Faults and recalls.

Engine / equipment

OM642 3.0 V6 CDI/BlueTEC (280/300/320/350 CDI, ML, GL, R, Sprinter)

Period mentioned

2005 onwards

Symptoms

Oil pooling in the engine's V, burning oil smell, drips under the engine; or a hiss or chirp next to an injector with an exhaust smell.

Possible cause described

The oil cooler seals (in the engine's V) degrade. Separately, injector washers leak combustion gas and carbon builds up around the injector.

Check for the garage

Visual inspection of the engine's V and the base of the injectors.

Cost cited in the source

Oil cooler seals: labour-heavy, approx. €800–1,800 (estimate)A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.2, 1.4, 1.9 and 2.0 TDI unit-injector (PD) engines, including the VW-sourced 2.0 CRD in Chrysler, Dodge and Jeep

Period mentioned

2000–2010

Symptoms

Growing noise from the cylinder head, power loss and rough running (cams and lifters); unstable idle, smoke or hesitation (injectors); on the 16-valve 2.0 TDI, coolant loss with no visible leak from a cracked head.

Possible cause described

The camshaft also drives the unit injectors and carries a heavy load: without VW 505.01 oil the lobes and lifters wear. 2.0 TDI PD injectors fail frequently. Some 16-valve 2.0 TDI heads (part number ending in A) crack; VW considered it fixed by the end of 2006.

Check for the garage

Check the oil history (VW 505.01), listen to the head, check injector balance rates with a diagnostic tool and, on the 16-valve 2.0 TDI, read the head part number (03G 103 351) and look for coolant loss.

Cost cited in the source

Camshaft and lifters: approx. €400–800; 2.0 TDI PD injectors: €900–2,000A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 120,000–200,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

OM646 2.1/2.2 CDI (C 200/220 CDI W203 and W204, E 200/220 CDI W211, Vito, Sprinter) and the 2.2 CRD in the Chrysler PT Cruiser

Period mentioned

2002–2010

Symptoms

Puffing or “chuffing” at idle, a diesel smell under the engine cover and a hard black crust around the injectors; power loss from sooted intake flaps or turbo.

Possible cause described

The copper washer under each injector fails and combustion gases escape, carrying diesel and oil that harden into a black crust (“black death”). Soot also seizes the intake flaps and turbo mechanism. Otherwise it is a very robust engine.

Check for the garage

Remove the engine cover and look for black residue around the injectors, listen at idle and check the intake flaps.

Cost cited in the source

Injector washers: approx. €200–800 depending on how advanced the crust isA rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: from 150,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

300C (LD) 3.6 V6 with the 8-speed automatic

Period mentioned

2016

Symptoms

When braking down a hill, or when lifting off suddenly after hard acceleration, the gearbox stays in a low gear and is slow to upshift, with the engine revving high. The rest of the time it shifts normally and there are no warning lights.

Possible cause described

It is a behaviour of the gearbox control unit (TCM) software. FCA improves it by reprogramming the TCM with the latest software (revised bulletin 21-063-15), for 2016 300s with the 3.6 V6 built up to 31/5/2016, also in Europe.

Check for the garage

Tell the garage in which situations it happens and ask them to check whether the gearbox control unit has the latest software before replacing gearbox parts.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Grand Voyager (RT) and 300C (LD) with multi-zone climate control

Period mentioned

2012–2015

Symptoms

With automatic climate control and the same temperature on both sides, one side gets noticeably colder air; with no warning.

Possible cause described

The sun sensor on the dashboard gives a false reading on one side. It leaves no fault code. According to Chrysler's technical tip (July 2016), the garage checks it by shining an incandescent lamp on each side of the sensor and seeing that both readings change equally.

Check for the garage

Check that nothing is covering the sensor on the dashboard. At the garage, ask for the sun sensor test before replacing flap motors.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

3.6 V6 Pentastar: Jeep Grand Cherokee, Wrangler and Gladiator, Chrysler Grand Voyager and 300C, Lancia Thema and Fiat Freemont

Period mentioned

2011 onwards

Symptoms

Oil spots under the car, oil on the block below the housing (in the engine’s “V”), frequent top-ups and, in serious cases, a low oil-pressure warning; sometimes coolant leaks too.

Possible cause described

The plastic housing that holds the oil filter and cooler sits in the middle of the engine, exposed to heat: with heat cycles it warps and cracks. Overtightening the filter cap also damages it. Chrysler revised the design in 2014, but leaks still occur.

Check for the garage

Look for oil in the centre of the engine and under the car; do not overtighten the filter cap. The usual repair is replacing the whole assembly (aluminium versions exist), removing the intake manifolds, with new gaskets.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

2.8 CRD by VM Motori: Jeep Cherokee, Wrangler, Chrysler Voyager, Dodge Nitro and Lancia Voyager

Period mentioned

2001–2018

Symptoms

Hesitation, smoke and loss of power from the EGR or particulate filter; a failing turbo or intercooler; if the timing belt breaks, serious damage (interference engine).

Possible cause described

The block is considered robust: problems usually come from the ancillaries (turbo, intercooler and emissions equipment, especially the EGR valve). Owners point out that the timing belt is expensive and must be changed on time (about 160,000 km).

Check for the garage

Check when the belt was changed; read the EGR and filter codes; check the turbo and intercooler pipes.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

VM Motori 3.0 V6 diesel (A630, “EcoDiesel”): Jeep Grand Cherokee and Gladiator, Chrysler 300C, Lancia Thema and Maserati Ghibli, Quattroporte and Levante

Period mentioned

2011 onwards

Symptoms

Coolant loss, white smoke or combustion in the intake manifold (cracked EGR cooler); deep metallic knock and the oil-pressure warning (bearings); on engines from 2020, low oil-pressure warnings or a failing high-pressure pump shedding metal.

Possible cause described

According to mechanics and owners, the EGR cooler cracks from thermal fatigue (Chrysler recalled it) and the crankshaft bearings can fail from lugging at low revs or carbon in the oil passages. On the third generation (from 2020) there was a recall for the Bosch CP4.2 fuel pump. Maserati uses the same VM engine in its diesels.

Check for the garage

Check the EGR-cooler and pump campaigns by VIN; watch the coolant and oil pressure; with knocking or the oil warning, stop. Avoid lugging the engine at very low revs under heavy load.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Chrysler Crossfire 3.2 V6 (Mercedes engine), also the SRT-6

Period mentioned

2003–2008

Symptoms

Coolant loss; on the SRT-6, the supercharger cuts out and the car loses power; leaks from the rocker cover and sump; failing windows and locks.

Possible cause described

What Car? considers the Mercedes 3.2 durable if serviced. TrueDelta owner logs record repeated auxiliary water-pump replacements (the SRT-6 intercooler pump fails in the heat), oil leaks and crankshaft-sensor failures.

Check for the garage

Watch the coolant level; on the SRT-6, check the supercharger pulls when hot; look for oil under the engine; ask for the history and whether the Takata airbag recall was done.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Model-year 2010 Chrysler Sebring, Dodge Avenger and Nitro, Jeep Cherokee (KK), Commander and Grand Cherokee

Period mentioned

Model year 2010

Symptoms

Brake failure without warning, with a risk of a crash.

Possible cause described

A brake-system part was fitted malformed or was missing (found at the Toledo North plant in November 2009). Chrysler recalled 24,177 vehicles, mostly Dodge Ram, plus the 2010 models listed.

Check for the garage

Check by VIN whether the car was in the campaign and whether it was done.

Cost cited in the source

Free under the recall.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Chrysler 300C LX (V6 and V8 petrol, 3.0 CRD)

Period mentioned

2005–2012

Symptoms

Knocks over bumps from the front control arm, lower ball joint and tie rod (part redesigned and back-ordered); a creaking rear axle; tyre-pressure sensor valves that corrode; electric mirrors not returning to position; rear seat belts locking; CAN-bus faults. On the 3.0 CRD: limp mode from the turbo boost regulator and the swirl-flap motor.

Possible cause described

Cases collected by Honest John. The valve corrosion comes from the galvanic pair between metal caps and the valve; the CAN faults, from boxes translating German and American codings (Mercedes base).

Check for the garage

Use plastic valve caps; check the front suspension; on diesels, read the turbo fault codes.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Chrysler PT Cruiser (petrol and 2.2 CRD)

Period mentioned

2000–2010

Symptoms

A fuel line chafing on the air-conditioning service port and leaking petrol (2001); a fuel-pump module flange that can leak in a rollover (2001–2002); a power-steering pressure hose rubbing on the differential cover on 2.4 automatics, with a fire risk (2001–2005); a dual-mass flywheel pin that comes loose and lodges between the flywheel and clutch disc on manuals (2003); rear quarter windows that can come off (2005–2006).

Possible cause described

Defects documented by US recalls; European cars may have equivalent campaigns: check by VIN.

Check for the garage

Check campaigns by VIN; look for fuel and steering-fluid leaks.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Chrysler Voyager and Grand Voyager RG (Town & Country in the US)

Period mentioned

2001–2007

Symptoms

A lower control-arm pivot bolt that can break and release the arm (2001); a tank-valve weld that can leak fuel (2002); a steering cooler hose that splits on the 3.3 and 3.8 V6, with a fire risk (2002–2004); air-conditioning water dripping onto the radio and shorting it (2001–2002); the power-liftgate latch (2003); a wiper-motor shaft that breaks (2005–2006); airbag sensors corroding where roads are salted (2005–2006).

Possible cause described

Defects documented by US recalls; European cars may have equivalent campaigns: check by VIN.

Check for the garage

Check campaigns by VIN; check the front suspension and steering-fluid leaks.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database