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

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… Repairs typically run $400-$1,500. Severity: high.

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

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 w… Repairs typically run $300-$1,200. Severity: high.

What is the 2007-2022 Mercedes-Benz Sprinter Front Lower Control Arm Ball Joint Wear (Radial Play, Inner Front Tire Wear)?

The Sprinter's front independent suspension puts the lower ball joints in constant compression under a heavy nose load. On vans in delivery/multi-drop service the lower ball joints wear out very quickly - fleet operators report annual replacement, with highway-mileage vans lastin… Repairs typically run $500-$1,600. Severity: high.

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

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 mista… Repairs typically run $900-$2,000. Severity: high.

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

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… Repairs typically run $200-$600. Severity: medium.

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

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 h… Repairs typically run $300-$1,500. Severity: medium.

What is the 2007-2013 Mercedes-Benz Sprinter Alternator-to-Starter "Y-Cable" Fusible Link Corrosion (Low Charging Voltage, No-Start)?

On NCV3 Sprinters the heavy charging cable runs from the alternator to the starter stud and then on to the battery, with a fusible link spliced into the harness (the so-called Y-cable). The splice is covered only by heat-shrink that is not truly watertight. Under sustained high-c… Repairs typically run $200-$700. Severity: medium.

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

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 ho… Repairs typically run $150-$2,500. Severity: medium.

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

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 code… Repairs typically run $50-$900. Severity: medium.

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

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… Repairs typically run $300-$3,000. Severity: medium.

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

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 run… Repairs typically run $550-$1,900. Severity: medium.

What is the 2007-2022 Mercedes-Benz Sprinter Water Pump and Thermostat Housing Coolant Leak (OM642 V6)?

On the OM642 the coolant pump and the thermostat housing sit together at the front of the engine and share a common failure story: the pump's shaft seal weeps and the thermostat housing gasket hardens and leaks. Owners report slowly disappearing coolant with no obvious puddle, be… Repairs typically run $500-$1,400. Severity: medium.

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

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, uncontroll… Repairs typically run $250-$700. Severity: medium.

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

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… Repairs typically run $200-$800. Severity: low.

What is the 2007-2018 Mercedes-Benz Sprinter HVAC Blower Motor Resistor / Regulator Failure (Fan Works Only on High or Cuts Out)?

The Sprinter's blower speed is controlled by a resistor/regulator module mounted in the airflow near the blower motor. It runs hot by design and the internal components fail from repeated heat cycling. The classic failure mode is that the fan works only on the highest speed setti… Repairs typically run $100-$450. Severity: low.

What is the 2007-2022 Mercedes-Benz Sprinter Central Locking / Door Lock Actuator Failure (Sliding and Rear Doors Won't Lock Remotely)?

Sprinter door lock actuators fail from a mix of water getting past the door seals and rusting the internal mechanism, worn internal gears after years of commercial-duty cycling, and - very commonly on the sliding door and rear barn doors - resistance in the sliding contact block… Repairs typically run $150-$700. Severity: low.

Mercedes-Benz · Known Issues

2009 Mercedes-Benz Sprinter Problems & Issues

2009 model year · 4,400+ owner reports · Updated September 2026

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According to Au7o's analysis of 4,400+ owner reports, the 2009 Mercedes-Benz Sprinter has 18 documented known issues, with 6 rated critical. The most serious are Steel Brake Line Corrosion and Rupture at the Chassis Clip Points (Road-Salt Vans) ($250-$1,500 repair), Turbocharger VNT Actuator Failure (Boost Faults, Limp Mode) ($400-$1,500 repair), 722.6 (NAG1) Automatic Transmission Conductor Plate Failure / Limp Mode ($300-$1,200 repair), Front Lower Control Arm Ball Joint Wear (Radial Play, Inner Front Tire Wear) ($500-$1,600 repair), Water Intrusion Into the SAM / Body Control Module and Engine ECU (Multiple Unrelated Electrical Faults) ($300-$2,500 repair) and OM642 V6 Oil Cooler Seal Leak (Oil in the Engine Valley) ($900-$2,000 repair). The most commonly reported issue is Turbo Resonator Crack and Boost Leak with 1,800 owner reports. Across all issues with published estimates, repair costs range from $50 to $3,000. DIY maintenance guides at .

Frequently Asked Questions

What are the most common Mercedes-Benz Sprinter problems?

According to Au7o's analysis of 4,400+ owner reports, the 2009 Mercedes-Benz Sprinter has 18 documented issues. The most frequently reported are: Steel Brake Line Corrosion and Rupture at the Chassis Clip Points (Road-Salt Vans), Turbocharger VNT Actuator Failure (Boost Faults, Limp Mode), 722.6 (NAG1) Automatic Transmission Conductor Plate Failure / Limp Mode. Of these, 6 are rated critical and should be addressed promptly.

Is the Mercedes-Benz Sprinter reliable?

The 2009 Mercedes-Benz Sprinter has 18 known issues documented across 4,400+ owner reports. 6 issues are rated critical: Steel Brake Line Corrosion and Rupture at the Chassis Clip Points (Road-Salt Vans) and Turbocharger VNT Actuator Failure (Boost Faults, Limp Mode) and 722.6 (NAG1) Automatic Transmission Conductor Plate Failure / Limp Mode and Front Lower Control Arm Ball Joint Wear (Radial Play, Inner Front Tire Wear) and Water Intrusion Into the SAM / Body Control Module and Engine ECU (Multiple Unrelated Electrical Faults) and OM642 V6 Oil Cooler Seal Leak (Oil in the Engine Valley). 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 $3,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Steel Brake Line Corrosion and Rupture at the Chassis Clip Points (Road-Salt Vans), typically costs $250-$1,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2007-2018 Mercedes-Benz Sprinter Steel Brake Line Corrosion and Rupture at the Chassis Clip Points (Road-Salt Vans)?

The Sprinter's hard brake lines run the length of the chassis and are held by plastic clips. Salt, grit and moisture pack into the clips and sit against the steel line, so corrosion is concentrated exactly where the line is clamped and hidden from view. Owners in salt-belt states… Repairs typically run $250-$1,500. Severity: high.

All 18 Known Issues

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 is the 2007-2018 Mercedes-Benz Sprinter Steel Brake Line Corrosion and Rupture at the Chassis Clip Points (Road-Salt Vans)?

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

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

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

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

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

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

2007-2018 Mercedes-Benz Sprinter: Water Intrusion Into the SAM / Body Control Module and Engine ECU (Multiple Unrelated Electrical Faults)#

2007-2013 Mercedes-Benz Sprinter: Alternator-to-Starter "Y-Cable" Fusible Link Corrosion (Low Charging Voltage, No-Start)#

2007-2022 Mercedes-Benz Sprinter: Central Locking / Door Lock Actuator Failure (Sliding and Rear Doors Won't Lock Remotely)#

2007-2018 Mercedes-Benz Sprinter: Steel Brake Line Corrosion and Rupture at the Chassis Clip Points (Road-Salt Vans)#

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

2007-2022 Mercedes-Benz Sprinter: Front Lower Control Arm Ball Joint Wear (Radial Play, Inner Front Tire Wear)#

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

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

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

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

2007-2022 Mercedes-Benz Sprinter: Water Pump and Thermostat Housing Coolant Leak (OM642 V6)#

2007-2018 Mercedes-Benz Sprinter: HVAC Blower Motor Resistor / Regulator Failure (Fan Works Only on High or Cuts Out)#