What Are the Most Frequent Mercedes Sprinter Issues?
The Mercedes-Benz Sprinter has built a reputation across Europe as a reliable, spacious, and multifunctional van. Used in delivery services, trades, and camper builds, the Sprinter is a trusted workhorse. But with every generation, new mechanical and electronic issues have surfaced. This guide explores the most frequently encountered Sprinter problems, starting with the latest models and working back to the earliest. We compiled insights from mechanics, vehicle forums, and professional drivers to highlight key fault patterns and offer prevention tips.
Frequent Faults in the Latest Mercedes Sprinter (VS30, 2018–Present)
The third-generation Sprinter introduced advanced infotainment, enhanced driver aids, and front-wheel-drive variants. Despite these improvements, a variety of early-life issues have been reported—especially in electronic systems and emissions management.
Why Does My Sprinter Show AdBlue Warnings?
- Messages like “Start not possible in x miles” are usually due to NOx sensor failure, AdBlue injector crystallization, or dosing module faults.
- Frequent fault codes: P229F, P2200.
- Solutions include sensor replacement, line flushing, and SCR reset via diagnostics.
Do Advanced Driver Assist Systems Randomly Shut Off?
- Lane Assist or Active Brake Assist may deactivate due to misaligned or dirty radar/camera sensors.
- Can be triggered by minor collisions or weather interference.
- Realignment or sensor replacement is often needed; dealership recalibration may be required.
Oil Around the Turbo? Could Be the Oil Separator
- The OM654 2.0 diesel engine can suffer oil separator leaks, leaving oily residue near the turbo and intake.
- May increase oil consumption and affect intercooler pipework.
- Fix: replace crankcase breather unit and gaskets.
Electric Parking Brake Not Releasing?
- Common on FWD variants—usually due to corrosion in the actuator or electronic fault.
- Can cause warning lights or complete failure to disengage.
- May require actuator or full caliper assembly replacement.
MBUX Infotainment Freezes or Reboots
- Owners report issues with MBUX freezing, losing settings, or Bluetooth dropouts.
- Touchscreen lag also commonly noted.
- Software updates or unit replacement may be covered under warranty.
Harsh Shifting in Lower Gears? Check the Transmission Software
- 9G-Tronic automatic may hesitate or shift abruptly between 1st–3rd gears.
- Updates or adaptation resets often resolve it.
- Persistent issues may require valve body inspection or fluid change.
What Problems Affect the Second-Generation Sprinter? (W906, 2006–2018)
This generation saw the transition to more complex emissions systems and electronics. While Sprinters from this era remain popular with fleets, issues related to engine components and exhaust treatment are common.
Why Does My Sprinter Keep Entering Limp Mode?
- DPF or EGR faults often lead to reduced power and illuminated warning lights.
- Fault codes like P2454, P0401, and P2463 indicate pressure sensor or soot overload problems.
- Common fixes include cleaning/replacing EGR valve and sensors or forced regenerations.
Timing Chain Rattle on Cold Start?
- OM651 engines can suffer chain stretch, especially with delayed oil changes.
- Symptoms: rattling noise, rough running, timing errors.
- Prevent engine failure by replacing the chain, tensioner, and guides early.
Glow Plug Warning Light Flashing?
- Could be a faulty glow plug control unit, even if plugs are functioning.
- Located under the intake manifold and prone to heat damage.
- Control unit replacement often resolves starting issues.
Carbon Buildup Around Injectors?
- Known as injector "blow-by", this leads to performance issues and strong fuel smell.
- Check for degraded copper seals or unseated injectors.
- Clean seating surface and fit new seals to prevent head damage.
Sagging Rear End? Faulty Air Suspension or Cracked Springs
- Air compressor failures are common in heavy-use vans.
- Symptoms: uneven ride height or loud compressor noise.
- Leaf springs may also crack under prolonged loading.
Does Your Sprinter Refuse to Start or Unlock the Steering?
- May be caused by a faulty Electronic Steering Lock (ESL) or ignition switch.
- Common on high-mileage vans—look for “Steering Lock Malfunction” message.
- Repairs often involve ESL replacement or reprogramming of immobilizer systems.
Is Rust the Biggest Threat to Older Sprinters? (W901–W905, 1995–2006)
Early Sprinter models are now often affected by age-related wear, especially rust. Still, many remain on the road due to their simple and dependable engines.
Where Does Rust Most Commonly Occur?
- Wheel arches, sills, door edges, and chassis rails are heavily affected.
- Subframe and suspension mounts require close inspection for structural rust.
- Underbody sealing and anti-corrosion treatments are vital for longevity.
What's "Black Death" in CDI Engines?
- Refers to leaking injector seals causing tar-like buildup on the cylinder head.
- Symptoms: strong diesel smell, hissing noise, hard starts.
- Requires seal replacement and sometimes machining of the injector seat.
Is That Whining Noise From Your Gearbox?
- Older manual gearboxes often suffer bearing wear, especially in 5th gear.
- Causes include high mileage and continuous heavy use.
- Rebuild with upgraded bearings is the long-term solution.
Why Is It Hard to Start in Cold Weather?
- Faulty glow plugs or relays often cause cold start problems.
- Indicator light may stay on too long or blink erratically.
- Use resistance tests to identify faulty components.
Does Steering Feel Loose or Make Clunking Sounds?
- Worn tie rods, anti-roll bar links, and steering box leaks are common.
- Older vans especially prone to power steering fluid leaks.
- Timely suspension work avoids more costly repairs.
ABS Lights On? Could Be Brake Line Corrosion or Sensor Issues
- Corrosion near the rear axle is common on older vans.
- ABS sensors may fail due to damaged wiring or corroded hubs.
- Regular inspections and early pipe replacements are highly recommended.
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