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2004 Dodge Sprinter 2500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Dodge REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Component Replacement & Adjustment -> Sprinter -> Evaporator Core, Replace
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
- Remove HVAC housing as outlined under "HVAC Housing, Replace."
- Remove gasket from evaporator and heater core tubes, Fig. .
- Remove screws that hold two HVAC housing halves together.
- Remove housing cover from housing.
- Remov...
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BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Disc Brakes -> Brake System Bleed -> Manual -> Master Cylinder -> Pressure
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
Manual
- Remove reservoir filler caps and fill reservoir with proper brake fluid.
- If calipers or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws.
- Close each bleed screw as fluid starts to drip from them.
- Fill master cylinder reservoir once more before proceeding.
- Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid, Fig. . Ensure bleed hose is immersed in fluid.
- Open up bleeder, then have an assistant press down brake pedal.
- Once brake pedal is down, close bleeder. Repeat bleeding unt...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> Sprinter -> Normal Service -> Severe Service
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
Normal Service
Replace as requ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
DRIVESHAFT, Replace
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
- Secure vehicle to prevent it from rolling.
- Make installing reference marks on propeller shaft.
- Remove retaining bracket bolts.
- Remove propeller shaft bolts from rear axle and transmission at flange.
- Remove propeller shaft intermediate bearing nuts from retaining bracket and bracket for brake cable. The brake cable bracket is only installed in vehicles with wheelbas...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
- Remove battery ground cable.
- Relieve belt tension by rotating ratchet and tensioner counterclockwise using suitable long handle drive ratchet.
- Remove drive belt starting at water pump pulley.
- Raise and support vehicle.
- Remove plastic cover and b...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Cabin Air Filter Service -> Chrysler LLC -> 2003-06 Sprinter -> Front Cabin Air Filter -> Rear Cabin Air Filter
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
On models less Assyst Maintenance Computer, cabin air filter element should be replaced every 30,000 miles. The filter should be replaced more often if air flow is less than normal.
On models with Assyst Maintenance Computer, cabin air filter element should be replaced when two wrench symbols are indicated on the instrument panel maintenance display panel. The filter should be replaced more often if air flow is less than normal.
Front Cabin Air Filter
- Open the hood.
- Remove the insulation from the ventilation housing.
- Disengage the front and rear ventilation housing locking clips.
- Sli...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Chrysler LLC Trucks -> Electronic Throttle Control Indicator ->
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
When the ignition is turned On, the lamp will light for approximately 6-12 seconds as a bulb inspection. If the lamp is illuminated with the engine running, the vehicle is usually drivable but the electronic throttle system must be diagnosed and servic...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water pump inlet tube.
- Remove radiator outlet hose from water pump inlet tube and from vehicle.
- Reverse proc...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
- Relieve belt tension by rotating ratchet and tensioner counterclockwise using suitable long handle drive ratchet.
- Remove drive belt starting at water pump pulley.
- Reverse procedure to ins...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
Component location diagrams for most 2004 Dodge Sprinter 2500 cars and light trucks sold in the U.S. from 1990+.
Power Door Locks/RKE Diagram for 2004 Dodge Sprinter 2500 2.7 L5 DIESEL Components on diagram: |
Body Components Diagram for 2004 Dodge Sprinter 2500 2.7 L5 DIESEL Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Dodge Sprinter 2500 cars and light trucks sold in the U.S.
2004 Dodge Sprinter 2500 2.7 L5 DIESEL Wiring Diagram Components on diagram: |
2004 Dodge Sprinter 2500 2.7 L5 DIESEL Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
OEM TSB listings for most 2004 Dodge Sprinter 2500 cars and light trucks sold in the U.S. from 1985+.
Document: Idle Instability - Rear A/C Idle Cutout Module Installation Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL Symptoms: |
Document: SAFETY RECALL H25 - STEERING COLUMN Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Dodge Sprinter 2500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Dodge Sprinter 2500 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Dodge Sprinter 2500 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Dodge Sprinter 2500 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Dodge Sprinter 2500 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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