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2011 Mercedes Sprinter (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: Sprinter Year: 2011 Generation Generation Code: 2nd Generation (NCV3) Generation Years: 2007-2018 👋 Introduction Market Position Segment: Light Commercial Vehicle (LCV), Van, Chassis Cab Target Audience: Fleet operators, small businesses, tradespeople, campers/converters, DIY mechanics, professional technicians. Competitive Analysis Key Competitors: Ford Transit, Ram ProMaster, Nissan NV, Chevrolet Express. Sprinter Advantage: Renowned for durability, reliability, fuel efficiency (diesel engines), class-leading cargo volume, and advanced safety features for its class. Key Features Manual Value Proposition: Vehicle-specific, dealer-level information ensuring accuracy and completeness for maintenance and repair tasks, crucial for maintaining the Sprinter's operational integrity and resale value. Vehicle Versatility: The Sprinter's modular design allows for numerous body styles and upfitting options, making this manual essential for a wide range of owners. 📋 Manual Details Coverage Areas Coverage Scope: All Models & All Repairs A-Z Page Count Estimated Page Count: Extensive (Detailed specification unavailable, but typical for comprehensive service manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (Likely PDF, searchability implied) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel injection, ignition, exhaust, emissions control, engine management systems (ECU/ECM diagnostics and reprogramming). Transmission Systems: Manual and automatic transmission service, repair, troubleshooting, clutch system, torque converter, transmission control modules (TCM). Drivetrain Systems: Driveshaft, differentials, axles, CV joints, hubs, wheel bearings. Suspension Systems: Front and rear suspension, shock absorbers, springs, control arms, ball joints, bushings, power steering system, steering linkage. Brake Systems: Hydraulic brake system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake pads, rotors, calipers, lines, master cylinder, brake booster, parking brake. Electrical Systems: Battery, charging system, starting system, lighting, wiring diagrams, fuses, relays, switches, comfort systems, body control modules (BCM). HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, repair, refrigerant handling, blower motor, evaporator, condenser, controls. Body And Interior: Body panels, doors, latches, locks, windows, mirrors, seats, dashboard, trim, sound deadening, sunroof (if applicable). Chassis And Frame: Frame construction, mounting points, chassis components. Diagnostics And Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, diagnostic procedures for all major systems. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections, belt and hose checks. Repair Procedures: Detailed step-by-step repair instructions for all major components and systems, including disassembly, inspection, repair, reassembly, and adjustment. Troubleshooting Guides: Systematic diagnostic flowcharts and procedures for identifying and resolving common and uncommon faults. Component Replacement: Instructions for replacing specific parts such as alternators, starters, fuel pumps, injectors, brake calipers, suspension components, etc. Calibration And Adjustment: Procedures for calibrating sensors, adjusting brakes, aligning suspension, and setting critical component clearances. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, color-coded and detailed. Torque Specifications: Precise torque values for all critical fasteners and bolts. Technical Depth Depth: Factory-level, comprehensive (covers everything from basic maintenance to complete overhaul and diagnostics). Diagnostic Capability: Advanced diagnostic procedures, including the use of specialized Mercedes-Benz diagnostic tools (e.g., STAR Diagnosis/XENTRY), sensor data interpretation, and ECU function analysis. Special Tools: Identification and usage of specific Mercedes-Benz special tools required for certain procedures. 📊 Manual Specifications File Format Format: Digital (PDF) Searchability: Likely contains searchable text for efficient information retrieval. Print Quality Quality: High resolution, suitable for printing individual pages or sections. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: OM642 (3.0L V6 Turbo Diesel) - Predominant engine for this generation in many markets. Engine Code Diesel Alternatives: Also available in various CDI (Common Rail Direct Injection) diesel variants, including inline-4 and V6 configurations depending on market and specific model variant. OM651 (2.1L Inline-4 Turbo Diesel) was also introduced during this generation. Performance Om642 Horsepower: Typically around 188 hp (135 kW) at 3800 rpm (specific output can vary by market and tune). Om642 Torque: Typically around 325 lb-ft (440 Nm) at 1400-2400 rpm (specific output can vary by market and tune). Fuel System Injection Type: Common Rail Direct Injection (CDI). Fuel Type: Diesel. Maintenance Notes Dpf Considerations: Diesel Particulate Filter (DPF) maintenance and regeneration procedures are critical for emission compliance and engine longevity. Manual will detail DPF cleaning and replacement. Egr System: Exhaust Gas Recirculation (EGR) system diagnosis and cleaning procedures will be covered, as EGR issues are common in high-mileage diesels. 🔧 Transmission Standard Transmission Type Standard: 5-speed or 6-speed manual transmission. Optional Transmission Type Optional: 5-speed or 7-speed G-Tronic automatic transmission (depending on engine and model year). Features Automatic Features: Selectable drive modes (e.g., Comfort, Sport), manual shifting capability (Tiptronic-style). Fluid Specifications Automatic Fluid Type: MB 236.14 (e.g., Mercedes-Benz ATF, Shell Spirax S6 ATF XYZ, Mobil ATF 134) or equivalent meeting specifications. Manual Fluid Type: Gear oil meeting MB-Approval 235.10 (e.g., synthetic gear oil). 📐 Dimensions Exterior Wheelbase Options: Multiple wheelbase options available, commonly 138.8 inches (3526...
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2011 Mercedes Sprinter (2nd gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
Sprinter
Year:
2011
Generation
Generation Code:
2nd Generation (NCV3)
Generation Years:
2007-2018
👋 Introduction
Market Position
Segment:
Light Commercial Vehicle (LCV), Van, Chassis Cab
Target Audience:
Fleet operators, small businesses, tradespeople, campers/converters, DIY mechanics, professional technicians.
Competitive Analysis
Key Competitors:
Ford Transit, Ram ProMaster, Nissan NV, Chevrolet Express.
Sprinter Advantage:
Renowned for durability, reliability, fuel efficiency (diesel engines), class-leading cargo volume, and advanced safety features for its class.
Key Features
Manual Value Proposition:
Vehicle-specific, dealer-level information ensuring accuracy and completeness for maintenance and repair tasks, crucial for maintaining the Sprinter's operational integrity and resale value.
Vehicle Versatility:
The Sprinter's modular design allows for numerous body styles and upfitting options, making this manual essential for a wide range of owners.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models & All Repairs A-Z
Page Count
Estimated Page Count:
Extensive (Detailed specification unavailable, but typical for comprehensive service manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (Likely PDF, searchability implied)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel injection, ignition, exhaust, emissions control, engine management systems (ECU/ECM diagnostics and reprogramming).
Transmission Systems:
Manual and automatic transmission service, repair, troubleshooting, clutch system, torque converter, transmission control modules (TCM).
Drivetrain Systems:
Driveshaft, differentials, axles, CV joints, hubs, wheel bearings.
Suspension Systems:
Front and rear suspension, shock absorbers, springs, control arms, ball joints, bushings, power steering system, steering linkage.
Brake Systems:
Hydraulic brake system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake pads, rotors, calipers, lines, master cylinder, brake booster, parking brake.
Electrical Systems:
Battery, charging system, starting system, lighting, wiring diagrams, fuses, relays, switches, comfort systems, body control modules (BCM).
HVAC Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, repair, refrigerant handling, blower motor, evaporator, condenser, controls.
Body And Interior:
Body panels, doors, latches, locks, windows, mirrors, seats, dashboard, trim, sound deadening, sunroof (if applicable).
Chassis And Frame:
Frame construction, mounting points, chassis components.
Diagnostics And Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, diagnostic procedures for all major systems.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections, belt and hose checks.
Repair Procedures:
Detailed step-by-step repair instructions for all major components and systems, including disassembly, inspection, repair, reassembly, and adjustment.
Troubleshooting Guides:
Systematic diagnostic flowcharts and procedures for identifying and resolving common and uncommon faults.
Component Replacement:
Instructions for replacing specific parts such as alternators, starters, fuel pumps, injectors, brake calipers, suspension components, etc.
Calibration And Adjustment:
Procedures for calibrating sensors, adjusting brakes, aligning suspension, and setting critical component clearances.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, color-coded and detailed.
Torque Specifications:
Precise torque values for all critical fasteners and bolts.
Technical Depth
Depth:
Factory-level, comprehensive (covers everything from basic maintenance to complete overhaul and diagnostics).
Diagnostic Capability:
Advanced diagnostic procedures, including the use of specialized Mercedes-Benz diagnostic tools (e.g., STAR Diagnosis/XENTRY), sensor data interpretation, and ECU function analysis.
Special Tools:
Identification and usage of specific Mercedes-Benz special tools required for certain procedures.
📊 Manual Specifications
File Format
Format:
Digital (PDF)
Searchability:
Likely contains searchable text for efficient information retrieval.
Print Quality
Quality:
High resolution, suitable for printing individual pages or sections.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
OM642 (3.0L V6 Turbo Diesel) - Predominant engine for this generation in many markets.
Engine Code Diesel Alternatives:
Also available in various CDI (Common Rail Direct Injection) diesel variants, including inline-4 and V6 configurations depending on market and specific model variant. OM651 (2.1L Inline-4 Turbo Diesel) was also introduced during this generation.
Performance
Om642 Horsepower:
Typically around 188 hp (135 kW) at 3800 rpm (specific output can vary by market and tune).
Om642 Torque:
Typically around 325 lb-ft (440 Nm) at 1400-2400 rpm (specific output can vary by market and tune).
Fuel System
Injection Type:
Common Rail Direct Injection (CDI).
Fuel Type:
Diesel.
Maintenance Notes
Dpf Considerations:
Diesel Particulate Filter (DPF) maintenance and regeneration procedures are critical for emission compliance and engine longevity. Manual will detail DPF cleaning and replacement.
Egr System:
Exhaust Gas Recirculation (EGR) system diagnosis and cleaning procedures will be covered, as EGR issues are common in high-mileage diesels.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed or 6-speed manual transmission.
Optional
Transmission Type Optional:
5-speed or 7-speed G-Tronic automatic transmission (depending on engine and model year).
Features
Automatic Features:
Selectable drive modes (e.g., Comfort, Sport), manual shifting capability (Tiptronic-style).
Fluid Specifications
Automatic Fluid Type:
MB 236.14 (e.g., Mercedes-Benz ATF, Shell Spirax S6 ATF XYZ, Mobil ATF 134) or equivalent meeting specifications.
Manual Fluid Type:
Gear oil meeting MB-Approval 235.10 (e.g., synthetic gear oil).
📐 Dimensions
Exterior
Wheelbase Options:
Multiple wheelbase options available, commonly 138.8 inches (3526 mm), 154.1 inches (3915 mm), and 170.1 inches (4320 mm).
Roof Height Options:
Standard height, high roof, and super-high roof configurations.
Cargo
Cargo Volume:
Varies significantly based on wheelbase and roof height. Can range from approximately 318 cubic feet to over 530 cubic feet (90 to 150+ cubic meters).
Weights
Gvwr Range:
Gross Vehicle Weight Rating (GVWR) typically ranges from 6,990 lbs to 11,030 lbs (3,175 kg to 5,000 kg), depending on configuration and chassis reinforcement.
🛡️ Safety Features
Ratings
Safety Certifications:
While specific year/model crash test ratings can vary, Mercedes-Benz vehicles are generally engineered to meet or exceed stringent safety standards. The Sprinter often features advanced safety systems for its class.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Esp:
Standard Electronic Stability Program (ESP), which includes functions like Crosswind Assist and Load Adaptive Control.
Traction Control:
Traction Control System (ASR).
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags and curtain airbags may be optional depending on configuration.
Seatbelts:
Three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Infotainment System:
Base models may feature basic radio with CD player. Higher trims or optional packages could include Bluetooth connectivity, USB input, and potentially a more advanced infotainment system with a color display.
Driver Assistance
Adaptive Esp:
ESP (Electronic Stability Program) with advanced features like Crosswind Assist, Load Adaptive Control (LAC), and roll-over mitigation.
Optional Assistance:
Optional features may include Parking Assist, Backup Camera, Lane Keeping Assist, and Collision Prevention Assist.
Connectivity
Connectivity Options:
Bluetooth for hands-free calling and audio streaming, auxiliary input, USB connectivity depending on the audio system configuration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 miles (24,000 km) or 1 year, whichever comes first, under normal operating conditions. Severe conditions may require shorter intervals.
Air Filter Replacement:
Recommended every 30,000 miles (48,000 km) or as needed based on operating environment.
Fuel Filter Replacement:
Recommended every 30,000 miles (48,000 km) for diesel engines.
Coolant Service:
Initial change typically at 15,000 miles (24,000 km) or 2 years, then every 30,000 miles (48,000 km) or 2 years thereafter.
Fluid Specifications
Engine Oil Type:
Synthetic SAE 5W-30 or 5W-40 engine oil meeting MB-Approval 229.51 or 229.52 specifications is typically required for diesel engines.
Coolant Type:
MB-Approval 325.0 (Long-life coolant, typically a blue or green silicate-containing antifreeze/coolant concentrate).
Brake Fluid Type:
DOT 4 brake fluid.
Known Issues
Common Diesel Issues:
DPF regeneration failures, EGR valve clogging, injector issues, glow plug problems, AdBlue system faults (if equipped with SCR), and turbocharger issues can be observed in diesel models.
Common Electrical Issues:
Wiring harness issues, sensor failures (e.g., ABS sensors, MAF sensors), and battery drain can occur.
Suspension Wear:
Ball joints, tie rod ends, and bushings can experience wear due to the vehicle's weight and typical usage patterns.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Mercedes-Benz has a long history of producing commercial vehicles, dating back to the early 20th century, known for engineering excellence and durability.
Model Evolution
Sprinter Lineage:
The Sprinter replaced the TN (Transporter) van in 1995 and has been a global leader in its segment since. The 2nd generation (NCV3) built upon the success of the first generation, introducing more modern features and refined powertrains.
Production
Manufacturing Locations:
Primarily manufactured in Düsseldorf, Germany, and Ludwigsfelde, Germany. Assembly also occurs in other locations globally, including the US for the North American market.
Sales Significance:
One of the best-selling vans worldwide, popular for its versatility and reliability across various commercial applications.
🏆 Awards & Recognition
Recognitions
Van Of The Year:
The Mercedes-Benz Sprinter has won numerous 'Van of the Year' awards globally across various model generations and body styles due to its innovation, practicality, and efficiency.
Industry Recognition:
Consistently praised by commercial vehicle publications and fleet operators for its durability, low cost of ownership, and adaptability.
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