2006–2010 Dodge Sprinter 2500, 3500 Service & Diagnostic Manual Set (81-370-06070CD)

This Dodge Sprinter 2500 and 3500 service and diagnostic manual set covers the VA platform with the 2.7L five-cylinder CDI diesel and NAG1 automatic transmission. It combines mechanical repair procedures with separate Body, Chassis, Powertrain, and Transmission diagnostics. The service-manual front matter carries document identifier 81-370-06070CD.

The ZIP contains nine English PDFs totaling 2,315 pages, including front matter and CD help/menu files. Procedure text is searchable, but many diagram labels are not.

• Engine repair: Compression and cylinder leak-down testing, cylinder-head removal, crankshaft and piston inspection, and timing-chain service.

• Fuel and emissions: Injector leak-quantity tests, low-pressure fuel-pump testing, turbocharger and charge-air cooler service, and EGR diagnostics.

• NAG1 transmission: Internal disassembly and assembly, clutch repair, electrohydraulic-unit service, shift-fault diagnosis, and adaptive initialization.

• Brakes and driveline: Bosch 5.7 ABS/ESP/TCS diagnostics, brake bleeding, and separate single- and dual-rear-wheel axle and hub procedures.

• Body electronics: Airbag, Instrument Cluster, Power Door Locks/RKE, Vehicle Theft Security System (VTSS), and CAN Bus/K-line troubleshooting with DRBIII.

• Heating and A/C: ATC function tests, front and rear HVAC repair, plus cabin-heater and heater-booster fault isolation.

• Body and chassis service: Door and sliding-door adjustments, body dimensions, suspension repairs, wheel alignment, steering diagnosis, and cooling-system tests.

Written for professional automotive technicians, these manuals assume access to the specified diagnostic equipment and special service tools.

CDI Engine and Fuel System Repair

The engine section includes cylinder-head bolt and surface inspection, camshaft alignment, crankshaft journal measurements, and piston-ring fitting. Compression-testing references identify adapters 8927 and 9295, alongside component-specific torque tables and inspection limits.

Fuel diagnosis covers rail-pressure faults, injector circuits, and crank/no-start complaints. The engine repair information prohibits cylinder-head resurfacing and states that oversized pistons are unavailable—relevant limits when planning internal engine work.

NAG1 Transmission and Rear Axle Service

Transmission coverage extends to K1, K2, and K3 input clutches, B1 and B2 holding clutches, geartrain end-play shim selection, and the torque converter. The diagnostic volume distinguishes active and stored DTCs and explains temperature-dependent shift scheduling and adaptive initialization/storage.

The rear-axle diagnosis section specifies axle replacement for a damaged or noisy differential. Its serviceability note limits replacement components to axle seals, axle bearings, pinion seals, and the differential cover.

Diagnostic and Electronic System Coverage

The manual distinguishes CAN Bus communication between modules from the separate K-lines used by the DRBIII. Its no-response tests help narrow down a communication fault before a module is condemned.

Connector pinouts and component locations support diagnosis of the Instrument Cluster, Central Timer Module (CTM), Security System Module, and cabin-heater hardware. Factory reference data covers terminal voltages, circuit integrity, relay functions, sensor values, and actuator tests.

Supplemental heaters: Cabin Heater Module (CHM) and Heater Booster Module (HBM) coverage includes heater pre-tests, lockout diagnosis, flame-sensor resistance, dosing-pump output, and verification tests. The CHM's integral coolant pump permits engine-off operation, distinguishing it from the HBM.

ATC testing: Coolant-temperature prerequisites, refrigerant-pressure sensor values, and evaporator/air-outlet resistance charts support heating and A/C diagnosis.

The airbag sections specify isolation precautions before connector testing to prevent accidental deployment. Incorrect clockspring centering can damage the clockspring when the steering wheel turns.

Technical Reference and Testing Parameters

Schematics include Bosch 5.7 Antilock Brake System—ABS, Engine Control Module, Automatic Temperature Control (ATC), Power Door Locks/RKE—Front Doors, and the NAG1 transmission electrical schematic.

Fuel/ignition wiring and ECM connector tables distinguish OBD and except-OBD configurations. Fluid capacities, approved-fluid specifications, adjustment data, and component inspection limits accompany the mechanical service sections.

File Format and Readability

• Service Manual: 1,458 pages.
• Body diagnostics: 312 pages.
• Chassis diagnostics: 94 pages.
• Powertrain diagnostics: 292 pages.
• Transmission diagnostics: 144 pages.
• Separate supporting files: Front matter, 4 pages; CD help, 9 pages; start menu, 1 page; welcome menu, 1 page.

The 15 supporting pages are already included in the 2,315-page total. Blank and notes pages, plus the ten feedback-form/address pages within the five manuals, are also included in their respective page counts.

Text search: Technical prose and tables have embedded text; many drawing labels remain outside the search function.

Navigation: All five technical manuals have detailed PDF bookmarks. Some legacy links between files contain malformed paths; the PDFs can be opened individually.

Diagram readability: Dense schematics require zooming to read small pin numbers, connector labels, and wire codes.