Dodge Sprinter 3500 User manual

TABLE OF CONTENTS
SECTION PAGE
1
INTRODUCTION .............................................................3
2
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE ...............................9
3
UNDERSTANDING THE FEATURES OF YOUR VEHICLE ...............................79
4
UNDERSTANDING YOUR INSTRUMENT PANEL ................................... 183
5
STARTING AND OPERATING .................................................265
6
WHAT TO DO IN EMERGENCIES ...............................................377
7
MAINTAINING YOUR VEHICLE ...............................................399
8
MAINTENANCE SCHEDULES ..................................................475
9
IF YOU NEED CONSUMER ASSISTANCE ..........................................489
10
INDEX ....................................................................499
1
2
3
4
5
6
7
8
9
10

INTRODUCTION
CONTENTS
mIntroduction ...........................4
mA Message From DaimlerChrysler Corporation . . . 4
mHow To Use This Manual ..................5
mWarnings And Cautions ...................7
mVan Conversions/Campers .................7
mVehicle Identification Number ...............8
mVehicle Modifications/Alterations ............8
1

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 instruc-
tions 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, so that the new owner will be
aware of all safety warnings.
When it comes to service, remember that your dealer
knows your vehicle best, has the factory-trained techni-
cians and genuine Mopartparts, and is interested in
your satisfaction.
A MESSAGE FROM DAIMLERCHRYSLER
CORPORATION
DaimlerChrysler Corporation and Cummins welcome
you as a new Dodge Ram Cummins Turbo Diesel-
powered truck owner.
Almost 100% of the heavy duty trucks in the United
States and Canada are diesel powered because of the fuel
economy, rugged durability, and high torque which per-
mits pulling heavy loads. Cummins engines power well
over half of these trucks. Now this same technology and
proven performance is yours in your new Dodge Ram
truck equipped with the Cummins, Turbocharged,
Charge Air Cooled, Diesel engine.
Your diesel truck will sound, feel, drive, and operate
differently from a gasoline-powered truck. It is important
that you read and understand this manual. You may find
that some of the starting, operating, and maintenance
procedures are different. However, they are simple to
4 INTRODUCTION

follow and careful adherence to them will ensure that
you take full advantage of the features of this engine.
Thank you for choosing the Dodge Ram truck with
Cummins Turbo Diesel power.
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.
Consult the following table for a description of the
symbols that may be used on your vehicle or throughout
this owner’s manual:
INTRODUCTION 5
1

6 INTRODUCTION

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.
VAN CONVERSIONS/CAMPERS
The Manufacturer’s Warranty does not apply to body
modifications or special equipment installed by van
conversion/camper manufacturers/ body builders. See
the Warranty information book, Section 2.1.C. Such
equipment includes video monitors, VCRs, heaters,
stoves, refrigerators, etc. For warranty coverage and
service on these items, contact the applicable manufac-
turer.
Operating instructions for the special equipment in-
stalled by the conversion/camper manufacturer should
also be supplied with your vehicle. If these instructions
are missing, please contact your selling dealer for assis-
tance in obtaining replacement documents from the
applicable manufacturer.
For information on the Body Builders Guide go to:
www.dodgebodybuilder.com. This website contains di-
mensional and technical specifications for your vehicle. It
is intended for Second Stage Manufacturer’s technical
support. For service issues, contact your dealer.
INTRODUCTION 7
1

VEHICLE IDENTIFICATION NUMBER
The vehicle identification number (VIN) is found on the
left front corner of the instrument panel, visible through
the windshield. This number also appears on the Auto-
mobile Information Disclosure Label affixed to a window
on your vehicle, the vehicle registration and title.
NOTE: It is illegal to remove the VIN.
VEHICLE MODIFICATIONS/ALTERATIONS
WARNING!
Any modifications or alterations to this vehicle could
seriously affect its roadworthiness and safety and
may lead to an accident resulting in serious injury or
death.
Vehicle Identification Number
8 INTRODUCTION

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
CONTENTS
mA Word About Your Keys ..................12
▫Ignition Key Removal ...................12
▫Locking Doors With The Key ..............14
mSentry Key ............................15
▫Replacement Keys ......................16
▫Customer Key Programming ..............17
▫General Information ....................18
mSteering Wheel Lock — If Equipped ..........18
▫If You Wish To Manually Lock The Steering
Wheel ..............................18
▫To Release The Steering Wheel Lock .........18
▫Automatic Transmission Ignition Interlock
System ..............................19
mSecurity Alarm System — If Equipped .........19
▫Rearming Of The System .................19
▫To Set The Alarm ......................19
▫To Disarm The System ...................20
2

mIlluminated Entry System — If Equipped .......20
mRemote Keyless Entry — If Equipped .........21
▫To Unlock The Doors ...................21
▫To Lock The Doors .....................22
▫Using The Panic Alarm ..................24
▫General Information ....................24
▫Transmitter Battery Service ...............25
mDoor Locks ............................26
▫Manual Door Locks — If Equipped .........26
▫Power Door Locks — If Equipped ..........27
▫Child Protection Door Lock ...............30
mWindows .............................31
▫Power Windows – If Equipped .............31
▫Power Sliding Rear Window – If Equipped ....33
▫Sliding Rear Window – If Equipped .........33
▫Wind Buffeting ........................33
mOccupant Restraints ......................34
▫Lap/Shoulder Belts .....................35
▫Adjustable Upper Shoulder Belt Anchorage ....42
▫Automatic Locking Retractors (ALR) Mode –
If Equipped ..........................43
▫Center Lap Belts .......................44
▫Seat Belt Pretensioners — If Equipped .......44
▫Enhanced Seat Belt Reminder System
(BeltAlert) ...........................45
▫Seat Belts And Pregnant Women ............46
▫Seat Belt Extender ......................46
10 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

▫Driver And Right Front Passenger Supplemental
Restraint System (SRS)—Airbags ...........47
▫Event Data Recorder (EDR) ...............59
▫Child Restraint ........................61
mNew Engine Break-In .....................74
mSafety Tips ............................75
▫Transporting Passengers .................75
▫Lock Your Vehicle ......................76
▫Exhaust Gas ..........................76
▫Safety Checks You Should Make Inside The
Vehicle ..............................77
▫Safety Checks You Should Make Outside The
Vehicle ..............................78
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 11
2

A WORD ABOUT YOUR KEYS
The dealer that sold you your new vehicle has the key
code numbers for your vehicle locks. These numbers can
be used to order duplicate keys from your dealer. Ask
your dealer for these numbers and keep them in a safe
place.
Ignition Key Removal
Automatic Transmission — If Equipped
Place the shift lever in PARK. Turn the ignition switch to
the LOCK position, and remove the key.
Ignition Key
Ignition Switch Positions
12 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

NOTE: If you try to remove the key before you place the
lever in PARK, the key may become trapped temporarily
in the ignition cylinder. If this occurs, rotate the key to the
right slightly, then remove the key as described. If a
malfunction occurs, the system will trap the key in the
ignition cylinder to warn you that this safety feature is
inoperable. The engine can be started and stopped but
the key cannot be removed until you obtain service.
NOTE: For vehicles not equipped with the Electronic
Vehicle Information Center (EVIC), the power window
switches, radio, hands–free system (if equipped), and
power outlets will remain active for 10 minutes after the
ignition switch is turned off. Opening either front door
will cancel this feature.
For vehicles equipped with the Electronic Vehicle Infor-
mation Center (EVIC), the power window switches,
radio, hands–free system (if equipped), and power out-
lets will remain active for up to 10 minutes after the
ignition switch is turned off. Opening either front door
will cancel this feature. The time for this feature is
programmable. For details, refer to “KEY OFF POWER
DELAY > OFF” under “Personal Settings (Customer
Programmable Features),” under “Electronic Vehicle In-
formation Center (EVIC)” in Section 3 of this manual.
WARNING!
Never leave children alone in a vehicle. Leaving
children in a vehicle unattended is dangerous for a
number of reasons. A child or others could be seri-
ously or fatally injured. Don’t leave the keys in the
ignition. A child could operate power windows,
other controls, or move the vehicle.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 13
2

CAUTION!
An unlocked car is an invitation to thieves. Always
remove key from the ignition and lock all doors
when leaving the vehicle unattended.
Manual Transmission — If Equipped
When the steering wheel is in the LOCK position, the
steering and ignition systems are locked to provide
antitheft protection for your vehicle. It may be difficult to
turn the key from the LOCK position when starting your
vehicle. Move the steering wheel left and right while
turning the key until it turns easily. To remove the key,
depress and hold the release button located between the
ignition switch and the instrument panel. Turn the igni-
tion key to LOCK and remove the key.
Locking Doors With The Key
You can insert the key with either side up. To lock the
door, turn the key rearward, to unlock the door, turn the
key forward. See Section 7 of this manual for door lock
lubrication.
Ignition Key Release Button
14 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

SENTRY KEY
The Sentry Key Immobilizer System prevents unautho-
rized vehicle operation by disabling the engine. The
system does not need to be armed or activated. Operation
is automatic, regardless of whether the vehicle is locked
or unlocked.
The system uses ignition keys, which have an embedded
electronic chip (transponder), to prevent unauthorized
vehicle operation. Therefore, only keys that are pro-
grammed to the vehicle can be used to start and operate
the vehicle. The system will shut the engine off in two (2)
seconds if someone uses an invalid key to start the
engine.
NOTE: A key, which has not been programmed, is also
considered an invalid key even if it is cut to fit the
ignition switch lock cylinder for that vehicle.
During normal operation, after turning on the ignition
switch, the Vehicle Security Alarm Indicator Light will
turn on for three (3) seconds for a bulb check. If the light
remains on after the bulb check, it indicates that there is
a problem with the electronics. In addition, if the light
begins to flash after the bulb check, it indicates that
someone used an invalid key to start the engine. Either of
these conditions will result in the engine being shut off
after two (2) seconds.
If the Vehicle Security Alarm Indicator Light turns on
during normal vehicle operation (vehicle running for
longer than 10 seconds), it indicates that there is a fault in
the electronics. Should this occur, have the vehicle ser-
viced as soon as possible.
NOTE:
• The Sentry Key Immobilizer System is not compatible
with some after-market remote starting systems. Use
of these systems may result in vehicle starting prob-
lems and loss of security protection.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 15
2

• Exxon/Mobil Speed Pass,™ additional Sentry Keys, or
any other transponder-equipped components on the
same key chain will not cause a key-related (transpon-
der) fault unless the additional part is physically held
against the ignition key being used when starting the
vehicle. Cell phones, pagers, or other RF electronics
will not cause interference with this system.
All of the keys provided with your new vehicle have
been programmed to the vehicle electronics.
Replacement Keys
NOTE: Only keys that are programmed to the vehicle
electronics can be used to start and operate the vehicle.
Once a Sentry Key is programmed to a vehicle, it cannot
be programmed to any other vehicle.
CAUTION!
Always remove Sentry Keys from the vehicle and
lock all doors when leaving the vehicle unattended.
At the time of purchase, the original owner is provided
with a four-digit PIN number. Keep the PIN in a secure
location. This number is required for dealer replacement
of keys. Duplication of keys may be performed at an
authorized dealer or by using the Customer Key Pro-
gramming procedure. This procedure consists of pro-
gramming a blank key to the vehicle electronics. A blank
key is one, which has never been programmed.
NOTE: When having the Sentry Key Immobilizer
System serviced, bring all vehicle keys with you to the
dealer.
16 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

Customer Key Programming
If you have two valid sentry keys, you can program new
sentry keys to the system by performing the following
procedure:
1. Cut the additional Sentry Key Transponder blank(s) to
match the ignition switch lock cylinder key code.
2. Insert the first valid key into the ignition switch. Turn
the ignition switch to the “ON” position for at least 3
seconds, but no longer than 15-seconds. Then, turn the
ignition switch to the “LOCK” position and remove the
first key.
3. Insert the second valid key into the ignition switch.
Turn the ignition switch to the “ON” position within 15
seconds. After ten seconds, a chime will sound. In
addition, the Vehicle Security Alarm Indicator Light will
begin to flash. Turn the ignition switch to the “LOCK”
position and remove the second key.
4. Insert a blank Sentry Key into the ignition switch. Turn
the ignition switch to the “ON” position within 60
seconds. After 10 seconds, a single chime will sound. In
addition, the Vehicle Security Alarm Indicator Light will
stop flashing. To indicate that programming is complete,
the indicator light will turn on again for 3 seconds and
then turn off.
The new Sentry Key is programmed. The Keyless Entry
Transmitter will also be programmed during this pro-
cedure.
Repeat this procedure to program up to 8 keys. If you do
not have a programmed sentry key, contact your dealer
for details.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 17
2

NOTE: If a programmed key is lost, see your dealer to
have all remaining keys erased from the systems
memory. This will prevent the lost key from starting your
vehicle. The remaining keys must then be repro-
grammed. All vehicle keys must be taken to the dealer at
the time of service to be reprogrammed.
General Information
The Sentry Key system complies with FCC rules part 15
and with RSS-210 of Industry Canada. Operation is
subject to the following conditions:
• This device may not cause harmful interference.
• This device must accept any interference that may be
received, including interference that may cause undes-
ired operation.
STEERING WHEEL LOCK — IF EQUIPPED
Your vehicle may be equipped with a passive steering
wheel lock. This lock prevents steering the vehicle with-
out the ignition key. If the steering wheel is moved no
more than 1/2 turn in either direction and the key is not
in the ignition switch, the steering wheel will lock.
If You Wish To Manually Lock The Steering
Wheel:
With the engine running, turn the steering wheel upside
down, turn off the engine and remove the key. Turn the
steering wheel slightly in either direction until the lock
engages.
To Release The Steering Wheel Lock:
Insert the key in the ignition switch and start the engine.
If the key is difficult to turn, move the wheel slightly to
the right or left to disengage the lock.
18 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE

NOTE: If you turned the wheel to the right to engage
the lock, you must turn the wheel slightly to the right to
disengage it. If you turned the wheel to the left to engage
the lock, turn the wheel slightly to the left to disengage it.
Automatic Transmission Ignition Interlock System
This system prevents the key from being removed unless
the shift lever is in PARK. It also prevents shifting out of
PARK unless the key is in the ON positions, and the
brake pedal is depressed.
SECURITY ALARM SYSTEM — IF EQUIPPED
This system monitors the vehicle doors and ignition for
unauthorized operation. When the alarm is activated, the
system provides both audible and visual signals. For the first
3 minutes the horn will sound and the headlights and
security telltale will flash repeatedly. For an additional 15
minutes only the headlights and security telltale will flash.
The engine will run only if a valid Sentry Key is used to start
the vehicle. Use of the Sentry Key will disable the alarm.
Rearming of the System:
The security system will rearm itself after the 15 addi-
tional minutes of headlights and security telltale flashing,
if the system has not been disabled. If the condition
which initiated the alarm is still present, the system will
ignore that condition and monitor the remaining doors
and ignition.
To Set the Alarm:
The alarm will set when you use the power door locks, or
use the Keyless Entry transmitter to lock the doors. After
all the doors are locked and closed the SECURITY light in
the instrument cluster will flash rapidly to signal that the
system is arming. The security light in the instrument
panel cluster will flash rapidly for about 16 seconds to
indicate that the alarm is being set. After the alarm is set,
the security light will flash at a slower rate to indicate
that the system is armed.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 19
2

NOTE: If the SECURITY light stays on continuously
during vehicle operation, have the system checked by
your dealer.
To Disarm the System:
Use the Keyless Entry transmitter to unlock the door. If
something has triggered the system in your absence, the
horn will sound three times when you unlock the doors
and the security lamp will flash for 30 seconds. Check the
vehicle for tampering.
The Security system will also disarm, if the vehicle is
started with a programmed Sentry Key. If an unpro-
grammed Sentry Key is used to start a vehicle, the engine
will run for 2 seconds and then the security alarm will be
initiated. To exit alarming mode, press the transmitter
Unlock button, or start the vehicle with a programmed
Sentry Key.
The Security Alarm System is designed to protect your
vehicle; however, you can create conditions where the
system will arm unexpectedly. If you remain in the
vehicle and lock the doors with the transmitter, the alarm
will sound when you pull the door handle to exit. The
door will be locked but the Security Alarm will not arm.
ILLUMINATED ENTRY SYSTEM — IF EQUIPPED
The courtesy lights will turn on when you use the keyless
entry transmitter or open the doors. This feature is only
available if you have Remote Keyless Entry.
The lights will fade to off after about 30 seconds or they
will immediately fade to off once the ignition switch is
turned on.
NOTE:
• The front courtesy overhead console, door courtesy
lights do not turn off if the dimmer control is in the
interior lights ON position (extreme top position).
20 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE