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2004 Dodge Sprinter 3500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Dodge REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
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- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Dodge Sprinter 3500 car and truck
repair procedures including Dodge engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Dodge Sprinter 3500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Automatic Temperature Control Systems Diagnosis & Testing -> Sprinter -> Description -> Air Outlet Temperature Sensor -> Ambient Temperature Sensor -> Heater-A/C Control Panel -> System Components
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
The Single Zone Automatic Temperature Control (ATC) system automatically maintains the selected comfort temperature. The system uses signals from the air outlet temperature sensor, ambient temperature sensor and CAN BUS to maintain selected temperature. Based on the sensor input the system will adjust air temperature, air flow volume and air flow distribution to maintain selected temperature, even under changing outside weather conditions.
System Components
Air Outlet Temperature Sensor
The air outlet temperature sensor is mounted on the heater housing. The senso...
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BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Anti-Lock Brakes -> Sprinter -> Description
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
When wheel slip is detected during a brake application, the ABS enters anti-lock mode. During anti-lock braking, hydraulic pressure in the individual wheel circuits is controlled to prevent any wheel from slipping. A separate hydraulic line and specific solenoid valves are provided for each wheel. The ABS can decrease, hold, or increase hydraulic pressure to each wheel brake. The ABS cannot, however, increase hydraulic pressure above the amount which is transmitted by the master cylinder during braking.
The Controller Anti-Lock Brake (CAB) is used to monitor wheel speeds and modulate...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> Sprinter -> Normal Service -> Severe Service
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
Normal Service
Replace as requ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
DRIVESHAFT, Replace
Vehicle: 2004 Dodge Sprinter 3500 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 3500 AUTOMOBILES
Starter, Replace
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
- Remove battery ground cable.
- Remove wiring to transmission bellhousing bolt.
- Cut tie-wraps and position wiring harness aside.
- Remove mounting nuts and solenoid wire connector and battery cable.
- Raise and support v...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Cabin Air Filter Service -> Chrysler LLC -> 2003-06 Sprinter -> Front Cabin Air Filter -> Rear Cabin Air Filter
Vehicle: 2004 Dodge Sprinter 3500 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 3500 AUTOMOBILES
Chrysler LLC Trucks -> Emission Maintenance Reminder Indicator -> Chrysler, Dodge & Plymouth
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
This Emission Maintenance Reminder System (Maintenance Required Lamp) is incorporated into the engine controller. The controller stores vehicle mileage into its memory every eight miles, then at 60,000, 82,500 or 120,000 miles it will light the EMR (Maintenance Required) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following components must be replaced and the EMR lamp reset:
- At 60,00 miles, proceed as follows:
- Replace EGR valve.
- Clean EGR passage.
- Replace PCV valve.
- At 82,500 miles, replace oxygen sensor.
- At 120,000 miles, proceed as ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at engine.
- Remove hose from engine.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- D...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Dodge Sprinter 3500 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 3500 AUTOMOBILES
Component location diagrams for most 2004 Dodge Sprinter 3500 cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Components Diagram for 2004 Dodge Sprinter 3500 2.7 L5 DIESELComponents on diagram: |
 Door Components Diagram for 2004 Dodge Sprinter 3500 2.7 L5 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Dodge Sprinter 3500 cars and light trucks sold in the U.S.
 2004 Dodge Sprinter 3500 2.7 L5 DIESEL Wiring DiagramComponents on diagram: |
 2004 Dodge Sprinter 3500 2.7 L5 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
OEM TSB listings for most 2004 Dodge Sprinter 3500 cars and light trucks sold in the U.S. from 1985+.
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Document: Idle Instability - Rear A/C Idle Cutout Module Installation Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL Symptoms: |
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Document: SAFETY RECALL H25 - STEERING COLUMN Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Dodge Sprinter 3500 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 3500 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 3500 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 3500 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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