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2002-2006 Dodge Sprinter 216, 316, 416, 616 shop manual Preview image 1
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2002-2006 Dodge Sprinter 216, 316, 416, 616 shop manual

Models covered in this manual:

  • Dodge Sprinter 216 CDI
  • Dodge Sprinter 316 CDI
  • Dodge Sprinter 416 CDI
  • Dodge Sprinter 616 CDI

File specifications

File size: 48.27 MB
File type: PDF
Language: English
Pages:2300

Printable: Yes
Estimated download time: 0.99 Minutes
$18.99 Instant Download

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Product Information

Table of Contents

1.0 Introduction

  • 1.1 System Coverage
  • 1.2 Six-Step Troubleshooting Procedure

2.0 Identification of System

3.0 System Description and Functional Operation

  • 3.1 Airbag System
    • 3.1.1 Driver Airbag
    • 3.1.2 Passenger Airbag
    • 3.1.3 Sidebag Airbag
    • 3.1.4 Seat Belt Tensioners
    • 3.1.5 Airbag Sensors
    • 3.1.6 Diagnostic Trouble Codes
    • 3.1.7 Active Codes
    • 3.1.8 Stored Codes
  • 3.2 Communication
    • 3.2.1 Diagnostic K-Lines
  • 3.3 Heating, Air Conditioning
    • 3.3.1 Automatic Temperature Control (ATC)
    • 3.3.2 Cabin Heating
    • 3.3.3 System Diagnostics
    • 3.3.4 ATC Heat Booster (HB)
    • 3.3.5 Diagnostic Module J (HB & ATC)
  • 3.4 Instrument Cluster
    • 3.4.1 System Description
    • 3.4.2 Electrical Signals
    • 3.4.3 System Diagnostics
  • 3.5 Wiper System
    • 3.5.1 Front Wiper System (FWS)
    • 3.5.2 Rear Wiper System (RWS)
  • 3.6 Seat Belt System
    • 3.6.1 Driver Seat Belt
    • 3.6.2 Passenger Seat Belt

4.0 Disclaimers, Safety, Warnings

  • 4.1 Disclaimers
    • 4.1.1 Technical Safety Information
    • 4.1.2 Safety Precautions for Testing
    • 4.1.3 Vehicle Safety Information
    • 4.1.4 Emergency Information
  • 4.2 Vehicle Damage Warnings
    • 4.2.1 Damage Due to Incorrect Testing
    • 4.2.2 Road Testing a Complaint Vehicle

5.0 Required Tools and Equipment

6.0 Glossary of Terms

7.0 Diagnostic Information and Procedures

  • 7.1 Airbag
    • Airbag Warning Indicator - Driver High
    • Airbag Warning Indicator - Driver Low
    • Driver Seat Belt Tensioner - Incorrect Feedback
    • Passenger Seat Belt Tensioner - Incorrect Feedback
  • 7.2 Starting Energy Finite
    • Driver Seat Belt Tensioner Circuit Open
    • Driver Seat Belt Tensioner Circuit Short
    • Passenger Seat Belt Tensioner Circuit Open
    • Passenger Seat Belt Tensioner Circuit Short
  • 7.3 Cabin Heater
    • Cabin Heater Control Switch Open
    • Cabin Heater Control Switch Short
    • Combustion Fan Circuit Open
    • Combustion Fan Circuit Short
  • 7.4 Communication
    • No Response from Airbag Control Module
    • No Response from Automatic Temperature Control
    • No Response from Heater Booster Module
    • No Response from Instrument Cluster
  • 7.5 Heating & Air Conditioning
    • AC Compressor Control High or Open
    • AC Compressor Control Low or Open
    • Air Outlet Temp Sensor High or Open
    • Air Outlet Temp Sensor Low or Open
  • 7.6 Instrument Cluster
    • Instrument Cluster Lamp Failure
    • Fuel Level Sensor Short to Ground
    • Fuel Level Sensor Short to Battery
    • Vehicle Speed Signal Missing
  • 7.7 Power Door Locks
    • Driver Cylinder Lock Switch Circuit Short to Ground
    • Rear Door Ajar Switch Circuit Short to Ground
  • 7.8 Vehicle Theft Security
    • Driver Cylinder Lock Switch Circuit Short to Ground
    • Rear Door Ajar Switch Circuit Short to Ground

8.0 Component Locations

  • 8.1 Airbag System Module
  • 8.2 Airbag Control Module
  • 8.3 Driver Seat Belt Tensioner
  • 8.4 Passenger Seat Belt Tensioner
  • 8.5 Cabin Heating System
    • 8.5.1 Heat Booster (HB)
    • 8.5.2 Automatic Temperature Control (ATC)
  • 8.6 Electrical System
    • 8.6.1 Diagnostic Module J
  • 8.7 Central Locking
    • 8.7.1 Rear Door Ajar Switch
  • 8.8 Wiper and Washer System
    • 8.8.1 Wiper Motor
    • 8.8.2 Wiper Relay

9.0 Wiring Diagrams and Troubleshooting

  • Wiring Diagrams
  • Troubleshooting Guides

10.0 Appendices

  • Appendix A: Technical Bulletins
  • Appendix B: Conversion Charts
  • Appendix C: Index

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