Sprinter

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Sprinter

144.jpg

Manufacturer Daimler AG
AKA Mercedes-Benz Sprinter
Freightliner Sprinter
Dodge Sprinter
Volkswagen Crafter
Production 1995 – present

   The Sprinter is a commercial vehicle that comes in a number of different configurations and is available in a number of different countries. Manufactured by Daimler AG under a few different brand names (Mercedes-Benz, Dodge, Freightliner, Volkswagen), the Sprinter could be considered a true "World Van."

   Jan 1, 2010, Sprinter vans will no longer be sold under the Dodge nameplate in the USA. They will be Mercedes-Benz Sprinters. 120 Mercedes-Benz dealerships, not including the current Freightliner dealerships, will be chosen to support and sell Sprinters.


Timeline of vans produced by Daimler AG:


Contents

T1N Sprinter 1st Generation (1994 – 2006)

T1N

Sprinter140.jpg

AKA Transporter 1 Neu
Production 1994 – 2005
2001 – 2006 (USA)
Assembly Düsseldorf, Germany
Ludwigsfelde, Germany
Buenos Aires, Argentina
Charleston, SC, USA
Engine 2.3l I4 TDI Diesel
2.9l I5 TDI Diesel
2.2l I4 CDI Diesel
2.7l I5 CDI Diesel
2.3l I4 Petrol
Transmission 5spd Manual
Sprintshift 6spd Semi-Auto
NAG1 5spd Auto
Wheelbase 118in (3000mm)
140in (3560mm)
158in (4015mm)
Length 197in
225in
263in
Width 78in
Height 93in (standard roof)
104in (high roof)
Fuel Capacity 100 liters/26.4 gallons
Towing Capacity 5000lb

   The Sprinter T1N (Transporter 1 Neu) is the replacement for the Bremer T1. T1N's come as cargo, passenger, or chassis versions. Production for the T1N continued into 2006 model year for the US market.

   T1N's comes in three wheelbases (118in, 140in, and 158in), two roof heights (standard and high), and two weight classes (2500 and 3500) where the 3500 series comes with dual rear wheels.

   Earlier models (1994-1999) exhibited a floating three pointed star in the middle of the grille. The design was later changed (2000) to a half circle cut out of the engine bonnet to encompass the three pointed star. The horizontal air vents just above the bonnet were widened in 2002.

   The T1N arrived in the US in 2001 as a Freightliner. All T1N cargo models were reassembled from kits at Freightliner's Gaffney, South Carolina Custom Chassis plant, and all passenger models were imported directly from the Düsseldorf plant. FedEx was the first US customer, buying the complete 2001 Gaffney production run. After the merger of Daimler-Benz and Chrysler becoming Daimler-Chrysler, the T1N began selling under the Dodge nameplate in late 2003. Both Freightliner and Dodge continued to sell the T1N in the US through the 2006 model year. Volkswagen and Mercedes worked together on the Sprinter and in the UK and elsewhere VW released the Sprinter as the LT.

Drawings

Powertrain

   Four diesel engines and one petrol engine were available. A 2.3l Turbo Diesel (TDI), 2.9l Turbo Diesel (TDI), 2.2l Turbo Diesel (CDI), 2.7l Turbo Diesel (CDI) and a 2.3l Petrol. Only the 2.7l CDI was available to the USA and Canada.

   The abbreviation "OM" stands for "Oil-Motor" and refers to today's diesel engines.

Diesel
Engine Capacity (l) Cyl-Arrg Power (hp) Torque(ft-lbs) Used
OM601 2.3 I4 72 96 1995-1999
OM602980 2.9 I5 121 207 1995-1999
OM611* 2.2 I4 80,107,127 148,199,221 2000-2005
OM612 2.7 I5 154 243 2000-2003
OM647 2.7 I5 154 243 2004-2006

*There are three versions of the OM611 engine.

Petrol
Engine Capacity (l) Cyl-Arrg Power (hp) Torque(ft-lbs) Used
M111 2.3 I4 141 159 2000-2005

   2004-2006 OM647's were fitted with turbo resonators that are known to crack at the seam and will cause the vehicle to go into Limp-Home Mode. The latest version of turbo resonators have a "Q5" on a small white sticker on the underside. [1].

Transmission

   Three transmissions were available; a 5 speed manual, a 6 speed semi-automatic (Sprintshift), and a 5 speed (selectable) automatic (NAG1; New Automatic Gearbox generation 1). The manual transmissions and the Sprintshift were not available in the USA or Canada.

Transmission 1st 2nd 3rd 4th 5th 6th Reverse Used
5 Speed Manual 5.05 2.60 1.52 1.00 0.78 4.76 1995-2005
4 Speed Automatic  ?  ?  ?  ?  ? 1995-1999
Sprintshift Semi-Auto 5.01 2.83 1.78 1.25 1.00 0.79 4.57 2000-2005
NAG1 Automatic 3.59 2.19 1.41 1.00 0.83 3.16 2001-2006

   A common characteristic of the NAG1 automatic transmission is a rumbling or vibration that occurs during light acceleration and coasting. An ingeniously designed fix for this noise and vibration can be ordered privately from a Sprinter-Forum member by searching "Rumble Strip Noise Cure". Most of the early NAG1s were coupled with a 3.72 Final Drive Ratio which produced the highest MPGs.

Chassis

   The front suspension consists of a single transversely mounted composite spring with shocks mounted near each front wheel. In some cases, the composite spring is known to sag over time. A steel replacement is available.

   The rear suspension consists of two longitudinally mounted leaf springs underneath each frame rail. Cargo and chassis versions have single leaves while the passenger versions have dual leaves on each side. The passenger spring leaf packs consist of a comfort spring and a spring for heavier loads.

   Driveshaft u-joints are not serviceable or replaceable [2]. The driveshaft assembly that includes the u-joints must be replaced entirely from the OEM. Aftermarket driveshaft suppliers have designed driveshafts with serviceable and replaceable U-joints inexpensively.

   The suspension for late 2002-2006 models are raised 30mm from previous year models to compensate for the move to larger 16 inch rims and tires. The front consist of a 30mm channel spacer. The rear springs had more arch. This can be identified by the plastic trim on the rear wheel wells. This was only for 140" and 158" wheelbase models. All 118" models stayed withe the shorter height and 15" rims.[3] and the rear contain reshaped leaf spring arches [4].

   The bearings and races for the rear axle are reported to be the same as those used in a late model Dodge Charger and at a much better price. [5]

Body

   Cargo and passenger versions comprise of a unibody steel construction. Chassis versions come in cab or crew cab versions with frames that extend beyond the back of the cab. Chassis crew cabs are not available in the USA.

   Passenger versions consist of 5 doors; a driver and passenger door, a sliding side door, and two rear barn type swing out doors. Cargo versions have an option of a driver's side sliding door. With a driver's side sliding door, a rear auxiliary heater cannot be ordered.

   There are four known types of OEM Mirrors that come from the factory. They can be identified by their support arms; plastic, short metal, long metal, and metal loop arms. [6] The mirrors with plastic arms come standard on most T1N versions except for the chassis. If parabolic mirrors were ordered as an additional option, it would default to short metal arms. Most chassis cabs come with the long metal arms, except when ordered with parabolic mirrors, the short metal arm mirrors were used. All were electric power and were heated.

   There are six fabric designs available for the interior seats; Arrow, Cara, Carat, Catano, Santos, and Venice. The available fabric design will depend on the options ordered.

   The maximum permissible roof load is:

  • Vehicles with low roof 660 lbs (300 kg)
  • Vehicles with high roof 330 lbs (150 kg)
  • The weight of any load carried on the roof, including the roof rack, must not exceed the maximum permissible roof load.

History

  • 1995 - Sprinter T1N is introduced.
  • 1996 -
  • 1997 -
  • 1998 -
  • 1999 -
  • 2000 - New front clip with half circle cut out of the engine bonnet encompasses the three pointed star. Also the interior of the cab is totally redesigned with the gear stick moving from the floor to the dash. With its new 156bhp engine option the Sprinter is blessed with previously unheard of power for a light commercial vehicle.
  • 2001 -
  • 2002 - Horizontal air vents just above the bonnet were widened. The face lift treatment also included new clear lenses for the headlights and a revised appearance for the rear light lenses. Mid-year the 140" and 158" models got a 30mm height lift
  • 2003 -
  • 2004 - The 2.7 liter diesel engine receives a new intake manifold.

             New EGR valve
             - Separate compressor for rear air conditioning and rear evaporator becomes roof mounted.
             - ESP become standard.

  • 2005 -
  • 2006 - The T1N continues to be sold in the North America. 3500 chassis models receive 16 inch rims.


NCV3 Sprinter 2nd Generation (2006 – present)

NCV3

Ncv3.jpg

AKA New Concept Van 3
Production 2006 – present
2007 – present (USA)
Assembly Düsseldorf, Germany
Ludwigsfelde, Germany
Buenos Aires, Argentina
Charleston, SC, USA
Engine 2.2l I4 CDI Diesel
3.0l V6 CDI Diesel
3.5l V6 Petrol
Transmission NSG370 6spd Manual
NAG1 5spd Auto
Wheelbase 128in (3250mm)
144in (3665mm)
170in (4320mm)
Length 232in
273in
289in
Width 79.7in
Height 95.5in (standard roof)
107.5in (high roof)
115.5in (mega roof)
GVWR 8550lb
11030lb
Fuel Capacity 25 gallons
Towing Capacity 5000lb

   The Sprinter NCV3 (New Concept Van 3) is the redesigned replacement for the Sprinter T1N. The NCV3 appeared in Europe and in other countries in 2006 and consist of cargo, passenger, and chassis versions. They were sold under the Mercedes Sprinter or VW Crafter nameplate. North America received its own NCV3 for the 2007 model year. The US cargo NCV3s are reassembled from kits in a new purpose-built Freightliner assembly plant located in Ladson, South Carolina, and the passenger models are imported directly from Germany. The NVC3 Sprinters are sold under both the Dodge and Freightliner nameplates.

   The NCV3 comes in three wheelbases (128in, 144in, 170in), three roof heights (standard, high, mega), four lengths, and two weight classes (2500, 3500) where the 3500's have the option of dual rear wheels or rear super singles. Neither the 128in wheelbase nor the rear super single tires are available in the USA market.

Powertrain

   Three engines are available. A 2.2l Turbo Diesel (CDI) , a 3.0l Turbo Diesel (CDI), and a 3.5l Petrol . The 2.2l CDI comes in four different power and torque levels and is not available in the USA. All diesels are now fitted with a Diesel Particulate Filter (DPF) that regenerates to burn off the collected soot.

   The abbreviation "OM" stands for "Oil-Motor" and refers to today's diesel engines.

Diesel
Engine Capacity(l) Cyl-Arrg Power (hp) Torque(ft-lbs) Used
OM646 2.2 I4 87,107,127,148 162,207,225,243 2006-2008
OM651 2.2 I4 95,129,163 184,225,266 2009-present
OM642 3.0 V6 154 280 2006-present
Petrol
Engine Capacity (l) Cyl-Arrg Power (hp) Torque(ft-lbs) Used
M272 3.5 V6 254 250 2006-present

Transmission

   An available 6 speed manual NSG370 and the 5 speed (selectable) automatic NAG1 (New Automatic Gearbox generation 1) continue to be used, however, the rumbling or vibration that occurred in the T1N while light on the accelerator and coasting has reportedly been eliminated. Other names for the NAG1 are W5A380 or G40.

Transmission 1st 2nd 3rd 4th 5th 6th Reverse Used
NSG370 Manual 5.014 2.831 1.789 1.256 1.00 0.828 4.569 2006-present
NAG1 Automatic 3.59 2.19 1.41 1.00 0.83 3.16 2006-present

Most of the 2007 US models (2500) came standard with a 4.18 rear end axle ratio which resulted in a slightly lower mpg which was "fixed" in 2008 with a 3.92 ratio.

Chassis

   The front suspension consists of a single transversely mounted composite spring with shocks mounted near each front wheel. The rear suspension consists of two longitudinally mounted leaf springs underneath each frame rail. Cargo and chassis versions have single leaves while the passenger versions have dual leaves on each side. The passenger spring leaf packs consist of a comfort spring and a spring for heavier loads.

   Driveshaft universal joints (u-joints) are not serviceable or replaceable [7]. The driveshaft assembly that includes the u-joints must be replaced entirely. However, the assembly can be replaced by an aftermarket driveshaft that is equipped with replaceable u-joints.[8]. The driveshaft is also referred to as the "propeller shaft". There are two or three driveshaft segments between the transmission and rear differential, depending on vehicle length.

   3500s - also known as 4xx or 5xx series depending on the regional market - may be ordered with the rear "super single" or "SuSi" axle. Although virtually the same carrying capacity as the four wheeled rear axle it has just two over-sized wheels on the rear axle instead. The benefit is to have a wider internal clearance between the rear wheel arches when compared to the traditional four wheels on the rear axle. This has operational benefits for many operators of panel bodied cargo variants, and is particularly useful for any operator who intends to use the Sprinter to carry pallets or skids. The Super Single tyre size is 285/65R16. SuSi axled Sprinters are not supplied with any spare wheel at all. The front and rear wheels of "SuSi" Sprinters are completely different sizes! To date (September 2012) SuSi axle Sprinters have only been observed in the European market.

Drawings

Body

   Cargo and passenger versions comprise of a unibody steel construction with the exception of mega roofs which are made out of a fiberglass composite. Chassis versions come in cab or crew cab versions with frames that extend beyond the back of the cab. Chassis crew cabs are not available in the USA. Colors remain the same for 2007 and 2008.

   Passenger versions consist of 5 doors; a driver and passenger door, a sliding side door, and two rear barn type swing out doors. Cargo versions have an option of a driver's side sliding door.

   A crew van option‎ is offered for the cargo version. This consists of a first row rear three passenger bench seat. There are floor cut outs for an addition bench seat in the second row, but the hardware necessary to secure it is not provided (the blind nuts are welded below the floor, but the holes have not been drilled).


   There are two fabric designs available for the interior seats; Brasso Gray and Brasso Black. The available fabric design will depend on the options ordered.


Maximum roof load and minimum number of pairs of roof rack supports on vehicles with (see page 630 in Owners manual) [9]:

  • Standard Roof 660lbs (300kg) with a minimum of 6 pairs of supports.
  • Raised Roof 330lbs (150kg) with a minimum of 3 pairs of supports.

The data is valid when the load is distributed evenly over the entire roof area. When using a shorter roof rack, reduce the load proportionately. The maximum load is 110 lbs (50 kg) per pair of roof rack supports.

Maximum normal tensile load on the lashing eyes, or tie downs are (see page 629 of the owner's manual)[10]:

  • Crewbus 786 lbf (3500 N)
  • Panel Van 1124 lbf (5000 N)

For these loads to be valid, you must tie into at least 2 tie down points.

Maximum normal tensile load on the lashing rails (see page 629 of the owner's manual)[11]:

  • Load rails in the load compartment floor 1124 lbf (5000 N)
  • Lower load rail on the side wall 562 lbf (2500 N)
  • Upper load rail on the side wall 337 lbf (1500 N)

History

  • 2006 - Sprinter NCV3 is introduced.
  • 2007 - NCV3 arrives in North America as a Dodge or Freightliner.
  • 2008 - New option of power sliding side door is introduced (Not in USA).

             - Two stage sliding door opening feature deleted (USA).
             - Backup camera option not available (USA).              - Rear drive axle changed to 3.92 (from 4.18 in 2007) to improve efficiency (USA).

  • 2009 - Petrol engine is discontinued (USA).
  • 2010 - The Dodge badge is dropped. Sprinters will be badged Mercedes-Benz and Freightliner (USA).

2010 is also the year that the US got the new Bluetec emissions system, requiring less energy so more power and mileage, but also requiring filling of a tank onboard with AdBlue DEF, a urea compound that helps catalyze the NOx in the exhaust.

  • 2010-2014 Euro5 emissions are met in Europe through use of a DPF filter
  • 2014> Euro6 diesel engines are reported to require AdBlue as well as the DPF filter.


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