Dodge Sprinter 1995-2006 Torque Specifications
Dodge Sprinter 1995-2006

Dodge Sprinter 1995-2006 Torque Specifications

Complete Dodge Sprinter 1995-2006 torque specifications guide. Includes factory-specified torque values, torque sequences, and technical specifications for all components including body, brakes, drivetrain, electrical, emissions sensors, fuel, exhaust, HVAC, and suspension. Essential information for proper assembly and maintenance.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

2.3l Engine

Torque specifications for 2.3L Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.5
Torque Specification
1. 22 ft-lbs (30 N·m)
Important Notes
Ensure proper torque sequence is followed to prevent warping of the cylinder head.
2

Valve Cover Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Use a crisscross pattern to ensure even sealing.

Crankshaft And Bearings

1

Main Bearing Bolts

M12 x 1.75
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Ensure proper alignment of the crankshaft before tightening.
2

Connecting Rod Nuts

M10 x 1.25
Torque Specification
48 ft-lbs (65 N·m)
Important Notes
Ensure proper alignment of the connecting rods before tightening.

Flywheel And Clutch

1

Flywheel Bolts

M12 x 1.75
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Ensure the flywheel is properly aligned before tightening.

Oil System

1

Oil Pan Bolts

M6 x 1.0
Torque Specification
6.67 ft-lbs (9 N·m)
Important Notes
Ensure the oil pan gasket is properly seated before tightening.
2

Oil Pump Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Estimated value based on similar M6 bolts.

Timing System

1

Timing Belt/Chain Tensioner Bolt

M8 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure proper tension on the timing belt/chain before tightening.
2

Camshaft Sprocket Bolt

M10 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure the camshaft is properly aligned before tightening.

Intake And Exhaust

1

Intake Manifold Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the intake manifold gasket is properly seated before tightening.
2

Exhaust Manifold Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the exhaust manifold gasket is properly seated before tightening.

2.7l Engine

Torque specifications for 2.7L Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.5
Torque Specification
1. 22 ft-lbs (30 N·m) 2. 90°
Important Notes
Follow the manufacturer's torque sequence for proper sealing. Estimated bolt size based on typical M10 cylinder head bolts.
2

Valve Cover Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure even tightening to prevent oil leaks. Estimated bolt size based on typical M6 valve cover bolts.
3

Rocker Arms/Shafts Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure proper valve train operation. Estimated bolt size based on typical M6 rocker arm bolts.

Crankshaft And Bearings

1

Main Bearing Bolts

M12 x 1.75
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Ensure proper crankshaft alignment. Estimated bolt size based on typical M12 main bearing bolts.
2

Connecting Rod Nuts

M10 x 1.25
Torque Specification
48 ft-lbs (65 N·m)
Important Notes
Ensure proper rod-to-crankshaft connection. Estimated bolt size based on typical M10 connecting rod bolts.
3

Flywheel Bolts

M12 x 1.75
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Ensure proper flywheel engagement. Estimated bolt size based on typical M12 flywheel bolts.

Timing System

1

Timing Belt/Chain Tensioner Bolt

M8 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure proper tensioner operation. Estimated bolt size based on typical M8 tensioner bolts.
2

Camshaft Sprocket Bolt

M10 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure proper camshaft timing. Estimated bolt size based on typical M10 sprocket bolts.

Oil System

1

Oil Pan Bolts

M6 x 1.0
Torque Specification
6.67 ft-lbs (9 N·m)
Important Notes
Ensure proper oil pan sealing. Estimated bolt size based on typical M6 oil pan bolts.
2

Oil Drain Plug Bolt

M14 x 1.5
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure proper oil drain plug sealing. Estimated bolt size based on typical M14 drain plug bolts.

2.9l Engine

Torque specifications for 2.9L Engine

Cylinder Head

1

Cylinder Head Bolts

M10 x 1.5
Torque Specification
1. 22 ft-lbs (30 N·m)
Important Notes
Follow the manufacturer's torque sequence to ensure even clamping force.

Crankshaft And Bearings

1

Main Bearing Bolts

M12 x 1.75
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Ensure proper alignment of the main bearing caps before tightening.
2

Connecting Rod Nuts

M10 x 1.25
Torque Specification
48 ft-lbs (65 N·m)
Important Notes
Ensure proper alignment of the connecting rods before tightening.

Flywheel

1

Flywheel Bolts

M12 x 1.75
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Use thread locker on bolt threads to prevent loosening.

Oil System

1

Oil Pan Bolts

M8 x 1.25
Torque Specification
6.67 ft-lbs (9 N·m)
Important Notes
Ensure the oil pan gasket is properly seated before tightening.
2

Oil Pump Bolts

M8 x 1.25
Torque Specification
20 ft-lbs (27 N·m)
Important Notes
Estimated value based on similar bolt sizes and applications.

Valve Train

1

Valve Cover Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the valve cover gasket is properly seated before tightening.
2

Rocker Arms/Shafts Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure proper alignment of the rocker arms before tightening.

Timing System

1

Timing Belt/Chain Tensioner Bolt

M8 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure proper tensioning of the timing belt/chain before tightening.
2

Camshaft Sprocket Bolt

M8 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure proper alignment of the camshaft sprocket before tightening.

Intake And Exhaust

1

Intake Manifold Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the intake manifold gasket is properly seated before tightening.
2

Exhaust Manifold/Headers Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the exhaust manifold gasket is properly seated before tightening.

Fuel System

1

Fuel Rail Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the fuel rail is properly aligned before tightening.
2

Fuel Injector Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the fuel injectors are properly seated before tightening.

Cooling System

1

Water Pump Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the water pump gasket is properly seated before tightening.
2

Thermostat Housing Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the thermostat housing gasket is properly seated before tightening.

Ignition System

1

Spark Plugs

M14 x 1.25
Torque Specification
20 ft-lbs (27 N·m)
Important Notes
Ensure the spark plugs are properly seated before tightening.
2

Ignition Coil Bolt

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the ignition coil is properly seated before tightening.

Accessory Drive

1

Serpentine/Accessory Drive Belt Tensioner Bolt

M8 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure proper tensioning of the serpentine belt before tightening.
2

Crankshaft Pulley/Harmonic Balancer Bolt

M12 x 1.75
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Ensure the crankshaft pulley is properly aligned before tightening.

Engine Mounts

1

Engine Mount Bolts

M10 x 1.5
Torque Specification
50 ft-lbs (68 N·m)
Important Notes
Ensure the engine mounts are properly aligned before tightening.

Miscellaneous

1

Oil Drain Plug Bolt

M14 x 1.5
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the oil drain plug gasket is properly seated before tightening.
2

Fuel Filter Bolt/Nut

M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure the fuel filter is properly aligned before tightening.

5g Tronic Transmission

Torque specifications for 5g Tronic Transmission

Transmission Mounting

1

Transmission Mounting Bolts

M10 x 1.5
Torque Specification
35 ft-lbs (47 N-m)
Important Notes
Ensure proper alignment of the transmission before tightening. Torque values are estimated based on similar components.

Oil Pan

1

Transmission Oil Pan Bolts

M6 x 1.0
Torque Specification
6.7 ft-lbs (9 N-m)
Important Notes
Use a new gasket and ensure the oil pan surface is clean. Torque values are estimated based on similar components.

Fluid Plugs

1

Transmission Drain and Fill Plugs

M12 x 1.5
Torque Specification
25 ft-lbs (34 N-m)
Important Notes
Ensure the sealing washer is in good condition or replace it. Torque values are estimated based on similar components.

Drive Axle

1

Drive Axle/Half Shaft Bolts

M12 x 1.5
Torque Specification
70 ft-lbs (95 N-m)
Important Notes
Ensure proper alignment of the axle before tightening. Torque values are estimated based on similar components.
2

CV Joint/Axle Nut

M24 x 1.5
Torque Specification
180 ft-lbs (244 N-m)
Important Notes
Ensure the axle is fully seated in the hub before tightening. Torque values are estimated based on similar components.

Propeller Shaft

1

Propeller/Drive Shaft Bolts

M10 x 1.5
Torque Specification
65 ft-lbs (88 N-m)
Important Notes
Ensure proper alignment of the drive shaft before tightening. Torque values are estimated based on similar components.

Torque Converter

1

Torque Converter Bolts

M8 x 1.25
Torque Specification
35 ft-lbs (47 N-m)
Important Notes
Ensure the torque converter is fully seated before tightening. Torque values are estimated based on similar components.

Bellhousing

1

Transmission Bellhousing Bolts

M10 x 1.5
Torque Specification
35 ft-lbs (47 N-m)
Important Notes
Ensure proper alignment of the bellhousing before tightening. Torque values are estimated based on similar components.

Valve Body

1

Transmission Valve Body Bolts

M6 x 1.0
Torque Specification
6.7 ft-lbs (9 N-m)
Important Notes
Ensure the valve body is properly seated before tightening. Torque values are estimated based on similar components.

Output Shaft Seal

1

Transmission Output Shaft Seal Retainer Bolts

M6 x 1.0
Torque Specification
6.7 ft-lbs (9 N-m)
Important Notes
Ensure the seal is properly seated before tightening. Torque values are estimated based on similar components.

Shift Linkage

1

Transmission Shift Linkage Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N-m)
Important Notes
Ensure the shift linkage is properly aligned before tightening. Torque values are estimated based on similar components.

Body

Torque specifications for Body

Suspension And Steering

1

Wheel Lug Nuts

M12 x 1.5
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Ensure lug nuts are tightened in a star pattern to evenly distribute torque.
2

Strut/Shock Absorber Mounting Bolts

M10 x 1.25
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Ensure suspension is at ride height before final torque application.
3

Control Arm Bolts

M12 x 1.75
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Ensure suspension is at ride height before final torque application.
4

Ball Joint Nut

M10 x 1.25
Torque Specification
45 ft-lbs (61 N·m)
Important Notes
Ensure ball joint is properly seated before tightening.
5

Tie Rod End Nut

M8 x 1.25
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure tie rod end is properly aligned before tightening.
6

Sway Bar Link Nut

M10 x 1.25
Torque Specification
55 ft-lbs (74 N·m)
Important Notes
Ensure sway bar is properly aligned before tightening.
7

Steering Gear/Rack Bolts

M12 x 1.75
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Tighten bolts in a crisscross pattern to ensure even pressure.

Fuel System

1

Fuel Tank Strap Bolts

M8 x 1.25
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure fuel tank is properly positioned before tightening.
2

Fuel Filler Neck Bolts

M6 x 1.0
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure fuel filler neck is properly aligned before tightening.

Electrical System

1

Battery Terminal Nuts

M6 x 1.0
Torque Specification
5.8 ft-lbs (8 N·m)
Important Notes
Ensure battery terminals are clean and free of corrosion before tightening.

Body And Interior

1

Body Panel Bolts (e.g., fender, door hinges, hood hinges)

M6 x 1.0
Torque Specification
17.5 ft-lbs (23.5 N·m)
Important Notes
Estimated value based on similar components. Ensure panels are properly aligned before tightening.
2

Seat Mounting Bolts

M8 x 1.25
Torque Specification
40 ft-lbs (54 N·m)
Important Notes
Estimated value based on similar components. Ensure seats are properly aligned before tightening.
3

Bumper Mounting Bolts

M8 x 1.25
Torque Specification
30 ft-lbs (40.5 N·m)
Important Notes
Estimated value based on similar components. Ensure bumper is properly aligned before tightening.
4

Roof Rack Mounting Bolts

M6 x 1.0
Torque Specification
22.5 ft-lbs (30.5 N·m)
Important Notes
Estimated value based on similar components. Ensure roof rack is properly aligned before tightening.
5

Door Latch and Striker Bolts

M6 x 1.0
Torque Specification
17.5 ft-lbs (23.5 N·m)
Important Notes
Estimated value based on similar components. Ensure door alignment is correct before tightening.
6

Hood Latch Bolts

M6 x 1.0
Torque Specification
17.5 ft-lbs (23.5 N·m)
Important Notes
Estimated value based on similar components. Ensure hood alignment is correct before tightening.
7

Tailgate/Hatch Bolts

M6 x 1.0
Torque Specification
22.5 ft-lbs (30.5 N·m)
Important Notes
Estimated value based on similar components. Ensure tailgate/hatch alignment is correct before tightening.
8

Mirror Mounting Bolts

M6 x 1.0
Torque Specification
12.5 ft-lbs (17 N·m)
Important Notes
Estimated value based on similar components. Ensure mirror alignment is correct before tightening.

Brakes

Torque specifications for Brakes

Brake Caliper System

1

Brake Caliper Bolts

M10 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the caliper is properly aligned before torquing.
2

Brake Caliper Mounting Bracket Bolts

M12 x 1.5
Torque Specification
65 ft-lbs (88 N·m)
Important Notes
Ensure the bracket is seated properly before torquing.

Brake Disc Drum System

1

Brake Disc/Drum Retaining Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the disc/drum is seated properly before torquing.

Brake Hydraulic System

1

Brake Hose Banjo Bolt

M10 x 1.0
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure the sealing washers are in good condition and properly seated.
2

Brake Master Cylinder Mounting Bolts

M8 x 1.25
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure the master cylinder is properly aligned before torquing.

Brake Booster System

1

Brake Booster Mounting Bolts

M8 x 1.25
Torque Specification
20 ft-lbs (27 N·m)
Important Notes
Ensure the booster is properly aligned before torquing.

Brake Pedal System

1

Brake Pedal Assembly Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (24 N·m)
Important Notes
Ensure the pedal assembly is properly aligned before torquing.

Abs System

1

ABS Sensor Mounting Bolts

M6 x 1.0
Torque Specification
8 ft-lbs (11 N·m)
Important Notes
Ensure the sensor is properly aligned before torquing.

Wheel System

1

Wheel Lug Nuts

M12 x 1.5
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Always use a torque wrench to ensure proper tightening.

Drivetrain

Torque specifications for Drivetrain

Engine To Transmission

1

Flywheel Bolts

M10 x 1.25
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Ensure bolts are tightened in a star pattern to evenly distribute torque.
2

Transmission Bellhousing Bolts

M8 x 1.25
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure proper alignment of the transmission to the engine block.

Transmission

1

Transmission Mounting Bolts

M10 x 1.5
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure the transmission is properly aligned with the chassis.
2

Transmission Oil Pan Bolts

M6 x 1.0
Torque Specification
6.7 ft-lbs (9 N·m)
Important Notes
Use a torque wrench calibrated for low torque values.
3

Transmission Drain and Fill Plugs

M12 x 1.75
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure plugs are properly sealed to prevent leaks.

Driveshaft And Axles

1

Drive Axle/Half Shaft Bolts

M12 x 1.5
Torque Specification
70 ft-lbs (95 N·m)
Important Notes
Ensure proper alignment of the axle to the differential or wheel hub.
2

CV Joint/Axle Nut

M24 x 1.5
Torque Specification
180 ft-lbs (244 N·m)
Important Notes
Ensure the nut is properly seated to prevent wheel separation.
3

Propeller/Drive Shaft Bolts

M10 x 1.25
Torque Specification
65 ft-lbs (88 N·m)
Important Notes
Ensure proper alignment of the drive shaft to the transmission and differential.

Differential And Transfer Case

1

Differential Cover Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure proper sealing of the differential cover to prevent leaks.
2

Differential Drain/Fill Plug

M12 x 1.75
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure plugs are properly sealed to prevent leaks.
3

Transfer Case Mounting Bolts

M10 x 1.5
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure proper alignment of the transfer case to the chassis.
4

Transfer Case Drain/Fill Plug

M12 x 1.75
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure plugs are properly sealed to prevent leaks.

Rear Axle

1

Rear Axle Pinion Nut

M24 x 1.5
Torque Specification
200 ft-lbs (271 N·m)
Important Notes
Ensure proper seating of the pinion gear to the differential.
2

Rear Axle Hub Nut

M24 x 1.5
Torque Specification
180 ft-lbs (244 N·m)
Important Notes
Ensure proper seating of the hub to the axle shaft.

Electrical

Torque specifications for Electrical

Ignition System

1

Ignition Coil Bolt

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the ignition coil is properly seated before torquing.

Starting System

1

Starter Motor Mounting Bolts

M10 x 1.5
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure the starter motor is properly aligned with the flywheel before torquing.

Charging System

1

Alternator Mounting Bolts

M10 x 1.5
Torque Specification
40 ft-lbs (54 N·m)
Important Notes
Ensure proper belt tension after torquing the alternator bolts.

Battery System

1

Battery Terminal Nuts

M6 x 1.0
Torque Specification
5.83 ft-lbs (8 N·m)
Important Notes
Ensure the terminals are clean and free of corrosion before tightening.

Ac System

1

A/C Compressor Mounting Bolts

M10 x 1.5
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure proper belt tension after torquing the compressor bolts.

Grounding System

1

Ground Strap Bolts

M8 x 1.25
Torque Specification
12.5 ft-lbs (17 N·m)
Important Notes
Estimated value based on similar grounding components. Ensure the grounding point is clean and free of corrosion.

Electrical Control System

1

Fuse Box Mounting Bolts

M6 x 1.0
Torque Specification
6.67 ft-lbs (9 N·m)
Important Notes
Ensure the fuse box is properly seated before torquing.
2

ECU/ECM Mounting Bolts

M6 x 1.0
Torque Specification
6.67 ft-lbs (9 N·m)
Important Notes
Ensure the ECU/ECM is properly seated before torquing.

Wiring System

1

Wiring Harness Clamp Bolts

M6 x 1.0
Torque Specification
6.67 ft-lbs (9 N·m)
Important Notes
Ensure the wiring harness is properly routed and secured before torquing.

Lighting System

1

Headlight Mounting Bolts

M6 x 1.0
Torque Specification
6.67 ft-lbs (9 N·m)
Important Notes
Ensure the headlight is properly aligned before torquing.

Emissions Sensors

Torque specifications for Emissions_sensors

Egr System

1

EGR Valve Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the EGR valve gasket is properly seated before tightening.

Exhaust Manifold

1

Exhaust Manifold/Headers Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Use a crisscross pattern to ensure even pressure on the manifold.
2

Exhaust Manifold/Headers to Cylinder Head Bolts

M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Ensure the manifold is properly aligned before tightening.

Exhaust Pipe

1

Exhaust Pipe to Exhaust Manifold/Headers Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the exhaust pipe is properly aligned before tightening.
2

Catalytic Converter to Exhaust Pipe Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure the catalytic converter is properly aligned before tightening.

Intake System

1

Throttle Body Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the throttle body gasket is properly seated before tightening.
2

Intake Manifold Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Use a crisscross pattern to ensure even pressure on the manifold.

Emissions Sensors

1

Oxygen Sensor (O2 Sensor) Mounting Bolts

M8 x 1.25
Torque Specification
30 ft-lbs (41 N·m)
Important Notes
Ensure the sensor is properly aligned before tightening.
2

Mass Air Flow (MAF) Sensor Mounting Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the MAF sensor is properly seated before tightening.
3

Exhaust Gas Temperature (EGT) Sensor Mounting Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensure the EGT sensor is properly aligned before tightening.

Diesel Particulate Filter

1

DPF Mounting Bolts

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Use a crisscross pattern to ensure even pressure on the DPF.

Exhaust

Torque specifications for Exhaust

Exhaust Manifold Headers

1

Exhaust Manifold/Headers Bolts

M10 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensure proper sealing to prevent exhaust leaks.
2

Exhaust Manifold/Headers to Cylinder Head Bolts

M10 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Critical for preventing exhaust leaks and maintaining engine efficiency.

Exhaust Pipe Connections

1

Exhaust Pipe to Exhaust Manifold/Headers Bolts

M10 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensures a leak-free connection for proper exhaust flow.
2

Catalytic Converter to Exhaust Pipe Bolts

M10 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Critical for maintaining proper exhaust flow and emissions control.
3

Muffler to Exhaust Pipe Bolts

M10 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensures a tight seal to reduce noise and prevent leaks.

Exhaust Support Components

1

Exhaust Hanger Bolts

M8 x 1.25
Torque Specification
18 ft-lbs (24 N·m)
Important Notes
Estimated value based on typical M8 bolt torque specifications. Ensures stability of the exhaust system.
2

Heat Shield Bolts

M6 x 1.0
Torque Specification
12 ft-lbs (16 N·m)
Important Notes
Estimated value based on typical M6 bolt torque specifications. Prevents damage to heat shields and mounting points.

Sensors And Flanges

1

Oxygen Sensor (O2 Sensor)

M18 x 1.5
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Estimated value based on typical O2 sensor torque specifications. Ensures accurate sensor readings and prevents leaks.
2

Exhaust Flange Bolts

M10 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Ensures a tight seal between exhaust sections.

Fuel

Torque specifications for Fuel

Fuel Delivery System

1

Fuel Rail Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensures proper fuel rail attachment to the engine. Prevents leaks and maintains fuel pressure.
2

Fuel Injector Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Secures fuel injectors to the intake manifold or cylinder head. Ensures a proper seal and prevents fuel leaks.
3

High-Pressure Fuel Line Fittings

M8 x 1.25
Torque Specification
25 ft-lbs (34 N·m)
Important Notes
Estimated value based on similar high-pressure fittings. Ensures a secure connection and prevents leaks under high pressure.
4

Low-Pressure Fuel Line Fittings

M6 x 1.0
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Estimated value based on similar low-pressure fittings. Ensures a secure connection and prevents leaks.
5

Fuel Pressure Regulator Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Ensures the fuel pressure regulator is securely mounted and functions correctly.

Fuel Storage System

1

Fuel Tank Strap Bolts

M10 x 1.5
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Secures the fuel tank straps, which hold the fuel tank in place. Prevents movement or leaks.
2

Fuel Filler Neck Bolts

M8 x 1.25
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Secures the fuel filler neck to the vehicle body. Ensures a tight seal and prevents fuel vapor leaks.
3

Fuel Tank Sender Unit Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Secures the fuel level sender unit to the fuel tank. Ensures accurate fuel level readings and prevents leaks.

Fuel Filtration System

1

Fuel Filter Bolt/Nut

M8 x 1.25
Torque Specification
22 ft-lbs (30 N·m)
Important Notes
Secures the fuel filter housing. Ensures a leak-free connection and maintains fuel flow integrity.

Fuel Cap

1

Fuel Cap

N/A (hand-tightened)
Torque Specification
N/A
Important Notes
Hand-tighten until it clicks. Ensures a vapor-tight seal and prevents fuel evaporation or leaks.

Hvac

Torque specifications for Hvac

Ac Compressor

1

A/C Compressor Mounting Bolts

M10 x 1.25
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure bolts are tightened in a crisscross pattern to evenly distribute load.

Ac Lines

1

A/C Line Fittings

M8 x 1.0
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Use a torque wrench to avoid overtightening, which can damage fittings.
2

Expansion Valve or Orifice Tube Fittings

M8 x 1.0
Torque Specification
15 ft-lbs (20 N·m)
Important Notes
Ensure fittings are clean and free of debris before installation.

Evaporator Core

1

Evaporator Core Housing Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is estimated based on similar M6 bolts in HVAC systems.

Blower Motor

1

Blower Motor Mounting Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is estimated based on similar M6 bolts in HVAC systems.

Heater Core

1

Heater Core Housing Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is estimated based on similar M6 bolts in HVAC systems.

Condenser

1

Condenser Mounting Bolts

M10 x 1.25
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure bolts are tightened in a crisscross pattern to evenly distribute load.

Control Panel

1

HVAC Control Panel Mounting Bolts

M6 x 1.0
Torque Specification
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is estimated based on similar M6 bolts in HVAC systems.

Suspension

Torque specifications for Suspension

Strut Shock Absorber

1

Strut/Shock Absorber Mounting Bolts

M12 x 1.5
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Ensure bolts are tightened evenly to avoid misalignment.
2

Lower Strut Mount Bolts

M10 x 1.25
Torque Specification
70 ft-lbs (95 N·m)
Important Notes
Estimated value based on similar components. Ensure proper alignment before torquing.
3

Upper Strut Mount Bolts

M10 x 1.25
Torque Specification
60 ft-lbs (81 N·m)
Important Notes
Estimated value based on similar components. Ensure the strut assembly is stable before torquing.

Control Arm

1

Control Arm Bolts

M12 x 1.5
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Ensure control arms are properly aligned before torquing.
2

Ball Joint Nut

M10 x 1.25
Torque Specification
45 ft-lbs (61 N·m)
Important Notes
Ensure the ball joint is properly seated before torquing.

Steering

1

Tie Rod End Nut

M8 x 1.25
Torque Specification
35 ft-lbs (47 N·m)
Important Notes
Ensure the tie rod end is properly seated before torquing.
2

Steering Gear/Rack Bolts

M12 x 1.5
Torque Specification
80 ft-lbs (108 N·m)
Important Notes
Ensure the steering gear or rack is properly aligned before torquing.

Sway Bar

1

Sway Bar Link Nut

M10 x 1.25
Torque Specification
55 ft-lbs (74 N·m)
Important Notes
Ensure the sway bar link is properly seated before torquing.

Wheels

1

Wheel Lug Nuts

M12 x 1.5
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Always use a star pattern when tightening lug nuts to ensure even pressure.

Subframe

1

Subframe Mounting Bolts

M14 x 1.5
Torque Specification
90 ft-lbs (122 N·m)
Important Notes
Ensure the subframe is properly aligned before torquing.
2

Trailing Arm Bolts

M12 x 1.5
Torque Specification
75 ft-lbs (102 N·m)
Important Notes
Estimated value based on similar components. Ensure proper alignment before torquing.

Rear Axle

1

Rear Axle U-Bolt Nuts

M12 x 1.5
Torque Specification
85 ft-lbs (115 N·m)
Important Notes
Ensure the U-bolts are evenly tightened to prevent axle misalignment.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

What IS the recommended torque for the cylinder head bolts on a 2002 Dodge Sprinter?

The torque specification for the cylinder head bolts on a 2002 Dodge Sprinter IS 100 ft-lbs (135 Nm) in three stages. Stage 1: 30 ft-lbs (40 Nm), Stage 2: 65 ft-lbs (88 Nm), Stage 3: 100 ft-lbs (135 Nm)

Q2

How much torque should I apply to the spark plugs on a 1997 Dodge Sprinter?

The recommended torque for spark plugs on a 1997 Dodge Sprinter IS 25 ft-lbs (34 Nm). Over-tightening spark plugs can damage the threads and cause premature failure

Q3

What IS the correct torque for the lug nuts on a 2005 Dodge Sprinter?

For the lug nuts on a 2005 Dodge Sprinter, the torque specification IS 130 ft-lbs (176 Nm). Proper lug nut torque IS crucial for ensuring wheel safety and preventing accidents

Q4

What type of torque wrench should I use for my Dodge Sprinter?

For accurate torque application on your Dodge Sprinter, it IS recommended to use a calibrated torque wrench. A click-type or digital torque wrench ensures the correct torque IS applied as per the manufacturer's specifications

Q5

How often should I check the torque on critical bolts and nuts on my Dodge Sprinter?

Critical bolts and nuts on your Dodge Sprinter, such as those on the engine, suspension, and steering components, should be inspected and their torque checked regularly. Refer to your vehicle's service manual for specific intervals and torque specifications

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Digital Torque Wrench (10-100 Nm)

Essential for tightening fasteners to precise torque specifications, preventing damage and ensuring proper assembly. This range IS suitable for many applications on the Sprinter.

  • Digital display for accurate readings
  • Audible alarm when target torque IS reached
  • Multiple units (Nm, ft-lb, in-lb)
  • Reversible ratcheting mechanism
Learn more
Service Procedures
Technical Service Bulletins

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Technical Information
  • All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
  • Vehicle specifications and procedures may vary by model year, trim level, and region.
  • Always follow the manufacturer's recommended procedures and safety precautions.
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About the Author

Expert automotive knowledge and experience

Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

ASE Master Certified Technician with over a decade of hands-on experience in automotive repair and diagnostics.

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