KNOWN FAULTS · Mercedes-Benz

Known faults for the Mercedes-Benz Sprinter (T1N).

2000–2006 · Diesel

Sources are not verified in real time and no entry confirms that your car is affected.

2 known faults with sources

Engines: 2.2 CDI (OM611/OM646) (Diesel)

OM646 injector seals (black death)Injection / intake

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.

Engines: 2.2 CDI (OM611/OM646) (Diesel) · 2.7 CDI (Diesel)

Applies if: Only if fitted with the automatic gearbox described in the record.

13-pin connector leak on the 722.6 gearboxAutomatic gearbox

Engine / equipment: 722.6 five-speed automatic (5G-Tronic), not the 7G-Tronic: C-Class W203, E-Class W210 and W211, CLK, S-Class W220, ML W163, SLK, SL R230, Vito and Sprinter with this gearbox
Period mentioned: 1996–2013
Symptoms: Oil around the electrical connector on the side of the gearbox, harsh shifts or slipping, delayed engagement and limp mode: the car stays in one gear (usually 2nd and reverse after a restart) and the engine light comes on.
Possible cause described: The plastic adapter of the 13-pin connector has O-rings that harden and let oil out. Oil can wick up inside the wiring to the gearbox control unit and damage it. If the problem persists after replacing the connector, there may be oil in the harness, a damaged wire or a conductor plate fault.
Check for the garage: Read the gearbox control unit codes before switching off if possible (a restart can clear them). Look for oil at the connector and, with it unplugged, on its pins and at the control unit plug. According to the service bulletin, the connector should only be removed with gearbox oil below 50 °C to avoid damaging the conductor plate, and the harness must be routed without tension.
Cost cited in the source: Connector adapter: about $15–20 in parts (US prices quoted in the sources), plus the lost fluid; labour extra. If oil has reached the control unit, the repair is bigger.A rough figure from the original database, not an up-to-date quote.