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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+
Cooling Fans -> Light Trucks & Vans -> Component Replacement -> 4.0L Engine -> 4.7L Engine -> Caravan, Town & Country & Voyager -> Cooling Fan -> Dakota & Durango -> Grand Cherokee -> Installation -> Liberty -> Pacifica -> PT Cruiser -> Removal
Vehicle: 2003 Dodge Sprinter 2500 2.7 L5 DIESEL
Cooling Fan
Caravan, Town & Country & Voyager
- Raise and support vehicle.
- Remove radiator outlet hose from mounting clips on fan shroud.
- On models equipped with auxiliary transmission cooler, remove lower cooling line from mounting clip on fan shroud.
- On all models, lower vehicle, then remove air cleaner and ducting from throttle body and vehicle.
- Disconnect electrical connector for cooling fan, then remove attaching screw for coolant recovery system from crossmember.
- Disconnect upper radiator mounts from crossmember. ...
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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+.
Hydraulic Brake Systems -> Diagnosis & Testing -> Caravan, Town & Country & Voyager -> Combination Valve Test -> Fixed Proportioning Valve Test -> Height Sensing Proportioning Valve Test -> Master Cylinder/Power Booster Test -> Power Booster Check Valve Test -> Power Booster Vacuum Test -> Pressure Differential Switch -> PT Cruiser
Vehicle: 2004 Dodge Sprinter 2500 2.7 L5 DIESEL
Master Cylinder/Power Booster Test
- Start engine and inspect booster vacuum hose connections for leaks.
- Stop engine and shift transmission into neutral.
- Pump brake pedal until all vacuum reserve in booster is depleted.
- Press and hold brake pedal under light foot pressure. Pedal should hold firm. If it falls away master cylinder is faulty.
- Start engine and note pedal action. Pedal should fall away slightly under light foot pressure, then hold firm.
- If no pedal action is felt, the power booster, vacuum supply or vacuum check valve are faulty. Proceed to "Power Booster Vacuum Test."
- If p...
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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: 2003 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: 2004 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+.
Wiring Diagrams -> Wire Color Code Identification
Vehicle: 2009 Dodge Sprinter 2500 3.0 V6 DIESEL
Refer to Fig. for wiring...
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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: 2007 Dodge Sprinter 2500 3.5 V6 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove belly pan.
- Remove bolt securing starter wiring harness retainer bracket to transmission bellhousing.
- Disconnect battery positive cables and starter solenoid wire from starte...
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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 -> 2007-09 Sprinter -> Front Cabin Air Filter -> Rear Cabin Air Filter
Vehicle: 2007 Dodge Sprinter 2500 3.5 V6 GAS
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.
- Detach the retaining tabs securing the cabin air filter to the fresh air inlet housing located in the engine compartm...
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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 -> Wait-To-Start Lamp ->
Vehicle: 2007 Dodge Sprinter 2500 3.0 V6 DIESEL
The wait-to-start lamp is used on diesel engine models. The lamp is lit by the PCM after the ignition is turned On. It gives the driver an indication to wait until the intake manifold air heater grid has had sufficient time to warm the intake air for a good qua...
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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+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2007 Dodge Sprinter 2500 3.5 V6 GAS
Lower
- Raise and support vehicle.
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water inlet tube.
- Remove radiator outlet hose from water inlet tube and from vehicle.
- Reve...
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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: 2008 Dodge Sprinter 2500 3.0 V6 DIESEL
- 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+.
 Engine Control Module Diagram for 2006 Dodge Sprinter 2500 2.7 L5 DIESELComponents on diagram: |
 Controls And Solenoids 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.
 2003 Dodge Sprinter 2500 2.7 L5 DIESEL Wiring DiagramComponents on diagram: |
 2008 Dodge Sprinter 2500 3.5 V6 GAS 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: FLASH PROGRAMMING FAILURE RECOVERY USING DRBIII - REVISED Vehicle: 2003 Dodge Sprinter 2500 2.7 L5 DIESEL Auto Systems: |
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Document: RECALL - FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING Vehicle: 2007 Dodge Sprinter 2500 3.0 V6 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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