the same type or one which has been
recommended by the manufacturer.
Freightliner-all.book Page 18 Monday, December 1, 2003 2:54 PM

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 19
2
Replacing Batteries
Rated voltage: 6 V
DC (2x 3V)
Rated current:10 mA
1. Release the
mechanical key
by pressing the
release button.
2. Remove the
battery cover.
3. Remove the battery and install
new one (note correct polarity;
positive terminal up).
4. Press on the battery cover until it
snaps into place.
SECURITY SYSTEM WITH TOWING AND
PASSENGER COMPARTMENT PROTECTION
(OPTIONAL)
The security system is ready for operation, if the
vehicle is locked with the remote keyless entry
transmitter.
If a door is open, the security system is not switched on
during the locking process.
Security system activation is indicated by the turn
signal lamps flashing three times in succession.
For a function check, when the security system is
switched on, the indicator lamps in the towing
protection/passenger compartment protection switch
flash.
The security system will switch off if the vehicle is
unlocked using the remote keyless entry transmitter.
The turn signal lamps flash once.
Freightliner-all.book Page 19 Monday, December 1, 2003 2:54 PM

20 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
The alarm is triggered if the security system has been
activated and
• A door is opened,
• a door is unlocked from inside,
• the engine cover is opened,
• the key is used to unlock the vehicle at any door,
• the key is turned to position 2 in the ignition lock.
Audible Alarm
The horn sounds for about 25 seconds.
Visual Alarm
The turn signal lamps flash for about 4 minutes.
Switching off the Alarm
The alarm will switch off immediately if the vehicle is
unlocked using the remote keyless entry transmitter.
NOTE: Do not manually unlock the doors as this will
trigger the alarm.
TOWING PROTECTION AND PASSENGER
COMPARTMENT PROTECTION SWITCH
(OPTIONAL)
See Section 4, Understanding Your Instrument Panel,
for switch locations.
Switch off the towing protection
Indicator lamp
As a function check, (1) the indicator
lamp (2) flashes when the security
system is switched on.
Switch off the passenger compartment protection.
Towing Protection
The towing protection is ready for operation after
30 seconds as the security system has been activated.
The alarm is triggered if the vehicle is lifted while the
security system is activated.
Switching off the Towing Protection
If the vehicle is to be transported or loaded, the towing
protection must be switched off in order to avoid a
false alarm.
Freightliner-all.book Page 20 Monday, December 1, 2003 2:54 PM