Mercedes Sprinter T1N, W901–W905 Workshop Manual

Mercedes Sprinter T1N Workshop Manual Dodge Sprinter 2002-2006. A complete set of technical documentation for the W901, W902, W903, W904, and W905 models. Contains complete step-by-step instructions for diagnostics and engine (OM611, OM612 CDI) repair, transmission, chassis, and bodywork. Includes detailed sections on CDI, ABS/ESP systems, driveshaft repair, electrical troubleshooting, and bodywork.

• Mercedes-Benz Truck Home page>>
• Mercedes-Benz Truck Fault Codes List>>
• Mercedes-Benz Sprinter T1N Wiring Diagram>>
• Mercedes Sprinter T1N Fuse and Relay Diagram>>
• Sprinter Home Page>>

1. Body and Corrosion Issues

Body corrosion: This is perhaps the most well-known and critical problem with the T1N.

• Particularly susceptible areas: Sills, wheel arches, lower door edges, fenders, and windshield frame.
• Frame-on-frame body: Although not strictly a frame structure, severe corrosion in load-bearing components can pose a serious risk.

2. Engine Malfunctions (Especially CDI Diesels)

The most common were CDI (Common Rail Diesel Injection) engines, such as the OM611, OM612, and OM647.

• Valve Cover Gasket and Injector: Common gasket issues, leading to oil leaks, are common.
• Injector Seals ("Copper Washers"): Injector sealing washers can burn out, causing blowby and soot accumulation around the injector (known as "black carbon" or "coke"). This can lead to injector failure or even damage to the cylinder head when attempting to remove it.
• Turbocharger: With age and mileage, problems arise with the turbo actuator (drive) or the turbo itself, leading to a loss of power.
• Common Rail System: Sensitivity to diesel fuel quality can lead to wear of the high-pressure fuel pump (HPFP) and injectors.

3. Transmission and Chassis Issues

• Propeller Shaft and Outboard Bearing: Wear of the propeller shaft outboard bearing is a common problem, manifested by vibration when accelerating.
• Automatic transmission (AT): Can be sensitive to overheating and requires strict adherence to oil change intervals.
• Springs: Frequent use under maximum load can cause springs to sag or break.

4. Electrical and electronic problems

• Wiring: Problems with oxidized contacts and wiring, especially in the rear of the vehicle (lights, sensors).
• ABS/ESP sensors: ABS/ESP sensors often fail due to corrosion and dirt.