Mercedes Sprinter 2002–2006 Service Repair Manual – PDF Download

🛠️ Mercedes Sprinter 2002–2006 Service Repair Manual – PDF Download

🔧 Complete factory service manual for the Mercedes-Benz Sprinter T1N chassis vans, covering model years 2002 to 2006. This workshop-grade PDF includes everything needed for diagnostics, maintenance, and mechanical repair of Sprinter 2500 and 3500 vans, including Freightliner and Dodge-branded versions.

📲 Downloadable, fully searchable, and printable – ideal for pro technicians and serious Sprinter owners.

🔍 Model Background

The Mercedes Sprinter (2002–2006) was a highly versatile and durable light commercial vehicle, designed for cargo transport, passenger shuttling, and utility applications. As part of the first-generation Sprinter lineup, this version offered improved refinement, expanded configurations, and robust diesel performance for both urban and long-haul use.

Available in various body styles—including panel vans, passenger vans, chassis cabs, and minibuses—the Sprinter could be tailored to a wide range of commercial needs. It featured multiple wheelbase lengths, roof heights, and payload capacities, making it a favorite among tradespeople, delivery services, and fleet operators.

Powering the 2002–2006 Sprinter were a range of inline-5 and inline-4 CDI (Common Rail Diesel Injection) engines, known for their fuel efficiency, torque-rich performance, and long service life. These engines were typically paired with a 5-speed manual or optional automatic transmission, driving the rear wheels or, in some versions, all four (4x4).

The Sprinter also offered improved ergonomics and safety features for its time, including ABS, traction control (ASR), and driver/passenger airbags. With its spacious interior, reliable drivetrain, and low operating costs, the 2002–2006 Sprinter earned a reputation as a benchmark in the commercial van segment.

📆 Model Years Covered:

• 2002 Mercedes Sprinter Van
• 2003 Mercedes Sprinter Van
• 2004 Mercedes Sprinter Van
• 2005 Mercedes Sprinter Van
• 2006 Mercedes Sprinter Van

✅ Model Variants Supported:

• Mercedes-Benz Sprinter 2500 / 3500
• Dodge Sprinter 2500 / 3500
• Freightliner Sprinter 2500 / 3500
• Chassis Types: 901–905

📘 What the Manual Covers:

• Routine Maintenance
• Fluids, torque specs, service intervals, belt routing
• Engine Systems
• OM647 2.7L 5-cylinder diesel engine rebuild, injection, cooling
• Transmission
• NAG1 5-speed automatic, torque converter, shift linkage
• Driveline & Axles
• Propshaft, differential service, axle bearing replacement
• Suspension & Steering
• Front struts, rear leaf springs, power steering rack
• Brakes
• ABS system, master cylinder, hydraulic lines, parking brake
• Electrical System
• Fuse boxes, wiring diagrams, relays, alternator, battery
• HVAC
• Heater core, AC compressor, blower motor, temperature sensors
• Body & Interior
• Doors, windows, dashboard, restraints, seating systems
• Wiring Diagrams
• Complete schematics for powertrain, lighting, sensors, modules

⚙️ Key Technical Specs:

• Engine: OM647 2.7L 5-cylinder turbo diesel
• Transmission: NAG1 5-speed automatic
• Cooling: Water-cooled, electric fan
• Brakes: 4-wheel disc with ABS
• GVWR: 8550–9990 lbs depending on model

💾 Format & Compatibility:

• File Format: PDF (Digital Download)
• Language: English
• Searchable & Printable: Yes
• Delivery: Instant download after checkout
• Works On: Windows, macOS, iOS, Android

🔍 Keywords:

Mercedes Sprinter 2500 3500 service manual PDF, OM647 diesel engine repair, T1N transmission rebuild, Dodge Sprinter wiring diagrams, Sprinter brake service, NAG1 gearbox, full Sprinter 2006 shop manual

❓ Mini FAQ:

Q: Does this manual cover both Mercedes and Dodge Sprinter vans?
A: Yes – it applies to all T1N chassis Sprinter vans, including Mercedes-Benz, Dodge, and Freightliner badged models from 2002–2006.

Q: Can I use this to perform a full engine or transmission rebuild?
A: Absolutely – the manual includes detailed teardown instructions, torque values, service limits, and schematics.

Q: Does it include wiring diagrams and fuse box info?
A: Yes – full electrical schematics and fuse details are included.

🧭 Helpful Resources for Mercedes Car Owners

• Why Every Car Owner Should Own a Service Manual – Find out how a downloadable repair manual can simplify maintenance and help you troubleshoot common problems on your own.
• Car Troubleshooter – Not sure what’s wrong with your Mercedes car? Our free tool lists common issues and DIY fixes across all major car brands.

🔧 Browse More Mercedes Car Manuals

Note: While our manuals are designed for DIY use, they do not replace professional mechanical training. If you're unsure about a repair or your car shows serious issues, we strongly recommend visiting a certified mechanic. These guides are best suited for owners with basic to moderate mechanical experience.