If you have purchased a used Sprinter Van (or Mercedes Rv) or plan to purchase a used Sprinter Van, you need to be educated on some common problems & technical difficulties that you will most likely experience relating to your Sprinter Van.
It is obvious to everyone that Sprinter Vans have grown in popularity in the past decade. They’re flexible vans for hauling cargo and can also be converted into a DIY camper or Rv.
Regardless of their versatility and German high quality, it’s important to know these top common faults and unfortunate issues with Sprinter Vans.
Keep in mind, a lot of these common problems have been corrected on the newer built Sprinter Vans. But, these mentioned repairs are problematic within the industry.
The good news is that all of these common problems can be repaired. We have selected the most common problems that we have seen over the years repairing Sprinter Vans.
The Top 11 Most Common Issues with Sprinter Van:
1. The “Rumble” Strip Sound / Torque Converter
We gave the name to this problem “rumble strip sound” because this issue is very similar to the sound and feel of driving over rumble strips on the side of the freeway. The result of this “rumble strip” noise points to the transmission torque converter. This “Rumble” Torque converter (TC) noise can be resulting from a few things. Typically, the transmission fluid is low or is incorrect. You can start out by checking the fluid level and adding the proper transmission fluid. If the Rumble strip noise remains, additional repairs will be needed. This issue can affect any Sprinter with the V6 3.0 engine and the 5 speed transmission.
So why does this happen?? The answer is not overly complicated, but the repairs can be complicated. The lock-up clutch of the torque converter wears out and this is the main reason for the shuddering. To fix this, we need to take a few steps. The first step is to remove the transmission from the truck. Next, the torque converter must be replaced with a new torque converter. We have had the torque converters rebuilt in the past but we typically install a new OEM torque converter. Pricing typically starts out at $1500.00 or more.
2. Injector Leaks - AKA “Black Death“
Injector leaks AKA “black death“ is another common problem with Sprinter Vans. We will try to explain the reason for this phenomenon.
Injector leaks allow combustion diesel gasses to escape from the engine into the atmosphere. The gasses will leave a residual black oily substance at the top side of the engine. This substance is known as “black death”. The black substance will continue to build up causing damage to all surrounding parts. Eventually, the injector leak can cause damage to the cylinder head.
Typically, the copper seal ring located at the injector is what fails or has been installed incorrectly by another service center. This allows the combustion gases to leak over time. Depending on the seriousness, you might hear a different sound in your engine compartment or you may begin to smell diesel fuel when the truck is running.
As this “black death” continues to escalate and build up, the truck will start to run poorly. If found early enough, the repairs can be handled much easier. If multiple injectors are leaking and the black substance is heavy, it can take a lot of time to break down and loosen up this “black death” build-up accumulation to gain access to the faulty injector(s). We’ve seen in the past that this repair is so extensive that the cylinder head was destroyed and needed replacing.
Pricing will always vary as it depends on each situation and the severity of the black oily (black death) substance.
3. Glow Plug & Glow Module Failure
A glow plug is an electrical heating tool that facilitates diesel powered cars/vans to reach the needed ignition temperature. The glow plugs and modules in Sprinter Vans do not last forever. Sooner or later they will fail which will result in a check engine light and a glow plug squiggly light to illuminate on the dash.
The good news, both the glow plugs and the glow plug module can be replaced at a very inexpensive cost.
If you live in colder climates like us in Michigan, you will immediately feel this problem as your Sprinter Van may have trouble starting during cold weather conditions. It is no longer uncommon for diesel Sprinter Vans to have failed glow plugs and modules.
Changing out a failed glow plug and a glow plug module can be a simple task. However, there are times that glow plugs become seized in the cylinder head. This is when a small repair can turn into a very serious and costly repair.
If a glow plug is tight and forced to be removed, the glow plug can break off inside the cylinder head resulting in a heavier repair that will ultimately be on the vehicle owner. If a glow plug is broken off, additional repairs will be needed. The broken glow plug can be removed with a few different techniques. But, there are times when the cylinder head must be removed to fully extract the broken glow plug. Our suggestion is to have a qualified service center inspect your glow plug issues prior to attempting to remove a failed glow plug.
Glow plugs replacement. $50 – $150 each cylinder and more if glow plugs are seized….
4. DPF Flex Pipe Leakage
This issue is seen quite often. Basically, the flex pipe will start to separate/crack which allows hot exhaust to exit the exhaust pipe. If this is not corrected immediately, the hot exhaust will burn/melt any and all electrical wiring in its path. Additionally, the hot exhaust will melt the DEF nozzle and all SCR aftertreatment parts. This burning of the wiring harness and aftertreatment parts will force the engine to shut down without any hopes of starting again. That is of course until fully repaired.
It’s not a simple issue to spot and commonly occurs before you can even notice the signs of the problem. Typically, you will notice your exhaust to be louder than normal. As the flex pipe continues to crack, this is when the damage will occur to the wiring harness and parts.
This impacts the 2007 and newer “906“ Sprinters with V6 engines. In the 2007-2009 this is part of the catalytic converter assembly. On the 2010 and newer models, this is part of the DPF/Catalytic converter assembly. In 2010 and newer, the exhaust will leak out from the cracked flex pipe and will melt all of the wiring triggering a countdown mode state which will eventually lead to engine shut-down. Your early signs will be loud exhaust with no advanced warning to this flex pipe breaking.
Repairs are very tedious and will typically start at $2,000. Increase in repair costs will depend on severity of damaged wiring.
5. The Frustrating Launch of Countdown Mode
All Sprinter Vans (2010 and newer) built with a diesel engine require Diesel Exhaust Fluid (Def). This SCR (selective catalytic reduction) or Def (diesel exhaust fluid) system is a very complex system and was designed for cleaner emissions.
The driver of a Sprinter Van must understand how and when to add Def to the SCR system. We always advise to add Def to their Sprinter Van after 2-3 diesel tank fill-ups. This will typically equate to 1000 – 1200 miles driven. We do stress caution as all Def usage fluctuates. Def is also used during idle time. So, if a driver of a Sprinter Van sits idle often, Def is being used often.
If a Sprinter van is simply run low or out of Def, you will launch the SCR countdown mode. You will find on dashboard warning: “StartS Remaining with a number“. The computer will launch the countdown from 9 (or 16) remaining starts and will go to 0. The countdown is referred to as key cycles. Every time you cycle the key to start the Sprinter, that is considered a count.
However, the countdown mode can also take place if there is a fault within the SCR system. If a malfunction is detected within the SCR system, the Diesel Sprinter Vans computer system will launch a countdown mode to notify the user of how many starts (key cycles) remain. The Sprinter Van is calling for Diesel exhaust fluid but the Def system is not functioning properly. Therefore, the SCR system will initiate a countdown mode to alert the user that the truck will enter a lock-out state if the Def system is not satisfied. This is a frustrating situation as we all know. Unfortunately, simply adding Def the Sprinter will not correct this issue. The truck obviously has a fault(s) and must be inspected to determine why the countdown mode was initiated.
This countdown mode does get worse if not addressed. When the countdown mode on the dash reaches “0“, your Sprinter Van will either enter a “Safe Mode/Idle Mode” or the Sprinter Van will not start. This is the computer programming advising the user that the Def system is reporting empty and Diesel exhaust fluid is required to operate properly. We all know that Def was most likely added which means there is a fault within the SCR system.
Typically, there are a few common parts that fail within the SCR system. The Nox sensors are a common part to fail on the Sprinter Vans. There is an Upstream Nox Sensor and a Downstream Nox Sensor. Both of these Nox Sensors are typically replaced as a set. The other parts include Def Injection Nozzle, Def Fuel Line, Def In-tank Heater, and more. All of these parts are costly and will eventually fail over time resulting in a complicated and costly repair.
We want to warn you about the importance of calling us immediately. The more starts remaining the better. If there are a few starts left, it becomes difficult and more laborious (more expensive) to determine the core of the problem.
Do not let the countdown go to “0“, otherwise you will have to tow your Sprinter to a service center. Unfortunately, not all service centers can restore your Sprinter from this SCR fault.
The good news is that we have solutions to these issues. As soon as you see the “CountDown“ on your dashboard, you must urgently contact Detroit Sprinter Center. We will help you find out the cause and a repair solution to your Sprinter Van.
Pricing will vary on these repairs.
6. Limp mode / Sprinter losing power
7. DEF Heater Failure
The main function of the heater to keep the Diesel Emission Fluid from freezing. Sprinter Van AdBlue heater collapse appears whilst the heater on the emission fluid tank burns out. This reason why engine warning light turns on. While the problem will be much less notable in the hot season as the liquid does not freeze, but there’s a big opportunity it’ll freeze in the course of the chillier months. This can affect any Sprinters from 2010+. (all Bluetec)
So there is a high probability that heater element burns out one day and it will cause a “check engine” to appear and this failure will launch “starts countdown“. We can deal with DEF and remove and replace the Sprinter DEF heating unit with a brand-new OEM. The exchanging cost of DEF heater $1,500.
8. Turbo Resonator “Oil Leak“ - Air leak
The original Sprinter Van Turbo Resonators (aka Silencer) are known to have problematic seals and O-Rings. Many call this symptom “Turbo leaking oil“. This actually is an Air Leak. This leak from the turbo is at the output side. Since it’s on the “slip fit“ end, it is probably the O-Ring that was flattened or torn. There’s constantly the threat that the leak will worsen over time (it is very clear that the moving air erodes the rubber seal as it passes through under high pressure) and eventually, you could begin seeing rapid drop-out when the ECU (Engine Control Unit) notices the loss of pressure.
So where does the oil come from if this is moving air?? A small amount of oil within the air in the turbo is OK. But if this air comes out through the sealing O-Ring, it is wrong and the seals and o-rings must be replaced. Detroit Sprinter Center can repair this for you at a very affordable price.
9. Clogged DPF / Regeneration
The Diesel Particulate Filter created to catch particles from the exhaust to prevent the appearance of harmful substances and thereby protect the environment. The DPF keeps the particles up to a certain capacity level, and once its volume full, the Sprinter ECU computer will automatically increase temp approximately to 1200 F° of the exhaust to burn it. This burn happens while you drive for longer distances on the highway speed in Particulate Filter. But, let’s say you use the wrong oil for your Sprinter (not 229.52) and you do not drive a van on longer highway speed, only in city mode. It can create a build-up accumulation of particles that can not be burned automatically during auto regeneration. So it will be a clogging filter as well as interrupting the flow of exhaust, at that point clogs limits exhaust flow and blocks it, so van needs manual regeneration.
If after regeneration ash level is still very high then only one choice left: replace old DPF.
An additional cause of the “clogs” problem may be a defective temp sensor, or EGR, or any problems that maintain DPF from doing regeneration. In those cases, we will hook up diagnostic tools and instruments and demand van manual regeneration.
10. Oil Cooler Leaking
Oil leaks commonly from the oil cooler gasket on Sprinters from 2007+. You can say this gasket the Achilles Heel of the Sprinters with V6 engine. Usually, this problem may occur after 120K miles. MB has modernized this gasket to improved material called Viton which prolongs life. You should know right away: this is a costly repair. Because it’s challenging to get to an oil cooler. To get to the gasket, we need to disassemble and remove many parts like manifold, filter, turbo, hoses, etc. Depending on model year gasket replacement from $1,500-$1,900
11. Intercooler Hose Leaking
The turbo to intercooler hoses, as well as the intercooler to intake hoses, are without a doubt BOTH OF THESE breaking down (cracking) and blowing and cracking out at the ends (sides) in the end, leading to the engines to go right into “limp home mode.” These hoses have a metallic fitting “formed” onto the hoses. These hoses breakdown failure start out along with cracks developing at the fitting. In the beginning, the very small crack split might create} an “occasional” limp home mode issue and after that apparently go back to normal mode. Pretty soon, these tiny small cracks “blow out” and even come to be significantly big cracks, setting the engine in limp and also destroying your timetable and plans. One of the most frequent hose to crack is actually the driver’s side intercooler to intake hose although both of these hoses are definitely experiencing this breakdown.
What are the Most Common and Typical
Troubles With used Sprinter Vans?
“Rumble Strip” Noise or Torque converter
Injector issue or “Black death“
Glow Plug Failure
Broken Exhaust Flex Pipe
Start Count Down
Losing power Limp mode
Clogged DPF
Air leak in Turbo Resonator
DEF Heater Failure
Oil Cooler Leak
Intercooler Hose Leaking
We service all Sprinter Vans in Livonia, MI
What Do We Offer
- Free Computer Diagnostic
- Free Estimates
- Oil change
- Fuel Filter Change
- Engine Air Filter and Cabin Air Filter Service
- Alternator Replacement
- Starter Replacement
- AC Compressor Replacement
- Brake Service and Repair
- Struts and Shock Replacement
- Drive Belt Replacement
- All Pulley’s Replacement
- Belt Tensioner Replacement
- DEF (BlueTec) Service
- DPF Service
- Fuel Injector Replacement
- EGR Replacement
- Fan Clutch Replacement
- Glow Plugs Replacement
- Coolant System Hose Replacement
- Water Pump Replacement
- Transmission Service
- Turbo Hoses Replacement
- Tire Rotation
- Transmission Conductor Plate Replacement
- Driveshaft Replacement
- Rear Axle Service
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