Mercedes-Benz · Known Issues

2007-2025 Mercedes-Benz Sprinter Problems: 13 Issues Every Owner Should Know

2007-2025 model years · 8,700+ owner reports · Updated June 2026

According to Au7o's analysis of 8,700+ owner reports, the 2007-2025 Mercedes-Benz Sprinter has 13 documented known issues, with 5 rated critical. The most serious are Diesel Injector Failure and Black Death (OM651/OM654) ($300-$3,000 repair), DEF/AdBlue SCR System Faults and Derate ($500-$3,500 repair), OM642 V6 Oil Cooler Seal Leak (Oil in the Engine Valley) ($900-$2,000 repair), 722.6 (NAG1) Automatic Transmission Conductor Plate Failure / Limp Mode ($300-$1,200 repair) and Turbocharger VNT Actuator Failure (Boost Faults, Limp Mode) ($400-$1,500 repair). The most commonly reported issue is Diesel Injector Failure and Black Death (OM651/OM654) with 2,400 owner reports. Across all issues, repair costs range from $50 to $3,500. DIY maintenance guides at au7o.io.

All 13 Known Issues

Community Reported

2,400 owners

On the 2010-2025 Mercedes-Benz Sprinter, sprinter diesel injectors develop seal failures leading to the "Black Death" condition where combustion gases leak past the injector copper washers, carbonizing and creating hard tar deposits around the injector bore. This is the most common and feared Sprinter repair, as advanced cases require expensive injector extraction procedures when the carbon welds the injectors in place.

This issue also affects: Mercedes-Benz GLK-Class

Common Symptoms

Black tar buildup around injectors visible under engine cover
Ticking noise from engine
Diesel smell in cab
Rough idle
Loss of power under load

How to Fix

Replace injector sealing washers and clean injector bores at the first sign of any leaking. If caught early this is a simple and inexpensive repair. Advanced cases with seized injectors may require specialized extraction tools or even cylinder head removal. Replace all injector washers simultaneously.

What you need to fix it

The exact parts — OEM, plus what owners actually use. Skip the internet hunt.

From owners — upgrades & tips (2,400+ fixed this)

NoteInspect your injector area at EVERY oil change. Black Death starts as a small seep and becomes catastrophic. A $20 copper washer replacement now prevents a $3,000 injector extraction later.

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Typical repair cost:$300 - $3,000

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High Confidence2,400 reportsLast reported by owners Mar 2026Reviewed Mar 2026

On the 2007-2021 Mercedes-Benz Sprinter OM642 3.0L V6 diesel, on 3.0L V6 OM642 diesel Sprinters the engine oil cooler sits deep in the valley of the V, sealed to the block by O-rings. The early orange seals harden and shrink from constant heat and weep engine oil, which collects in the valley and runs down the back of the block, often mistaken for a rear main seal leak. Owners see 'Check Oil Level'/'Oil Level Low' messages, a dropping dipstick and oil stains under the van; in severe cases oil migrates into the coolant. Mercedes upgraded to purple Viton seals around 2010, which reduced but did not eliminate failures.

This issue also affects: Mercedes-Benz G-Class

Common Symptoms

Check Oil Level / Oil Level Low warning
Oil dripping at back/bottom of engine valley
Oil stains under parked van
Falling dipstick level
Oil contamination in coolant in severe cases

How to Fix

Replace the oil cooler O-ring seals (use the factory PURPLE Viton seal kit, not the early orange seals); most shops replace the oil cooler itself plus all reassembly gaskets while in there. The job is labor-intensive because the turbocharger, intake manifolds and EGR cooler must come off to reach the cooler. Budget 8-10 hours of shop labor.

Typical repair cost:$900 - $2,000

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

On the 2007-2022 Mercedes-Benz Sprinter, sprinter diesels use a variable-geometry turbo whose vane position is controlled by an electronic actuator (PWM-driven on the OM642; vacuum/wastegate-controlled on some OM651). The actuator's electronics or worm-drive wear out, so the ECU can no longer command correct boost. The van loses power intermittently and falls into limp mode, often with under/over-boost codes. A complication on the OM642: each actuator carries vehicle-specific programming, so an un-coded replacement will itself throw a fault and stay in limp mode.

This issue also affects: Mercedes-Benz GLA, Mercedes-Benz G-Class, Mercedes-Benz C-Class

Common Symptoms

Intermittent power loss / limp mode
Underboost or overboost
Check engine light
Poor acceleration
Higher fuel consumption

How to Fix

Confirm the fault with a scan (e.g., P2010 pointing to the turbo actuator Y77/1, or P0299 underboost) and rule out boost leaks (cracked hoses, failed turbo resonator) and a bad vacuum transducer first. Replace or rebuild the turbo actuator; on the OM642 the new actuator must be programmed/adapted to the vehicle. Clear codes after repair.

Typical repair cost:$400 - $1,500

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

Community Reported

1,800 owners

On the 2007-2018 Mercedes-Benz Sprinter 3.0L V6 Diesel OM642, the plastic turbo resonator (charge air pipe) on OM642-equipped Sprinters cracks from heat cycling and vibration, causing a significant boost leak. The engine loses power dramatically, especially under load or when climbing grades. This is one of the most common failure items on pre-2019 Sprinters and typically occurs between 60,000-100,000 miles.

This issue also affects: Mercedes-Benz C-Class

Common Symptoms

Significant loss of power under load
Whistling or hissing noise from engine bay
Black smoke under acceleration
Check engine light with boost codes
Poor fuel economy

How to Fix

Replace the cracked plastic turbo resonator with an upgraded aluminum aftermarket unit. The OEM plastic part will crack again — do not use the original design replacement. Several companies make aluminum turbo resonators that are a permanent fix. Installation is straightforward and takes about 1-2 hours.

What you need to fix it

The exact parts — OEM, plus what owners actually use. Skip the internet hunt.

From owners — upgrades & tips (1,800+ fixed this)

UpgradeRudy's Diesel aluminum turbo resonator is the go-to upgrade. It replaces the failure-prone plastic OEM part permanently. Under $150 and takes an hour to install. (Rudy's Diesel Aluminum Turbo Resonator)
View on Amazon

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Typical repair cost:$200 - $600

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High Confidence1,800 reportsLast reported by owners Dec 2025Reviewed Mar 2026

Community Reported

1,500 owners

On the 2007-2025 Mercedes-Benz Sprinter, sprinter glow plugs fail with age, causing hard starting in cold weather, rough idle when cold, and white smoke on startup. The OM642 V6 is particularly prone to glow plug seizure in the cylinder head, making removal difficult and risking broken glow plugs that require cylinder head removal to extract.

This issue also affects: Mercedes-Benz GLK-Class

Common Symptoms

Hard starting in cold weather
Extended cranking before engine fires
Rough idle for first 30-60 seconds when cold
White smoke on startup
Glow plug warning light staying on

How to Fix

Replace all glow plugs as a set. Apply anti-seize compound to new glow plug threads. On the OM642, use penetrating oil on the glow plugs and allow it to soak before removal to reduce seizure risk. If a glow plug breaks during removal, specialized extraction tools are available before resorting to head removal.

What you need to fix it

The exact parts — OEM, plus what owners actually use. Skip the internet hunt.

From owners — upgrades & tips (1,500+ fixed this)

TipReplace glow plugs proactively every 80,000 miles before they seize. Apply anti-seize compound generously. A broken glow plug extraction on the OM642 can cost $1,000+ in labor alone.

Part links may earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$300 - $1,500

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High Confidence1,500 reportsLast reported by owners Jan 2026Reviewed Mar 2026

On the 2007-2018 Mercedes-Benz Sprinter OM642 3.0L V6 diesel, the OM642 V6 intake manifolds use plastic swirl/runner flaps driven by a small actuator through a plastic connecting linkage. Oil mist and heat make the plastic linkage and pivots brittle; they crack and break, leaving the flaps stuck and triggering P2015 (and runner-control codes). A failed swirl-flap motor (often from an oil leak into the actuator) produces the same fault. The result is rough idle, power loss, a lit engine light and limp mode.

This issue also affects: Mercedes-Benz G-Class, Mercedes-Benz M-Class

Common Symptoms

Check engine light
Rough idle
Power loss / limp mode
Delayed acceleration
Failed emissions test

How to Fix

Repair with an aftermarket metal swirl-flap/runner linkage kit (a permanent fix versus the original plastic parts), or replace the intake manifold(s). A failed actuator motor is sometimes worked around with a resistor bypass. Clear codes after repair.

Typical repair cost:$50 - $900

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

On the 2007-2022 Mercedes-Benz Sprinter OM642 3.0L V6 diesel, the OM642 crankshaft pulley is a harmonic balancer with a bonded rubber ring between an inner hub and outer pulley. With age the rubber degrades and the outer ring separates or wobbles, causing belt-drive vibration, accessory misalignment and squeal. If left unchecked, uncontrolled crank vibration can wear bearings and, in extreme cases, has been linked to crankshaft damage. Owners also report harmonic-balancer bolt failures, usually from improper torque or reusing the bolt.

This issue also affects: Mercedes-Benz G-Class

Common Symptoms

Engine/front-end vibration
Belt squeal or chirp
Visible wobble or separated rubber on crank pulley
Accessory belt misalignment or wear

How to Fix

Replace the harmonic balancer/crankshaft pulley with a new OEM-quality unit, always using a new crankshaft bolt torqued to spec (the bolt is a stretch/torque-to-yield fastener — do not reuse). Inspect the front crank seal and accessory belt while there.

Typical repair cost:$250 - $700

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

Community Reported

1,900 owners

On the 2014-2025 Mercedes-Benz Sprinter, the Sprinter diesel exhaust fluid (DEF/AdBlue) selective catalytic reduction system is plagued by faults in the dosing module, NOx sensors, DEF heater, and SCR catalyst. Failures trigger the dreaded "engine derate" countdown that limits vehicle speed to 5 mph if not resolved, stranding commercial vehicles. The system is sensitive to DEF quality and cold weather.

This issue also affects: Mercedes-Benz B-Class, Mercedes-Benz GLA, Mercedes-Benz V-Class

Common Symptoms

Check engine light with SCR fault codes
Engine derate countdown warning on dashboard
Vehicle limited to 5 mph (derated)
DEF warning light illuminated
Higher fuel consumption

How to Fix

Diagnose the specific failed component with Star Diagnostics — the system has multiple failure points. Common repairs include the DEF dosing module, NOx sensors, DEF heater element, and DEF quality sensor. Use only ISO 22241-certified DEF fluid. A full SCR reset with Star Diagnostics is required after component replacement.

What you need to fix it

The exact parts — OEM, plus what owners actually use. Skip the internet hunt.

From owners — upgrades & tips (1,900+ fixed this)

NoteNever use non-certified DEF fluid. Cheap DEF causes crystallization in the dosing module and destroys the SCR catalyst. Buy from reputable suppliers only. BlueDEF from Peak is widely recommended.

Part links may earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$500 - $3,500

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High Confidence1,900 reportsLast reported by owners Mar 2026Reviewed Mar 2026

On the 2007-2020 Mercedes-Benz Sprinter, sprinter diesels (OM642 V6 and OM651 4-cylinder) recirculate soot-laden exhaust through the EGR valve and cooler. Over tens of thousands of miles the valve and the cooler's small passages choke with hard carbon, causing the valve to stick, EGR flow to read out of range, rough running, power loss and limp mode. Short-trip/urban duty cycles accelerate the buildup. The cooler is often more clogged than the valve and frequently cannot be cleaned, requiring replacement.

This issue also affects: Mercedes-Benz B-Class, Mercedes-Benz GLA, Mercedes-Benz G-Class

Common Symptoms

Reduced power / limp mode
Rough idle
Check engine light
Hesitation under load
Failed emissions test

How to Fix

Scan for EGR codes, then clean or replace the EGR valve and inspect the EGR cooler. A clogged cooler usually must be replaced rather than cleaned. Clear adaptation/fault codes after the repair. Periodic highway driving and quality low-ash diesel oil help slow recurrence.

Typical repair cost:$550 - $1,900

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

On the 2007-2025 Mercedes-Benz Sprinter, sprinters used for city delivery — frequent stops, short trips and long idles — rarely reach the exhaust temperatures needed to complete a DPF regeneration. Soot accumulates until the filter is restricted, lighting the DPF warning, reducing power and eventually forcing limp mode with a speed limit. This is one of the most common operational complaints for urban-duty European-spec diesel vans.

This issue also affects: Mercedes-Benz B-Class, Mercedes-Benz GLA, Mercedes-Benz A-Class

Common Symptoms

DPF warning light
Reduced power / limp mode
Speed limitation
Frequent regeneration attempts
Increased fuel use

How to Fix

If caught early, drive at highway speed for 20-30 minutes at higher RPM to trigger passive regeneration, or perform a forced/active regeneration with a compatible scan tool. A heavily loaded filter may need professional off-vehicle cleaning; a damaged or ash-saturated DPF must be replaced. Long term, schedule regular highway runs to allow regens to complete.

Typical repair cost:$300 - $3,000

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

On the 2007-2018 Mercedes-Benz Sprinter, sprinters with the 5-speed 722.6 (NAG1) automatic use an internal conductor plate that carries the shift-solenoid wiring and the input/output speed sensors. The conductor plate is a known weak point: when it fails the transmission control unit gets bad speed signals, lights the warning lamp and drops the van into limp-home mode, typically stuck in a single gear (often 2nd). Symptoms include harsh or delayed shifts and an inability to shift out of second.

Common Symptoms

Stuck in one gear (limp-home, often 2nd)
Harsh or delayed shifts
Transmission warning / engine management light
No shift out of second gear

How to Fix

Replace the conductor plate (and inspect the valve body) inside the transmission. On the 722.6 the conductor plate does not require programming, but transmission fault codes must be cleared with a scan tool afterward or the van stays in limp mode. Fresh ATF and filter are typically done at the same time.

Typical repair cost:$300 - $1,200

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

On the 2007-2018 Mercedes-Benz Sprinter, older NCV3/W906 Sprinters are well known for rusting at the rear wheel arches, lower door edges, around the rear door hinges and in the wheel-well pinch welds. Thin factory corrosion protection on these high-wear panels, combined with road salt and stone strike, lets rust take hold; owners report bubbling and perforation, and some have seen it begin within the first year/low mileage. The third-generation VS30 (2019+), built with more galvanized steel, is markedly more rust-resistant.

Common Symptoms

Bubbling paint on wheel arches and sills
Surface rust at rear door seams
Bare/chipped metal on arch lips
Perforation in wheel-well pinch welds

How to Fix

Inspect arches, sills, door bottoms and rear door seams at least twice a year. Treat surface rust early before it perforates, apply cavity wax/underbody protection to vulnerable arches, and keep rear-door and arch drains clear so water cannot pool in the seams. Perforated panels require cut-out and weld-in repair.

Typical repair cost:$150 - $2,500

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High ConfidenceVerified0 reportsLast reported by owners Invalid DateReviewed Jun 2026

Community Reported

1,100 owners

On the 2007-2025 Mercedes-Benz Sprinter, the Sprinter sliding door rollers and track wear out from the heavy door weight and frequent commercial use. The upper and center rollers are most commonly affected, causing the door to become difficult to open or close, bind in the track, or hang crooked. In commercial fleet use, this can happen as early as 50,000 miles.

Common Symptoms

Door difficult to open or close
Grinding noise when sliding door
Door hangs crooked or does not close flush
Door sticks partway through travel
Visible wear on roller bearings

How to Fix

Replace the worn door rollers (upper, center, and lower). Clean and lubricate the door track. Check the door alignment and adjust as needed. All three roller assemblies should be replaced simultaneously. Lubricate the track monthly in commercial use environments.

What you need to fix it

The exact parts — OEM, plus what owners actually use. Skip the internet hunt.

From owners — upgrades & tips (1,100+ fixed this)

TipLubricate the sliding door track with white lithium grease every month if the vehicle is used commercially. This doubles the roller lifespan. Clean out debris before applying fresh grease.

Part links may earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$200 - $800

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High Confidence1,100 reportsLast reported by owners Feb 2026Reviewed Mar 2026

Frequently Asked Questions

What are the most common Mercedes-Benz Sprinter problems?

According to Au7o's analysis of 8,700+ owner reports, the 2007-2025 Mercedes-Benz Sprinter has 13 documented issues. The most frequently reported are: Diesel Injector Failure and Black Death (OM651/OM654), DEF/AdBlue SCR System Faults and Derate, OM642 V6 Oil Cooler Seal Leak (Oil in the Engine Valley). Of these, 5 are rated critical and should be addressed promptly.

Is the Mercedes-Benz Sprinter reliable?

The 2007-2025 Mercedes-Benz Sprinter has 13 known issues documented across 8,700+ owner reports. 5 issues are rated critical: Diesel Injector Failure and Black Death (OM651/OM654) and DEF/AdBlue SCR System Faults and Derate and OM642 V6 Oil Cooler Seal Leak (Oil in the Engine Valley) and 722.6 (NAG1) Automatic Transmission Conductor Plate Failure / Limp Mode and Turbocharger VNT Actuator Failure (Boost Faults, Limp Mode). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Mercedes-Benz Sprinter problems?

Repair costs for known Mercedes-Benz Sprinter issues range from $50 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Diesel Injector Failure and Black Death (OM651/OM654), typically costs $300-$3,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What year Mercedes-Benz Sprinter is the most reliable?

Reliability varies across model years of the Mercedes-Benz Sprinter. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2007-2025 Mercedes-Benz Sprinter with 13 documented issues documented across 8,700+ owner reports.

All 13 Known Issues

2010-2025 Mercedes-Benz Sprinter: Diesel Injector Failure and Black Death (OM651/OM654)#

Common Symptoms

How to Fix

What you need to fix it

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2007-2021 Mercedes-Benz Sprinter: OM642 V6 Oil Cooler Seal Leak (Oil in the Engine Valley)#

Common Symptoms

How to Fix

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2007-2022 Mercedes-Benz Sprinter: Turbocharger VNT Actuator Failure (Boost Faults, Limp Mode)#

Common Symptoms

How to Fix

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2007-2018 Mercedes-Benz Sprinter: Turbo Resonator Crack and Boost Leak#

Common Symptoms

How to Fix

What you need to fix it

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2007-2025 Mercedes-Benz Sprinter: Glow Plug Failure and Cold Start Issues#

Common Symptoms

How to Fix

What you need to fix it

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2007-2018 Mercedes-Benz Sprinter: Intake Manifold Swirl Flap Linkage Breakage (P2015)#

Common Symptoms

How to Fix

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2007-2022 Mercedes-Benz Sprinter: OM642 Harmonic Balancer / Crankshaft Pulley Rubber Failure#

Common Symptoms

How to Fix

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2014-2025 Mercedes-Benz Sprinter: DEF/AdBlue SCR System Faults and Derate#

Common Symptoms

How to Fix

What you need to fix it

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2007-2020 Mercedes-Benz Sprinter: EGR Valve and EGR Cooler Carbon Clogging (Limp Mode, P0400-Series Codes)#

Common Symptoms

How to Fix

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2007-2025 Mercedes-Benz Sprinter: Diesel Particulate Filter (DPF) Clogging from Short-Trip / Urban Use#

Common Symptoms

How to Fix

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2007-2018 Mercedes-Benz Sprinter: 722.6 (NAG1) Automatic Transmission Conductor Plate Failure / Limp Mode#

Common Symptoms

How to Fix

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2007-2018 Mercedes-Benz Sprinter: Rear Wheel-Arch and Body Seam Corrosion (Pre-VS30 W906)#

Common Symptoms

How to Fix

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2007-2025 Mercedes-Benz Sprinter: Sliding Door Roller and Track Wear#

Common Symptoms

How to Fix

What you need to fix it

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Other Mercedes-Benz Models

Frequently Asked Questions

What are the most common Mercedes-Benz Sprinter problems?

Is the Mercedes-Benz Sprinter reliable?

How much does it cost to fix common Mercedes-Benz Sprinter problems?

What year Mercedes-Benz Sprinter is the most reliable?

What is the 2010-2025 Mercedes-Benz Sprinter Diesel Injector Failure and Black Death (OM651/OM654)?

What is the 2014-2025 Mercedes-Benz Sprinter DEF/AdBlue SCR System Faults and Derate?

What is the 2007-2021 Mercedes-Benz Sprinter OM642 V6 Oil Cooler Seal Leak (Oil in the Engine Valley)?

What is the 2007-2018 Mercedes-Benz Sprinter 722.6 (NAG1) Automatic Transmission Conductor Plate Failure / Limp Mode?

What is the 2007-2022 Mercedes-Benz Sprinter Turbocharger VNT Actuator Failure (Boost Faults, Limp Mode)?

What is the 2007-2018 Mercedes-Benz Sprinter Turbo Resonator Crack and Boost Leak?

What is the 2007-2025 Mercedes-Benz Sprinter Glow Plug Failure and Cold Start Issues?

What is the 2007-2018 Mercedes-Benz Sprinter Rear Wheel-Arch and Body Seam Corrosion (Pre-VS30 W906)?

What is the 2007-2020 Mercedes-Benz Sprinter EGR Valve and EGR Cooler Carbon Clogging (Limp Mode, P0400-Series Codes)?

What is the 2007-2018 Mercedes-Benz Sprinter Intake Manifold Swirl Flap Linkage Breakage (P2015)?

What is the 2007-2022 Mercedes-Benz Sprinter OM642 Harmonic Balancer / Crankshaft Pulley Rubber Failure?

What is the 2007-2025 Mercedes-Benz Sprinter Diesel Particulate Filter (DPF) Clogging from Short-Trip / Urban Use?

What is the 2007-2025 Mercedes-Benz Sprinter Sliding Door Roller and Track Wear?