Most Common Mercedes-Benz Sprinter Problems
Mercedes-Benz (and Dodge) Sprinter vans can last over 200,000, but you may experience a few problems before you reach that milestone. The common problems with the Mercedes-Benz Sprinter vans include clogged DPF filters, AdBlue heater element failure, and transmission issues.
DEF Heater Failure
DEF heater failure is a common problem that affects most 2010 and newer Mercedes-Benz Sprinters. The AdBlue tank has a heater to keep the DEF from freezing. The heater element burns out, which causes the check engine light to come on and limp mode.
This may not be a problem in the summer, but it will allow DEF to freeze in colder climates and winter. If ignored, it will lead to an active start countdown being initiated.
For help with this problem, follow our guide on how to replace the Mercedes-Benz Sprinter AdBlue heater.
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Broken exhaust flex pipe.
This is a common problem for the 2007 or 906 chassis with the V6 OM642 diesel engine. In the 2007, 2008, and 2009 model years, this is part of the catalytic converter. On the 2010 and newer models, it is part of the Diesel Particular Filter. Exhaust leaks from the flex pipe can melt wiring nearby, causing the engine to shut off, not restart, and start the counter.
No Start Count Down.
Sprinter vans 2010 model and above with “Bluetec” will start counting down remaining start cycles if any of these conditions are met: if there is an issue with the DEF Adblue system. If the DEF level is not monitored and runs out, Nox sensors fail, or any other components related to the DEF/Adblue system fail. Once the countdown is started, it is strongly advised to get your sprinter diagnosed before it gets to the last few remaining start cycles.
DPF Clogged
Sprinter’s Diesel Particular Filter (DPF) captures soot from the exhaust, so you do not see black smoke. DPF accumulates soot until it reaches a level to do what is known as regeneration.
During regeneration, the ECU causes the DPF to reach a very high temperature of around 1,200F, incinerating the soot. Remember that ash will build up inside the DPF and not be burned out if incorrect engine oil is used.
The DPF can clog up and restrict exhaust flow. If the ash content is too high, one option is to manually force DPF regeneration with the SDS Start Scanner. If manual regeneration fails, the only option is to replace the DPF.
Problems that can prevent DPF regeneration include:
- faulty temperature sensor,
- swirl flap motor,
- EGR valve,
- The running issue keeps the DPF from regenerating.
If not corrected, the exhaust will have severe restrictions, and the van will lose power as it clogs up further.
Reduced power / limp mode.
A Limp Mode is a safety feature in Sprinter that protects the engine from damage. It may be activated if you push the engine too hard to the limit. When MIL illuminates or Check Engine Light flashes on your dashboard, it indicates Limp Mode.
It tries to lower engine power to prevent further damage to affected components. The onboard computer or ECU would switch the turbo off to reduce power, forcing the owner to take the van to the Sprinter shop and have it serviced. Limp mode is generally caused by faulty EGR, faulty oxygen sensor, swirl flap motor, leaking intercooler hoses, actuator, resonator, etc.
Oil Cooler Leaks
Sprinter oil cooler leaks are common on the 2007-present models with the OM642 V6 engine. The oil cooler seals are where most engine oil leaks occur.
Mercedes has updated the seals to much better Viton material, increasing their life. Because it’s difficult to reach the location, the oil cooler is expensive to repair. The turbocharger, intake manifold, and other parts have to be removed to gain access to it.
Glow Plug Issues
As with any diesel engine, Sprinter’s glow plugs and modules do not last forever. Also, stubborn plugs sometimes break off in the cylinder head. In most cases, we have special tools to drill out and extract the glow plug without removing the cylinder head. Pricing varies on glow plugs depending on engine and year.
Injector Issue / “Black Death“
An additional typical problem is usually called “black death. “ The copper seal ring, located in the middle of the injector and cylinder head, deteriorates and makes it possible for combustion gasses to escape. As a result, black tar and coal-like black material would accumulate over fuel injectors.
The replacement or removal of injectors mostly causes it if new ones do not replace copper seals or if seals are incorrectly installed. This allows the combustion gasses to leak over time. Depending on the seriousness, you might smell an unusual exhaust/fuel odor when the engine runs and even hear it puff.
Depending upon the seriousness, it can take time to break down and loosen up this “black death” build-up accumulation and secure the injector to change the seal. The injector and cylinder head must sometimes be removed to obliterate the tar.
Noise from the Torque Converter
This “Rumble” Torque converter noise can result from several things, including wrong transmission fluid oil or a lack of fluid level, but the most expensive fault is when the torque converter’s lock-up clutch wears out.
This issue can affect any Sprinter (except four-cylinder engines). The fix is costly because the transmission would need to be pulled down, the torque converter rebuilt, and the transmission and torque converter reinstalled.
Frequently Asked Questions
Are our Sprinter vans expensive to maintain?
The fatal flaw in the Mercedes-Benz Sprinter’s exhaust system is directly related to the components involved. The cost of maintaining and repairing these vehicles is a staggering average of ten cents per mile.
What is a Glowplug?
A glow plug is an electrical pre-heating device used in a diesel engine to warm up the fuel before ignition. This is important in cold weather and climates since glowplugs should heat diesel to a pre-defined temperature before igniting. A glow plug controller/timer determines and commands the timing and duration of glowplug duty.
What is DEF?
Diesel Exhaust Fluid is a non-hazardous solution consisting of 32.5% urea and 67.5% de-ionized water. DEF is sprayed into the exhaust stream of diesel vehicles to break down dangerous NOx emissions into harmless nitrogen and water.
What is DPF?
Diesel Particulate Filter—A pollution control device commonly connected to Diesel Engines that filters particulates from the exhaust and burns them off during regeneration. There are two types of DPF: the common mode is Active, in which the car’s ECU / ECM controls regeneration, and the other is Passive.
How many miles will a Mercedes Sprinter last?
Sprinter will easily see a lifespan of over 300,000 miles. As long as you stay on top of regular maintenance, the longevity of a Mercedes Sprinter will serve you well. However, these vans are not devoid of some major common issues, and these problems are expensive to repair.
We hope you find the Most Common Mercedes-Benz Sprinter Problems guide helpful. Check these troubleshooting and repair guides for more help on your Mercedes-Benz.
