State Street Auto ServiceThis 2011 Freightliner Sprinter 2500 Mercedes-Benz OM642 CDI6 6 CYL broke down on the freeway and was towed to our shop in Whitmore Lake, MI. The engine suddenly quit running. This a commercial vehicle with approximately 216,000 miles of hard use on the odometer. The vehicle had been neglected and needed much work by the time it quit running.
Problem
The engine will not crank over, and the DEF counter said 10 starts remaining. This indicates a sudden failure with many possible causes.
Diagnosis
Performed quick vehicle computer self-test and verified error codes present. Pushed vehicle into the shop. Performed OBD scan test and retrieved error codes. Performed mechanical & visual inspections with the vehicle on the hoist. Found exhaust flex joint broken and wiring harness above exhaust burnt and melted. Recommended repair of the exhaust system and wire harness as a starting point to allow clearing error codes & retesting. Reported found problems to the vehicle owner and got permission to proceed with the repair.
Repairs
Exhaust Flex Pipe Repair
Removed necessary components to access flex pipe and cut out old flex pipe from exhaust system. Cleaned and prepared both sections of exhaust pipe for welding new flex joint. Installed new flex joint with exhaust pipe extensions and weld into position. Checked for exhaust system leaks. Reassembled components that were removed during repairs.
Why do Sprinter van exhaust flex pipes fail? Intense vibration from the diesel engine, heavy exhaust system, rust from exposure to road salt and rain, intense exhaust heat, extreme hot and cold cycles, and generally poor design.
Broken Sprinter van exhaust flex pipe
Wiring Repair
Removed necessary components to gain access to the damaged wiring harness. Cut out damaged wiring sections and spliced new wires into the wiring harness. Wiring connections were crimped and weather sealed with shrink wrap. Secured new wiring in fresh wire loom cover and routed in the correct position. Cleared all computer error codes and ran re-test. Additional error codes returned that required additional testing for engine no crank issue.
No Start Problem
Performed additional pinpoint testing. Retrieved error codes after clearing and testing starter circuit active code and found failed starter relay fuse. Replaced with a new fuse, which immediately failed which indicated a short circuit. Further testing indicates the issue is isolated to the fuse block. Removed the fuse block from the vehicle and inspected the fuse holder. Cleaned fuse terminals. Performed resistance testing and found within specifications. Reassembled fuse box, and installed new fuse. The engine cranked and started. Suspect a possible shorted connection in the fuse box or locked-up module. Working as of now, but it should be monitored, and if the issue returns may need to replace the fuse box assembly.
D-RATE DEF Counter On Error
Performed additional pinpoint testing and found the distributor can bus block has a shorted circuit. Removed necessary components to gain access and replaced block. Made all necessary electrical connections and self-tested with the engine on and the scan tool hooked up. Performed performance testing and attempt to perform manual regeneration and block shorted circuit again. Performed additional probing and find additional wires burnt in a different section of the initial wire harness found under the vehicle. The outer wiring cover was not melted, but individual wires inside were damaged. Performed additional wiring harness repairs. Performed DEF self-test and got the vehicle to manually regenerate exhaust this time.
EGR Valve Problem
Performed road test and found engine turbo boost under specifications and engine lacking power. Performed OBD scan test and found error code for EGR valve stuck closed. Performed pinpoint testing and found to need EGR valve replacement. Replaced EGR valve, cleared error code, performed retest, and road test to verify the issue with lack of power is fixed. Let vehicle cold soak overnight and performed second final road test with no issues.
Oil Filter Housing Oil Leak
Clean and degrease Oil Filter Housing and surrounding area. Removed necessary components to gain access and removed oil filter housing from the engine. Inspected mounting points for cracks or damage. Removed old gasket. Cleaned, inspected, and prepared surfaces for a new gasket. Installed new oil filter housing gasket and remounted housing to the engine. Reassembled components that were removed during repair.
Inter-cooler Hose Replacement
Removed necessary components to gain access to and removed both left and right inter-cooler hoses. Inspected mounting points. Installed new hoses and secured them to the vehicle as outlined in the workshop repair manual.
NOTE: Found water in the air tube which suggests water intrusion, which could be sucked into the engine. Removed inter-cooler and drained accumulated water inside as a preventative measure. Removed necessary components to gain access to and removed inter-cooler from the vehicle, drained water, reinstalled inter-cooler, and secured to the vehicle. Reassembled components that were removed during repairs.
Two problems to notice here. First is the oil leak at the front of the engine. Second is the swollen intercooler hose which has deteriorated from the oil from the oil leak
Oil Leak Clean & Degrease
Performed complete engine oil leak clean & degrease. Need to return the vehicle in 500 miles for a recheck for oil leaks.
Premium Diesel Engine Oil Service
Change engine oil and filter. Used premium synthetic 5w30 Mercedes-Benz BlueTec approved synthetic motor oil and high-quality oil filter. Courtesy safety inspection. Test drove the vehicle for sounds, vibrations, or concerns. Raised vehicle on a hoist and performed a visual inspection of steering, suspension, and tires, set TPMS to factory pressure specifications, brake visual inspection, fluid leaks, level, and condition. Top off under-hood fluids.
Transmission Oil Pan Gasket & Filter Replacement
Removed necessary components to gain access to and removed transmission oil pan. Drained transmission oil. Removed old gasket material and cleaned, inspected & prepared both surfaces for new gasket material. Removed the old filter and installed a new filter. Installed new gasket material and secured pan to transmission. Torqued hardware in proper sequence as outlined in the workshop repair manual. Reassembled components that were removed during repairs. Added new transmission fluid.
Fuel Filter Replacement
Removed the air cleaner housing and the fuel lines from the fuel filter. Disconnected the return line and electrical connector. Removed and replaced the fuel filter assembly, and reinstalled the lines and connector. Bled the air from the fuel system and started the vehicle looking for any fuel leaks.
Power Steering Fluid Change
Installed BG power steering system cleaner and allow to work through the power steering system. Performed BG power steering fluid flush using specialized equipment that removes old fluid and replaces it with new fluid. Operate the power steering system to allow new fluid to flow through the system. Check that the power steering fluid is at the correct level.
Upper & Lower Radiator Hose Replacement
EGR Coolant Hose Replacement
Removed necessary components to gain access, drained coolant from the radiator, then removed both upper & lower radiator hose and EGR bypass coolant hose. Inspected all mounting points. Installed new hoses and reassembled any components removed during repairs.
Cooling System Fluid Change
Prepared cooling system for a coolant flush. Added BG coolant cleaning chemical after the engine is up to operating temperature and ran the engine for 15 minutes. Connect the coolant change machine and run. Inspect coolant hoses and clamps. Refill with the proper mix of coolant. Pressure test cooling system. Check the thermostat and cooling fan operation. Check for the correct coolant level.
Tips
The wiring problems could have been avoided if this vehicle had received regular maintenance rather than waiting for a problem. The Sprinter van exhaust flex joint is a common problem that must be regularly monitored.
Many Sprinter van repair costs can be decreased if problems are fixed as soon as they are noticed. Not quickly fixing problems often leads to larger, more expensive problems. Most of the other repairs on this vehicle are expected repairs considering the vehicle's age and mileage.
Many expensive Sprinter Van repairs can be avoided with regular maintenance and inspections, especially oil change services and fuel filter changes. State Street Auto Service knows the Sprinter Van very well. We can help you by recommending what services are essential and what should be watched. We can help save you on Sprinter van service and repair.
Contact State Street Auto Service for Sprinter van repair service near Ann Arbor, MI.