Model Variant:
Sprinter 2500 / 3500 cargo and passenger vans (Dodge-badged Freightliner Sprinter, built by Mercedes-Benz)
Production Years Covered:
2002 model year
Origin:
Mercedes-Benz T1N platform
Chassis Type:
Full-size light commercial van
Target Audience:
Fleet operators, commercial delivery businesses, upfitters, and DIY owners needing a high-roof, high-cargo-capacity full-size van
Market Segment:
Full-size cargo and passenger van segment
Main Competitors:
Ford E-Series, Chevrolet Express, GMC Savana
Key Advantage:
Diesel fuel economy, taller standing interior height, tighter turning radius, and longer service intervals than domestic van rivals
Engine:
Mercedes-Benz 2.7L turbocharged inline-5 diesel
Interior Height:
Stand-up cabin with high-roof configuration
Efficiency:
Diesel powertrain tuned for commercial duty cycles and low fuel consumption
Systems Covered:
Engine, transmission, brakes, suspension, electrical, HVAC, body, and all major vehicle systems
Manual Type:
Factory-equivalent service and repair manual (workshop manual)
Delivery Method:
Instant download
Zoom:
Zoom in/out supported
Requirements:
Adobe PDF Reader and WinZip
Compatibility:
All versions of Windows and Mac
Engine:
2.7L turbo diesel — disassembly, assembly, inspection, and rebuilding procedures
Fuel System:
Diesel injection system, fuel lines, filters, and pump service
Transmission:
Manual and automatic transmission removal, overhaul, and adjustment
Driveline:
Drive shafts, differentials, axles, and wheel bearings
Brakes:
Disc and drum brakes, ABS, parking brake, and hydraulic system bleeding
Suspension:
Front and rear suspension, springs, shock absorbers, and steering
Electrical:
Wiring diagrams, starting and charging systems, lighting, and gauges
HVAC:
Heating, ventilation, and air conditioning service and diagnostics
Body & Interior:
Panels, doors, trim, seats, glass, and body dimensions
Repair Procedures:
Step-by-step disassembly, assembly, cleaning, and reinstalling procedures
Diagnostics:
Troubleshooting charts and fault-finding for all major systems
Maintenance:
Scheduled maintenance and tune-up procedures
Specifications:
Critical torque values, clearances, and adjustment specifications
Illustrations:
Pictures, diagrams, and exploded views throughout
Special Tools:
Required tools listed for each procedure
Level:
Written primarily for professional technicians, with adequate data for do-it-yourself mechanics
Prerequisites:
Basic knowledge of electrical and mechanical concepts assumed
Scope:
Covers topics typically found in a factory service manual and owners manual combined
Parts Data:
Part identification, specifications, and wear limits for serviceable components
Fluids & Filters:
Capacities and approved fluid specifications
Torque Data:
Fastener torque specifications provided per procedure
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Engine:
2.7L (2685 cc) OM647 turbocharged inline-5 diesel
Valvetrain:
SOHC, 10 valves
Aspiration:
Turbocharged, intercooled
Horsepower:
Approximately 154 hp
Torque:
Approximately 243 lb-ft
Fuel Economy:
N/A - not specified in the manual description
Type:
Diesel direct injection with electronic control
Filter Service:
Regular fuel filter replacement covered in maintenance schedule
Standard Transmission:
6-speed manual transmission
Optional Transmission:
5-speed automatic transmission (NTG / Mercedes-Benz automatic)
Drive Configuration:
Rear-wheel drive
Clutch Service:
Clutch removal, inspection, and replacement procedures included
Automatic Service:
Fluid service, diagnostics, and adjustment procedures included
Wheelbase:
118 in (2500) or 140 in (3500) depending on configuration
Length:
Approximately 191–229 in depending on wheelbase and body style
Height:
High-roof configuration, approximately 96–104 in
Curb Weight:
Approximately 5,000–5,500 lb depending on configuration
GVWR:
8,550 lb (2500) / 9,900 lb (3500) approximate
Airbags:
Driver and front passenger airbags
Seatbelts:
Three-point front seatbelts with pretensioners
Structure:
Reinforced commercial van body structure
ABS:
Four-wheel anti-lock braking system
Traction:
Standard rear-wheel drive with ABS support
Crash Test Ratings:
N/A - not specified for this model in the manual
Audio System:
AM/FM radio with CD player (commercial van configuration)
Wiring:
Complete audio and electrical wiring diagrams in the manual
Systems:
N/A - not specified for this model era; 2002 Sprinter predates modern driver assistance features
Onboard Diagnostics:
OBD-II compliant with fault code retrieval procedures covered in the manual
Oil & Filter:
Extended diesel service intervals; schedule covered in the manual
Fuel Filter:
Regular replacement per maintenance schedule
Air Filter:
Periodic inspection and replacement intervals specified
Transmission Service:
Fluid and filter service intervals covered
Engine Oil:
Diesel-rated engine oil per Mercedes-Benz specification (e.g., MB 228.3)
Coolant:
Mercedes-Benz approved coolant with specified capacities
Known Issues / Common Wear Items
Common Wear Items:
Turbo supply line seals, glow plugs, fuel filters, and brake components
Diesel Notes:
Cold-start glow plug system maintenance covered
Manufacturer:
Built by Mercedes-Benz (DaimlerChrysler); sold in the US as Dodge Sprinter and Freightliner Sprinter
Platform Lineage:
Mercedes-Benz T1N Sprinter platform, introduced in Europe in 1995
US Introduction:
Sprinter launched in North America for the 2001 model year under Freightliner and Dodge badges
2002 Model Year:
Second year of US availability with established 2.7L diesel powertrain
Assembly Plant:
Düsseldorf, Germany (kits shipped for US final assembly at Freightliner facilities)