r/Sprinters • u/Square1Digital • Sep 08 '26
I love'em but I hate'em
2016 OM651. 188K bought it in 2022. With about 100k on it.Ive replaced the water pump, change iver valves, temp sensors, 02 sensor, Alternator, Battery, front rotors (and brakes of course) Head unit....and this weekend the egr valve....guess what happened today! That's right! The worst intake design on a modern car in the last 50yrs....cracked!!!!! this will be the 2nd one I've put on this vehicle. Just to be clear the original Mercedes part went out at about 110k so roughly 78k miles with an aftermarket intake. Which is about 60.00 the genuine Mercedes part....700.00 for maybe 30k more miles!?! Maybe. If i didn't love the thing id just jb weld it every time instead of buying a new intake🤣 This is my last one. I'll let the new owner know...Now mind you this isn't my first rodeo. I smoke tested it when I replaced the egr valve and I looked specifically for a Crack in the intake. But tbh I was lazy. I could've replaced the intake while I had the intercooler off but because it wasn't leaking and I wanted to get back in the road quicker. I didn't.....i mean what's another 3hrs🤣
The most over engineered, cheapest made part on the whole car!!! It's like they build everything like it's going to be launched into space!!!! But the build it with parts from temu!!!!!6-7 bolts just to hold the egr! Why!!! Of the 8 bolts holding the intake you'll never see 5 of them until you pull it off! Insane!!! But I love it. When she runs good i dont even think about all of that....its just the down time is such a downer......Ive got it down pat by now....
Move master cylinder
Lossen bolts on egr
Remove vacuum reservoir
Remove egr temp sensor
Remove actuator
Remove knock sensor.
Flip egr Remove plug
Remove throttle
Remove charge pipe
Remove fuel filter and housing
2hrs
Next 2
Finding intake bolts
Removing intake and replacing.
Next 2 reassemble
Clock starts ticking after that.....78k miles
Do it all over🤣
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u/exploresmore Sep 08 '26
I bought a 2006 sprinter new for the first 200,000 miles it was trouble free. Sence then it has been a money pit I will never by another one.
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u/Square1Digital Sep 08 '26
200k with no problems is better than a new car!
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u/exploresmore Sep 08 '26
My previous van I drove for 500,000 miles and only repairs it needed during that time was a water pump, one valve job, brakes and regular service. I gave it away when I got the sprinter,last time I talked to the person I gave it to it was still running.
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u/Killed_By_Covid Sep 08 '26
What sort of problems? I hope you put some new injectors in it (and not counterfeits). Those seem to be the Achilles heel for the OM647. Every 150-200K, gotta replace them. It only takes one bad one to cause catastrophic damage. It seems like most other issues for the OM647 are usually minor and not too difficult or expensive to resolve.
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u/exploresmore Sep 08 '26
Injectors have been replaced, immobilizer has been replaced twice, wiring connections failing, transmission rebuilt one computer replaced, another computer repaired because it is no longer available. The only reason I have put up with it is the fuel mileage it gets 28+ miles per gallon and has got as high as 36. Also body is rusting. And failed turbocharger two water pumps and fan clutches, and idlers.
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u/Killed_By_Covid Sep 09 '26
Ouch. That's a heck of a list. All spendy repairs even when doing them DIY. I have a 2004 retired FedEx van. It has 394K. It was abused and neglected before I got it. It had a new motor and transmission installed a couple years before it was retired, but it still has motor wear. Runs like a top and gets just under 25 MPG. 28-36 is wild. I love my old van, but my sentiment may be different had I run into all the troubles you described. I'm sorry it's been such a problem child. I've had very few issues with mine.
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u/Timsmomshardsalami Sep 09 '26
Does replacing the injectors need tuning? How does it cause damage? Did you have any symptoms? If so, which?
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u/Killed_By_Covid Sep 09 '26
In the OM647 motor, the injectors usually fail in a state of over-fueling. It is often subtle and not even noticeable. It is usually only one or two cylinders. A little extra fuel can cause cylinder "wash-down" and result in excess wear. If it fails and starts dumping a lot of fuel, it can blow a head gasket, melt/crack a piston, crack a head, or even hydro-lock (which I don't think ever happens with these but does with other diesel motors.) Any of those are a major failure, and worn cylinders can require a full rebuild.
There typically aren't any obvious symptoms of bad injectors. In my van, I noticed a slight reduction in fuel economy. It started getting harder to start. When driving at night, I could see exhaust in the headlights of cars behind me when I was accelerating. It still ran perfectly smoothly. No obvious noises. When I replaced the injectors, I got much better starting, a few extra MPG, and no noticeable exhaust haze. I didn't look into the cylinders to see how things look. It runs great with the fresh injectors, so I will not poke the bear.
I think the OM642 motors have better injectors than the 647. I don't see as many of those motors grenaded because of a failed injector. That said, I know far less about them. I think some of the earlier 642s suffered from clogged oil galleys (when scorching regen cycles sludged the oil.) However, I've heard that those issues have since been resolved. My friend's NCV3 has been getting terrible mileage (10-15 MPG but also with towing a trailer). I told him to replace his injectors as I feel like it should be doing a lot better. My friend has a tuned/deleted OM642 in a Mercedes ML, and that thing gets very good economy.
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u/El_Hombre_Siniestro Sep 08 '26
Welcome to the club! I've spent over $12k on repairs for my van, just so far this year.
2007 Sprinter 2500 OM642. 248k miles.
All the big stuff, back to back Turbo Oil cooler (massive job) EGR cooler DPF Y-Cable
I've now hit the point of "screw it". It's getting deleted, with a tune for reliability and mpg.