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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
Drive Belt Data -> Domestic Light Trucks & Vans -> 2003-04
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
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BRAKE SERVICE PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Disc Brakes -> Rotor, Replace -> 1500 & 2004-05 2500 & 3500 -> Caravan, Town & Country & Voyager -> Commander -> Dakota & Durango -> Dual Rear Wheel -> Front -> Full Size Pickup -> Grand Cherokee -> Liberty -> Pacifica -> PT Cruiser -> Rear -> Rear w/Dual Wheels -> Rear w/Single Wheel -> Single Rear Wheel -> Sprinter -> Wrangler
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
Caravan, Town & Country & Voyager
- 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, n...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Sprinter
Vehicle: 2004 Dodge Sprinter 3500 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 2004 Dodge Sprinter 3500 AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> U-Joint with Injected Rings -> U-Joint with Snap Rings
Vehicle: 2004 Dodge Sprinter 3500 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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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Dodge Sprinter 3500 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 batt...
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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 -> Traction Control System Warning Lamp ->
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
This lamp should light for a approximately 6-8 seconds when the ignition is turned On as a bulb check. If the warni...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Dodge Sprinter 3500 AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Dodge Sprinter 3500 2.7 L5 DIESEL
- Drain radiator coolant into suitable container.
- Remove mounting screws and cover, then push pin fasteners and fascia mounting screws.
- Pull bumper off support brackets and disconnect electrical connectors.
- Remove rivets, mounting screws and grille.
- Remove mounting bolts and headlamps.
- Remove heat shield.
- Remove clamps and rubber mounts, then mounting bolts and radiator crossmember.
- Remove mounting bolts and front bumpers.
- Recover air conditioning refrigerant.
- Disconnect condenser outlet port liquid line fitting, Fig. . Discard seal, then plug or tape opening.
- Disconnect condenser inlet p...
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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+.
 SRS Components Diagram for 2004 Dodge Sprinter 3500 2.7 L5 DIESELComponents on diagram: |
 Engine Compartment 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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