Mercedes sprinter turbo cutting out

[Dave SL]

We're having problems with one of our Sprinters at work, a 2001 313 MWB.

At high speed the turbo seems to cut-out (this is very unnerving when tanking down the motorway). The only way to correct things is to turn the ignition off and back on after which it's fine. It was happening every week or so but has got progressively worse, happening 5 times on one long journey last week.

The vehicle's got a full main dealer service history and has been back a couple of times with this fault. I believe they originally replaced or overhauled the turbo under warranty when this first happened. Most recently they apparently repaired a chaffed cable on the wiring harness but it's not solved the problem and as I say it's getting worse.

Has any body got any ideas? I'm less concerned about the garage bills than getting the van fixed quickly. My concern is that the Merc dealer seems unable to sort it.

 

[Sprint'n'Go]

This sounds like it could be a problem with the vacuum system. There are a number of thin brown pipes running around the engine bay these go from the brake servo to the turbo and also the air box as it is used to activate the air recirculation. If any of these pipes have split or been holed or come unattached then that could be your problem. Apparantly it is quite common for the pipes to come off the air box, there are 2 pipes attached to it. it's on the passenger side of the engine bay tucked up in the corner by the wing and under the windscreen. I have experienced this myself so it is definitely worth checking here and all along the other pipes.

 

[dava]

Sounds like it could be the turbo boost sensor or it's associated wiring. The sensor is located in the air intake pipe passenger side down the side of the radiator and it goes to the intercooler, it's held in with 2 torx screws and a multi plug wiring on to it, in fairness this would bring up a fault code and be logged in the ECU and your MB garage would know this. Also check the wiring from this wich goes into the loom that runs down the front of the radiator, lower passeneger side corner, if you take the front grille off you can see it better. The harness rubs through on the corner of the radiator and causes this problem, quite a common fault on sprinters, while your there just check the drivers side harness as well, although not as common as the passenger side worth looking at it, this may not show up as a logged fault unless it's permently shorting to earth. Another thing to check is the harness that goes to the starter, this is clipped to the engine block by a metal clip this rubs through and also causes cut outs or dying, again may or may not show up as a fault code, it depends on wether it is intermittent or not and by what you are saying it's intermittent. As you accelorate the engine moves on the mountings and goes to earth causing a loss of power.
Hope this is of help.

 

[Cnics]

I have had this. It happened in July twice on the same trip, with a simple restart it cured it, i was only 10 miles from my destination and had been traveling nearly 400 miles. The van was parked up and left where it was for a few hours whilst i did my work. On setting off again it was fine all the way home. I thought no more about it, it was extremely hot that day and i'd been pushing the van quite hard with a substantial load as i was running short of time, i put it down to maybe the turbo overheating etc and a safety device kicking in. I have since done around 20,000 miles in it without problems. Until Saturday night.

Van, loaded, pulling a small trailer up the M5 at about 3am. 2 more people in the front asleep so no radio on, van is very quite now since i've done the fan.
We hit a bit of an incline so i push a little more on the throttle to hold a steady 60mph i hear the turbo whistle a little fo a second and then it seems to get a fair bit louder (not a worryingly loud noise but noticeable to those who know). At this moment the van lost alot of power (ie no turbo). I struggled to keep it much above 50mph (in 4th by this point). A quick switch off and on whilst traveling cured this. It did this a further 3 times on the journey, each time the same, it seemed to be when i touched the throttle a bit more it would lose the power. the trip was from Plymouth to Gt Yarmouth but after the M11 stretch it didn't do it again, coming home last night to the Midlands didn't do it once. I had no sleep over the weekend so i've not had chance to look at anything yet. But if these symptons seem any different to anyone and they have other suggestions i'd be happy to hear them.

 

[mrfwonderful2000]

The same thing has been happening to my 2001 311 Sprinter for the last 2 years since replacing the faulty turbo with a working used one! Merc independant cant figure it out!

 

[Cnics]

And a further 1300 miles on and it has not caused any more problems, If i can keep going 6 months or so between issues like that and a simple switch off and on cures it then i can't see the tool kit coming out just yet! The only worry is if it gets worse and will not rectify itself, i'm often pulling a HEAVY load so sans turbo really works it hard.

 

[Phil_C36_AMG]

There is a valve just under the airbox, 1 electrical plug and 3 vacuum pipes, it is the boost control solenoid and its common to fail giving a total lack of boost pressure.

 

[Cnics]

Ok this problem has reared its head again a few times, a few the other week (then i've done 1000 miles again with no problems) and tonight i have done say 40 miles. and i got a takeaway on the way home, parked up to eat it left it ticking over for 10 minutes say. went to pull off and had nothing at all. no amount of switching off and back on again would cure it. I'll have to see if its still the same in the morning.

the van had a front end knock (clown reversed into it whilst it was parked outside my house) which badly dinted the front end and shorted a load of wires out that run under the front of the intercooler. I THOUGHT i had sorted that wiring out. Perhaps i have not. i would be interested to know in a bit more detail where abouts these wires are dava.

I shall also check what Phil says.

My work has been quiet since Christmas. its just starting to build back up. Sods law says i'm going to have to have the van off the road when i'm busy.

 

[lackofgrip]

having owned a 200sx which is a turbo i would say 99% its a turbo hose thats leaking under pressure or actuator that is sticking

 

[appi-AUTO-fix]

Thanks guys....this helped alot....made a youtube vid too and put your this link on....solid advice