KNOWN FAULTS · Mercedes-Benz

Mercedes-Benz Vito / Clase V (W638) 2.2 CDI common problems.

2000–2003 · Diesel

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

2 known faults with sources

Applies if: The Vito W638 2.2 CDI is the OM611, the OM646’s predecessor with the same type of injector washers.

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.

Applies if: Weak points of this model from inspections, breakdown statistics and recalls; anything specific to one engine is stated in the sheet.

Rust and engines on the Vito and V-Class W638Known weak points

Engine / equipment: Mercedes Vito and V-Class W638 (petrol and CDI)
Period mentioned: 1996–2003
Symptoms: Very fast rust on the bonnet, wings and underside; head gaskets, alternator, oil and water pumps with leaks that overheat the engine; on CDIs, injectors, injection pump and glow plugs; a bell-housing seal that leaks oil and makes the clutch slip; driveshafts, ignition and noisy gearboxes; at inspection, rusty or cracked brake pipes and hoses.
Possible cause described: According to CarWiki, the panels were stamped with poorly finished edges that encourage corrosion; faults increase from about 80,000 km.
Check for the garage: Check rust and brake pipes thoroughly; check coolant and oil 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.