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Dodge Sprinter 2500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Dodge REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Dodge Sprinter 2500 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 2500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Dodge Sprinter 2500 cars and light trucks from 1990+
Component Replacement & Adjustment -> Sprinter -> A/C Heater Control, Replace
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
- Move shift selector to "D" position.
- Remove shift lever frame trim with suitable flat bladed tool.
- Remove storage compartment and ashtray from accessory switch bezel, Fig. .
- Remove accessory bezel retaining screw, then the bezel.
- Remove instrument panel center bezel retaining screws, then the bezel from instrument pane...
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BRAKE SERVICE PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Dodge Sprinter 2500 cars and light trucks from 1990+.
Disc Brakes -> Rotor, Replace -> 1500, 2500 & 3500 -> 2500 & 3500 -> 5-Stud Rotors -> 8-Stud Rotors -> Aspen, Dakota & Durango -> Caravan & Town & Country -> Commander -> Compass, Liberty, Nitro & Patriot -> Dual Rear Wheel -> Front -> Full Size Pickup -> Grand Cherokee -> Pacifica -> PT Cruiser -> Rear -> Rear w/Dual Wheels -> Rear w/Single Wheel -> Single Rear Wheel -> Sprinter -> Wrangler
Vehicle: 2008 Dodge Sprinter 2500 3.5 V6 GAS
Caravan & Town & Country
- Raise and support vehicle, then remove wheel and caliper as outlined under . Support caliper at all times to prevent brake hose damage.
- Slide brake rotor off hub.
- Reverse procedure to install. Clean brake rotor with alcohol or other suitable solvent.
Commander
Front
- Raise and support vehicle using suitable lift or jack.
- Remove tire and wheel assembly.
- Remove caliper as outlined in .
- Secure caliper anchor assembly using suitable wire.
- Remove and discard O-ring securing disc brake rotor on hub.
- Remove rotor from hub and bearing.
- Reverse procedure to install, noting the...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Dodge Sprinter 2500 cars and light trucks sold in the U.S. for 1980+.
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Sprinter
Vehicle: 2006 Dodge Sprinter 2500 2.7 L5 DIESEL
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its ada...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Dodge Sprinter 2500 cars and light trucks from 1990+.
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> U-Joint with Injected Rings -> U-Joint with Snap Rings
Vehicle: 2005 Dodge Sprinter 2500 2.7 L5 DIESEL
This procedure describes a propeller shaft equipped with a cardan joint in the tube yoke. For propeller shafts equipped with a companion/slip yoke, repeat the steps to remove the remaining cardan joint.
U-Joint with Snap Rings
Disassemble
- Tap outside of bearing cap with a drift to loosen snap ring.
- Remove snap rings from both sides of yoke.
- Position yoke with grease fitting if equipped, pointing up.
- Position a socket with a inside diameter large enough to receive bearing cap, beneath yoke on a press.
- Place another socket with an outside diameter smaller than bearing cap on ...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Dodge Sprinter 2500 cars and light trucks sold in the U.S. from mid 1990's+.
Description
Vehicle: 2008 Dodge Sprinter 2500 3.5 V6 GAS
The TPMS (Tire Pressure Monitor System) consist of 4 tire pressure sensors attached to each wheel through the valve stem mounting hole, 2 transponders, a TPMS module and a TPMS telltale lamp, Fig. .
The wheel sensors monitor tire pressure, air temperature inside the tire, wheel acceleration and the sensor internal ba...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Dodge Sprinter 2500 cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2006 Dodge Sprinter 2500 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 veh...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Dodge Sprinter 2500 cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Chrysler LLC -> 2003-06 Sprinter -> Front Cabin Air Filter -> Rear Cabin Air Filter
Vehicle: 2006 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 Dodge Sprinter 2500 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Dodge Sprinter 2500 cars and light trucks sold in the U.S. from 1990+.
Chrysler LLC Trucks -> Emission Maintenance Reminder Indicator -> Chrysler, Dodge & Plymouth
Vehicle: 2006 Dodge Sprinter 2500 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 Dodge Sprinter 2500 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Dodge Sprinter 2500 cars and light trucks from 1990+
Radiator, Replace
Vehicle: 2009 Dodge Sprinter 2500 3.0 V6 DIESEL
- Disconnect negative battery cable at battery.
- Drain cooling system into a suitable container.
- Remove front grille.
- Detach radiator hose at bottom right of radiator and position aside.
- Disconnect transmission cooler lines at radiator and position aside. DO NOT crimp or bend lines.
- Remove front bumper.
- Remove intake air housing.
- Remove condensor fan.
- Detach both coolant recovery hoses at radiator and position aside.
- Disconnect wiring connector at coolant level sensor.
- Remove upper radiator hose and position aside.
- Remove radiator fan.
- Remove radiator fan shroud.
- Separate A/C condensor from r...
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SERPENTINE BELT SERVICE PROCEDURES FOR Dodge Sprinter 2500 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Dodge Sprinter 2500 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2007 Dodge Sprinter 2500 3.5 V6 GAS
- Remove radiator fan and shroud. Radiator fan assembly is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the mounting nut countercl...
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COMPONENT LOCATION DIAGRAMS FOR Dodge Sprinter 2500 AUTOMOBILES
Component location diagrams for most Dodge Sprinter 2500 cars and light trucks sold in the U.S. from 1990+.
 Sentry Key Remote Entry Module Diagram for 2004 Dodge Sprinter 2500 2.7 L5 DIESELComponents on diagram: |
 Body Components Diagram for 2008 Dodge Sprinter 2500 3.5 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Dodge Sprinter 2500 AUTOMOBILES
OEM drawn wiring diagrams for most Dodge Sprinter 2500 cars and light trucks sold in the U.S.
 2008 Dodge Sprinter 2500 3.0 V6 DIESEL Wiring DiagramComponents on diagram: |
 2006 Dodge Sprinter 2500 2.7 L5 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Dodge Sprinter 2500 AUTOMOBILES
OEM TSB listings for most Dodge Sprinter 2500 cars and light trucks sold in the U.S. from 1985+.
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Document: AUTOMATIC TRANSMISSION DIAGNOSTIC TEARDOWN PROCEDURE - REVISED Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL Auto Systems: |
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Document: AUTOMATIC TRANSMISSION SHIFTING CONCERNS Vehicle: 2003 Dodge Sprinter 2500 2.7 L5 DIESEL Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR Dodge Sprinter 2500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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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