🏷️ Basic Information

Make:

Dodge

Model:

Sprinter 2500

Year:

2009

Generation Name:

Second Generation (NCV3)

Chassis Code:

NCV3

👋 Introduction

Market Segment:

Light Commercial Vehicle (LCV), Van, Passenger Van, Cargo Van

Key Competitors:

Ford Transit, Chevrolet Express, GMC Savana, Mercedes-Benz Sprinter (original platform sharing)

Versatility:

The Dodge Sprinter 2500 is renowned for its modularity, offering configurations for cargo, passenger transport, recreational vehicles (RV chassis), and specialized vocational use. This adaptability makes it a popular choice for businesses and custom builders.

Standing Height:

Available in various roof height options, providing significant interior standing room, a key differentiator for cargo and passenger comfort.

Drivetrain Options:

Primarily rear-wheel drive (RWD), with all-wheel drive (AWD) available on some configurations for enhanced traction in adverse conditions.

📋 Manual Details

Coverage Areas:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body & Frame, Interior, Exterior, Diagnostics, Troubleshooting, Wiring Diagrams

Page Count:

Extensive (Software - Digital Access, no specific page count)

Manual Type:

Official Service and Repair Manual Software

Language:

English

Format:

Software (Digital Download/Access)

📖 Manual Coverage

Engine Systems:

Engine mechanical, Fuel system (injection, pumps, filters), Ignition system, Cooling system, Lubrication system, Exhaust system, Emission control systems

Transmission Drivetrain:

Automatic Transmission (e.g., NAG1), Clutch, Driveshafts, Axles, Differentials, Transfer Case (if applicable for 4x4 variants)

Suspension Steering:

Front and Rear Suspension, Steering system (rack and pinion, power steering), Wheel Alignment

Brakes:

Hydraulic system, ABS, ESP, Brake pads, Rotors, Calipers, Parking brake

Electrical Electronics:

12V Battery system, Alternator, Starter, Lighting, Fuses, Relays, Body Control Module (BCM), Powertrain Control Module (PCM), Infotainment system, Power accessories (windows, locks, mirrors), Diagnostic Trouble Codes (DTCs)

HVAC:

Air Conditioning (A/C) system, Heating system, Ventilation, Climate control module

Body Frame:

Chassis, Body panels, Doors, Hood, Liftgate, Bumpers, Interior trim, Seats, Glass

Maintenance Procedures:

Oil change, Filter replacements (oil, air, fuel, cabin), Fluid checks and changes (coolant, brake fluid, transmission fluid, power steering fluid), Spark plug replacement, Belt inspection and replacement, Tire rotation and balancing

Repair Procedures:

Engine component replacement (e.g., starter, alternator, water pump), Transmission service and repair, Brake component replacement (pads, rotors, lines), Suspension and steering component repair (shocks, struts, tie rods), Electrical component troubleshooting and replacement, HVAC system repair, Body panel repair and replacement

Diagnostic Procedures:

OBD-II scanning and interpretation, Symptom-based troubleshooting guides, Component testing procedures, Diagnostic Trouble Code (DTC) clearing and analysis

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all systems, including power distribution, ground points, and connector pinouts

Technical Depth:

Detailed diagnostic procedures, component-level repair instructions, torque specifications, fastener tightening sequences, special tool requirements, overhaul procedures, troubleshooting flowcharts

📊 Manual Specifications

File Format:

Proprietary Software Platform (Searchable, Interactive)

Print Quality:

N/A (Digital Format)

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code:

OM642 (3.0L V6 Turbodiesel)

Engine Type:

Turbodiesel V6

Displacement:

2987 cc (3.0 Liters)

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

15.5:1

Horsepower:

188 hp @ 3800 rpm

Torque:

325 lb-ft @ 1400-2400 rpm

Fuel Type:

Diesel

Injection System:

Common Rail Direct Injection (CRDI) with Turbocharger

Fuel Filter Part Number:

A 642 090 00 59 (example, refer to manual for exact)

🔧 Transmission

Transmission Type:

5-Speed Automatic (NAG1 / W5A 580)

Optional Transmission:

None typically for 2009 model year in US market for 2500 RWD/AWD. Older generations had manual transmissions.

Transmission Fluid Type:

MB Specification 236.14 (e.g., Pentosin ATF134, Mobil ATF 134)

Transmission Fluid Capacity:

Approximately 7-8 liters for a dry fill; consult manual for precise capacity and fill procedure.

📐 Dimensions

Wheelbase Options:

140.6 inches (3571 mm) and 170.3 inches (4326 mm)

Overall Length 140Wb:

233.4 inches (5928 mm)

Overall Length 170Wb:

273.4 inches (6944 mm)

Exterior Width:

79.7 inches (2024 mm)

Interior Height Standard Roof:

Approximately 66.1 inches (1680 mm)

Interior Height High Roof:

Approximately 76.0 inches (1930 mm)

Cargo Volume 140Wb High Roof:

Approx. 475.0 cubic feet

Cargo Volume 170Wb High Roof:

Approx. 551.0 cubic feet

Gvwr:

8,550 lbs (3878 kg) to 10,000 lbs (4536 kg) depending on configuration

Curb Weight:

Varies significantly based on configuration, typically 4,500 - 5,500 lbs

Towing Capacity:

Up to 5,000 lbs (2268 kg), consult specific vehicle build sheet.

🛡️ Safety Features

NHTSA Ratings:

Individual ratings vary by configuration and model year. Typically good performance in frontal and side impacts for its class. Full details available from NHTSA for specific configurations.

Electronic Stability Program:

Standard (ESP)

Anti Lock Braking System:

Standard (ABS)

Traction Control:

Standard

Airbags:

Driver and Passenger front airbags. Side curtain airbags may be optional or standard depending on passenger van configurations.

Seatbelts:

3-point inertia reel seatbelts for all seating positions.

💡 Technology Features

Infotainment System:

Factory-installed radio with AM/FM, CD player, and potentially auxiliary input or Bluetooth connectivity depending on trim level and options.

Navigation:

Optional factory navigation system available on higher trims or as an add-on.

Cruise Control:

Standard

Parking Sensors:

Optional rear parking sensors.

Auxiliary Input:

Commonly available for audio devices.

Usb Port:

Less common on this model year, but possible on some higher-spec units.

🔧 Maintenance

Oil Change Interval Diesel:

Typically every 15,000 miles or 1 year, whichever comes first. However, frequent short trips or severe duty may require more frequent changes. Refer to the manual for specific conditions.

Air Filter Replacement:

Inspect every 15,000 miles, replace as needed or every 30,000 miles. Severe conditions may require more frequent replacement.

Fuel Filter Replacement Diesel:

Typically every 30,000 miles. Crucial for diesel engine longevity.

Transmission Fluid Service:

Mercedes-Benz recommends inspection at 20,000 miles and service at 40,000 miles or as indicated by the vehicle's Flexible Service System (FSS). This often means checking condition and level, with replacement recommended under severe service or at a specified mileage.

Engine Oil Specification:

MB-Approval 229.51 (Low SAPS synthetic oil) - typically 5W-30 or 0W-30. Check manual for exact viscosity.

Engine Oil Capacity:

Approximately 8.5 liters (8.9 US quarts) with filter change.

Coolant Specification:

MB-Approval 325.0 or 326.0 (Ethylene Glycol based, blue or green color)

Brake Fluid Specification:

DOT 4 Plus

Egr Cooler:

The Exhaust Gas Recirculation (EGR) cooler can be prone to leaks, leading to coolant loss and white smoke from the exhaust.

Om642 Injector Seals:

Cracked or leaking injector seals can cause rough running, misfires, and fuel smell.

Dpr Filter Clogging:

Diesel Particulate Filter (DPF) regeneration issues or clogging can occur, especially with short trips, leading to reduced power and dashboard warning lights.

Transmission Shift Quality:

Some owners report occasional harsh shifts or hesitation from the NAG1 transmission, which may require software updates or internal transmission service.

📚 Vehicle History

Parent Company:

Daimler AG (Mercedes-Benz)

Platform Origin:

The NCV3 Sprinter platform was originally developed by Mercedes-Benz and later marketed and sold under the Dodge brand in North America from 2003 to 2009 (Dodge Sprinter) and then as the Mercedes-Benz Sprinter again starting in 2010. This manual covers the final year of the Dodge branding.

Manufacturing Location:

Düsseldorf, Germany (and later North Charleston, South Carolina, USA for North American models in later years, but 2009 were primarily German-built).

🏆 Awards & Recognition

Commercial Van Awards:

The Sprinter platform has consistently received praise in commercial vehicle publications for its practicality, cargo capacity, and fuel efficiency. Specific awards may vary year to year but reflect its market leadership.

Rv Chassis Recognition:

The Sprinter chassis is a highly favored platform for Class B RVs and custom camper vans due to its robust engineering and driving dynamics.