2004 Dodge Sprinter 2500 Service and Repair Manual

This factory service and repair manual for the 2004 Dodge Sprinter 2500 applies to Base-trim vans in two 3-door forms, the standard cargo van and the standard passenger van. Power comes from one engine, a turbocharged 2.7L five-cylinder diesel in inline layout with dual overhead camshafts. The manual gives procedures, torque values and wiring diagrams for the engine, diesel fuel system, cooling, transmission, drivetrain, brakes, steering and electrical system.

Engines covered

• 2.7L inline-five (165 cu in) — DOHC, turbocharged, diesel

Body styles covered

• 3-door standard cargo van
• 3-door standard passenger van

Trims covered

• Base

Known issues on the 2004 Sprinter 2500. Electrical faults lead the 12 owner complaints, with 5, followed by the engine at 3, engine and cooling at 3, and stability control and power train at 2 apiece. There is also 1 recall: certain 2004 Sprinter 2500 vans with rear air conditioning could have a rear dome lamp whose lens could warp under sustained heat and humidity, after which a short at the lamp's switching contacts could cause a fire. A heat-resistant replacement lamp was installed. Wiring diagrams and electrical diagnostics apply.