Known faults for the Mercedes-Benz Sprinter (VS30).

Engine / equipment

OM651 2.1/2.2 CDI (C 200/220/250 CDI, E 200/220/250, GLK, Vito, Sprinter)

Period mentioned

2008 onwards

Symptoms

Chain rattle on a cold start; on early units, loud injector knocking; coolant loss from the plastic coolant manifold or the EGR cooler.

Possible cause described

Plastic chain guide and a hydraulic tensioner that loses pressure (the chain is at the rear). Early units used problematic piezo injectors that Mercedes replaced in a campaign.

Check for the garage

Listen to a cold start, check the dealer's injector campaign history and check the coolant level.

Cost cited in the source

Chain: approx. €1,500–3,000 (estimate)A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

OM654 2.0 and OM656 3.0 diesel (C, E, S, GLC, GLE, GLS, G-Class from 2016)

Period mentioned

2016–2026

Symptoms

AdBlue or emissions warnings with a start countdown; particulate filter warning; power loss or rough idle from a dirty EGR.

Possible cause described

These are robust engines; faults concentrate in the emissions system. The AdBlue system (injector, NOx sensors and SCR catalyst) sometimes fails, especially in the cold, and the particulate filter and EGR foul if the car mostly does short trips.

Check for the garage

Read AdBlue and NOx sensor codes with Xentry, check the particulate filter regeneration history and how the car is used (short trips).

Cost cited in the source

AdBlue system: approx. €500–1,200; particulate filter: €1,000–2,000A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: from 100,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

OM654 2.0 diesel in the Sprinter (VS30)

Period mentioned

Intercoolers built before 02/02/2024

Symptoms

Yellow low coolant warning with no leak to be seen; sometimes the engine misfires or surges. Possible codes: P25567B (coolant level too low) and P30040B (temperature sensor after the intercooler).

Possible cause described

The liquid-cooled intercooler (charge air cooler) leaks coolant internally, which reaches the intake and the cylinders. Mercedes-Benz also names two other possible causes: another leak in the cooling system or a modification of the system the brand does not allow. It is described in its XENTRY technical note LI09.41-N-079165.

Check for the garage

Pressure test of the cooling system. If it loses pressure with no visible leak, the garage removes the throttle valve or the charge air temperature sensor to look for coolant inside the intercooler and does a compression test. If confirmed, the coolant is cleaned out of the intake and cylinders and the intercooler (one built after 02/02/2024), glow plugs, oil and filter are replaced.

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

OM654 2.0 diesel in the Sprinter (VS30) with 4th-generation SCR

Period mentioned

Model years 2023 and 2024 (built before 01/08/2024)

Symptoms

Engine warning light on, sometimes with an AdBlue warning, with codes P20F409 (AdBlue consumption too low) or P202E84 (fault of AdBlue metering valve 1, engine side). It happens more with frequent starts and stops.

Possible cause described

According to Mercedes-Benz XENTRY technical note LI49.20-N-079157: a leak in the AdBlue system, an internal fault of AdBlue injector no. 1 (metering valve, engine side) or an air pocket in its line. On model year 2023 and 2024 Sprinters, the design of the AdBlue line causes those air pockets; replacing the tank or the line does not fix it.

Check for the garage

The garage runs the guided tests for those codes, looks for leaks at the AdBlue tank, pump, line and injectors and checks the line does not touch the exhaust. If there is no leak and the injector passes its test, on 2023 and 2024 vans it is enough to reset the AdBlue pump learned values, run the SCR system start-up again and do a test drive of about 30 km; no parts need replacing.

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

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

3.0 V6 CDI OM642 in the Sprinter (906 and 907)

Period mentioned

2006–2026

Symptoms

Bucking or surging always between 1,700 and 1,900 rpm, especially on level roads with a light load; above and below that it runs fine. Sometimes with EGR valve codes and the engine warning light.

Possible cause described

Soot between the EGR valve flap and its seat slows it down, so it does not reach the position the control unit asks for in time, and the valve (and sometimes the boost control) oscillates. Mercedes describes it in information LI14.20-N-073867 (January and June 2026 versions): the EGR valve and cooler are cleaned, or the valve is replaced if the fault is electrical.

Check for the garage

Note the exact rpm at which it happens. At the garage, the manufacturer's test is to unplug the EGR valve and test drive: if the bucking disappears, the EGR is cleaned before replacing injectors or the turbo.

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

Mercedes eSprinter electric (VS30)

Period mentioned

2024–2025

Symptoms

More pedal force is needed and the stopping distance grows; loss of drive and a park lock (P) that may not hold.

Possible cause described

In the US: NHTSA 24V-316 (184 vans) for an ESP software error that increases the force needed to brake, and 25V-090 (689) because the welds on the helical gear of the rear e-axle can fail; the electric axle is replaced.

Check for the garage

Check by VIN whether the campaigns exist in your country; always apply the handbrake when parking.

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