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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+
Vacuum & Wiring Diagrams -> Light Trucks & Vans -> Sprinter
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
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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+.
Anti-Lock Brakes -> Sprinter -> System Service -> Automatic Load-Dependant Brake Pressure Controller (ALB) -> Brake System Bleed -> Component Replacement -> Controller Anti-Lock Brake (CAB) Module -> Front Wheel Speed Sensor -> Hydraulic Control Unit (HCU) -> Rear Wheel Speed Sensor
Vehicle: 2007 Dodge Sprinter 2500 3.5 V6 GAS
Brake System Bleed
The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module.
Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir.
T...
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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: 2007 Dodge Sprinter 2500 3.5 V6 GAS
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, Replace
Vehicle: 2008 Dodge Sprinter 2500 3.5 V6 GAS
- 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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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+.
Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Identification -> Intermittent & Poor Connections -> Intermittents -> Poor Connections -> TPMS Check
Vehicle: 2008 Dodge Sprinter 2500 3.0 V6 DIESEL
Accessing Diagnostic Trouble Codes
Connect a suitably programmed scan tool to DLC (Data Link Connector) and follow manufacturer's instructions.
Diagnostic Trouble Code Identification
Refer to Fig. for diagnostic trouble code identification.
Clearing Diagnostic Trouble Codes
Connect a suitably programmed scan tool to DLC (Data Link Connector), and follow manufacturer's instructions.
TPMS Check
When diagnosing a tire pressure issue, check the TPMS telltale lamp on the instrument cluster after placing the ignition switch in the On position. If after 10 seconds, the telltale is illumi...
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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+.
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 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: 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 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 -> Air Bag Indicator Lamp ->
Vehicle: 2009 Dodge Sprinter 2500 3.0 V6 DIESEL
The air bag indicator lamp lights for 6-8 seconds each time the ignition is turned On. The lamp indicates a system self-test is being performed by the air bag co...
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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+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2005 Dodge Sprinter 2500 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 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: 2005 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 Dodge Sprinter 2500 AUTOMOBILES
Component location diagrams for most Dodge Sprinter 2500 cars and light trucks sold in the U.S. from 1990+.
 Seat Components Diagram for 2007 Dodge Sprinter 2500 3.5 V6 GASComponents on diagram: |
 Engine Compartment Components Diagram for 2005 Dodge Sprinter 2500 2.7 L5 DIESELComponents 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: RECALL - AIR BAGS:SIDE/WINDOW Vehicle: 2007 Dodge Sprinter 2500 3.5 V6 GAS Auto Systems: |
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Document: POWER STEERING FLUID USAGE - REVISED Vehicle: 2003 Dodge Sprinter 2500 2.7 L5 DIESEL Auto Systems: |
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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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