DODGE SPRINTER Workshop Repair Manual All 2006-2010 ModelS COVERED
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🏷️ Basic Information Identification Make: Dodge Model: Sprinter Model Years Covered: 2006, 2007, 2008, 2009, 2010 Product Type: Workshop Repair Manual 👋 Introduction Market Position Target Audience: DIY enthusiasts, professional mechanics, fleet maintenance personnel. Competitive Analysis Value Proposition: Provides exhaustive repair information to reduce labor costs and ensure accurate repairs. Key Features Accessibility: Instant download provides immediate access to critical repair data. Comprehensiveness: Covers all aspects of vehicle maintenance, repair, and diagnostics. Clarity: Easy-to-read format with clear diagrams and step-by-step instructions. 📋 Manual Details Coverage Areas Vehicle Platform: Dodge Sprinter (All Models) Global Coverage: Yes Page Count Estimated Page Count: Thousands (typical for comprehensive workshop manuals) Manual Type Type: Comprehensive Workshop Service and Repair Manual Language Language: English Format Format: PDF (Portable Document Format) Delivery Method: Instant Download Compatibility Operating Systems: PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, Windows 7, Windows 8, etc.) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, and specifications for all applicable engines. Transmission: Service, repair, and adjustment procedures for all transmission types. Drivetrain: Coverage of axles, drive shafts, differentials, and related components. Suspension: Front and rear suspension systems, including component replacement and alignment procedures. Steering: Power steering system diagnostics and repair, steering column, and linkage. Brakes: Hydraulic and mechanical brake system components, ABS, and parking brake. Electrical System: Wiring diagrams, component testing, diagnostic procedures, starter, alternator, battery. Fuel System: Fuel delivery, injection system, fuel pump, lines, and emissions control. Cooling System: Radiator, fan, water pump, thermostat, and coolant specifications. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, and emissions components. Climate Control: HVAC system diagnostics, repair, refrigerant handling, and component replacement. Body And Interior: Body panel repair, door mechanisms, interior trim, glass replacement, and seating systems. Safety Systems: Airbag systems, seatbelt pre-tensioners, and safety restraint system diagnostics. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, and general upkeep. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major vehicle systems and components. Overhaul: Detailed procedures for complete engine and transmission overhauls. Adjustment: Precise adjustment procedures for brakes, clutches, and other systems. Disassembly Reassembly: Clear instructions for dismantling and reassembling components. Installation: Guidance on installing new or replacement parts. Technical Depth Depth: Comprehensive, from basic maintenance to advanced diagnostics and component rebuilds. Visual Aids: Includes exploded views, diagrams, illustrations, and pictures for clarity. Data Format: Specifications, step-by-step instructions, procedures. 📊 Manual Specifications File Format Type: PDF Searchability: Searchable text for quick information retrieval. Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Various Diesel and Gasoline engines dependent on specific Sprinter configuration (e.g., Mercedes-Benz OM642 V6 Diesel, Mercedes-Benz OM647 I5 Diesel, Chrysler engines for gasoline variants). Performance Horsepower Torque: Specifications for each engine variant will be detailed within the manual (e.g., typical ranges for OM642 188-258 hp, 325-443 lb-ft torque). Fuel System Fuel Type: Diesel (CDI - Common Rail Direct Injection), Gasoline. Injection System: Common Rail for diesel engines, Port Fuel Injection or Direct Injection for gasoline variants. Engine Management ECU Details: Information on Engine Control Units (ECUs), sensors, and actuators. Engine Maintenance Timing Belt Chain: Procedures for timing belt or chain inspection and replacement (if applicable). 🔧 Transmission Standard Transmission Type: Typically 5-speed or 7-speed automatic transmissions (e.g., Mercedes-Benz 722.6 series for many diesel models), manual transmissions also available on some variants. Optional Optional Transmission: Availability of different transmission options based on engine and chassis configuration. Features Transmission Fluid: Specific transmission fluid type and capacity requirements will be detailed, e.g., MB 236.14 for 722.6 transmissions. Torque Converter: Information on torque converter service and diagnosis. 📐 Dimensions Exterior Wheelbase: Various wheelbase options available (e.g., 138 inches, 158 inches, 170 inches). Overall Length: Varies significantly with wheelbase and body style (e.g., Cargo Van, Passenger Van, Chassis Cab). Weights Gvwr: Gross Vehicle Weight Rating will vary by configuration, typically from 8,550 lbs to 11,030 lbs. Curb Weight: Curb weight will vary by configuration. Cargo Cargo Volume: Significant cargo volume, varying by wheelbase and roof height. 🛡️ Safety Features Ratings Crash Test Ratings: Information on available safety features and potentially crash test performance where applicable for the model years. Active Features ABS: Anti-lock Braking System (ABS) operation and diagnostics. Esp: Electronic Stability Program (ESP) operation and diagnostics. Passive Features Airbags: Frontal airbags, side airbags (if equipped), and airbag system diagnostics. Seatbelts: Seatbelt operation, pre-tensioners, and related systems. 💡 Technology Features Infotainment Radio Options: Various audio system options, including CD players, auxiliary inputs, and optional navigation systems. Driver Assistance Cruise Control: Standard or optional cruise control systems. Connectivity Bluetooth: Availability of Bluetooth hands-free communication in higher trim levels or optional packages. 🔧 Maintenance Service Intervals Oil Change: Typical intervals around 10,000-15,000 miles or 12 months,...
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Various Diesel and Gasoline engines dependent on specific Sprinter configuration (e.g., Mercedes-Benz OM642 V6 Diesel, Mercedes-Benz OM647 I5 Diesel, Chrysler engines for gasoline variants).
Performance
Horsepower Torque:
Specifications for each engine variant will be detailed within the manual (e.g., typical ranges for OM642 188-258 hp, 325-443 lb-ft torque).
Fuel System
Fuel Type:
Diesel (CDI - Common Rail Direct Injection), Gasoline.
Injection System:
Common Rail for diesel engines, Port Fuel Injection or Direct Injection for gasoline variants.
Engine Management
ECU Details:
Information on Engine Control Units (ECUs), sensors, and actuators.
Engine Maintenance
Timing Belt Chain:
Procedures for timing belt or chain inspection and replacement (if applicable).
🔧 Transmission
Standard
Transmission Type:
Typically 5-speed or 7-speed automatic transmissions (e.g., Mercedes-Benz 722.6 series for many diesel models), manual transmissions also available on some variants.
Optional
Optional Transmission:
Availability of different transmission options based on engine and chassis configuration.
Features
Transmission Fluid:
Specific transmission fluid type and capacity requirements will be detailed, e.g., MB 236.14 for 722.6 transmissions.
Torque Converter:
Information on torque converter service and diagnosis.
📐 Dimensions
Exterior
Wheelbase:
Various wheelbase options available (e.g., 138 inches, 158 inches, 170 inches).
Overall Length:
Varies significantly with wheelbase and body style (e.g., Cargo Van, Passenger Van, Chassis Cab).
Weights
Gvwr:
Gross Vehicle Weight Rating will vary by configuration, typically from 8,550 lbs to 11,030 lbs.
Curb Weight:
Curb weight will vary by configuration.
Cargo
Cargo Volume:
Significant cargo volume, varying by wheelbase and roof height.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Information on available safety features and potentially crash test performance where applicable for the model years.
Active Features
ABS:
Anti-lock Braking System (ABS) operation and diagnostics.
Esp:
Electronic Stability Program (ESP) operation and diagnostics.
Passive Features
Airbags:
Frontal airbags, side airbags (if equipped), and airbag system diagnostics.
Seatbelts:
Seatbelt operation, pre-tensioners, and related systems.
💡 Technology Features
Infotainment
Radio Options:
Various audio system options, including CD players, auxiliary inputs, and optional navigation systems.
Driver Assistance
Cruise Control:
Standard or optional cruise control systems.
Connectivity
Bluetooth:
Availability of Bluetooth hands-free communication in higher trim levels or optional packages.
🔧 Maintenance
Service Intervals
Oil Change:
Typical intervals around 10,000-15,000 miles or 12 months, dependent on driving conditions and diesel particulate filter (DPF) regeneration cycles for diesel models. Specific intervals detailed in manual.
Air Filter Replacement:
Recommended at specified mileage or if visibly dirty. Consult manual for exact intervals.
Fuel Filter Replacement:
Crucial for diesel engines, recommended at intervals such as every 20,000-30,000 miles, depending on fuel quality. Manual will provide specific recommendation.
Fluid Specifications
Engine Oil:
Specific API or ACEA specifications and viscosity grades (e.g., MB-Approval 228.51 or 229.51 for diesel engines, such as 5W-30 or 10W-30). Manual will specify exact grade and capacity.
Coolant:
Specific coolant type (e.g., MB-Approval 325.0 or 326.0 for silicate-free long-life coolant), typically a 50/50 mix with distilled water. Manual will specify capacity.
Brake Fluid:
DOT 4 brake fluid is commonly specified. Manual will confirm type and replacement interval.
Known Issues
Dpf Clogging:
Diesel Particulate Filter (DPF) clogging can be an issue, especially with short-distance driving. Manual will provide regeneration and cleaning procedures.
Egr Issues:
Exhaust Gas Recirculation (EGR) valve issues can occur, particularly in diesel engines. Manual will detail diagnosis and cleaning.
Injector Problems:
Common Rail diesel injectors can sometimes require service or replacement. Manual will cover testing and replacement.
📚 Vehicle History
Brand Heritage
Dodge Commercial:
Dodge's history in the commercial vehicle market, with the Sprinter representing a significant entry in the light commercial van segment.
Model Evolution
Sprinter Platform:
The Dodge Sprinter (2003-2009) was a rebadged Mercedes-Benz Sprinter. From 2006-2010, it continued this partnership, with Mercedes-Benz taking over full production and branding for the Sprinter in North America in 2010. This manual covers the Dodge-branded variants during this period.
Production
Manufacturing:
Primarily manufactured by Mercedes-Benz (DaimlerChrysler/Daimler AG) in Germany and later assembled in the US.
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards for the Dodge-branded Sprinter are less common, the Mercedes-Benz Sprinter platform itself has consistently been recognized as a leader in its segment for utility, reliability, and versatility.
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