2004 Mercedes-Benz Sprinter

The 2004 Mercedes-Benz Sprinter, also known as the Dodge Sprinter in North America, is a versatile van popular for commercial and recreational use. The 2004 models primarily featured a 2.7L inline 5-cylinder diesel engine, producing around 154 horsepower and 243 lb-ft of torque. A gasoline V6 was also available as an option. Owners often praise the Sprinter for its cargo capacity, fuel efficiency (for a van of its size, particularly with the diesel engine), and relatively high roof, enabling easier movement inside. Common complaints revolve around maintenance costs, parts availability, and some reliability issues, especially related to electrical components and diesel-specific parts.

Engine

2.7L Inline 5-Cylinder Diesel

• Black Death (Injector Seal Leaks)
  • Description/Symptoms: Fuel injector seals fail, allowing combustion gases to escape and form a black, tar-like substance around the injectors. This can lead to fuel leaks, poor engine performance, and eventual injector failure.
  • Solution: Replace the copper injector seals and clean the affected area. In severe cases, the injectors themselves may need to be replaced.
  • Estimated Cost to Fix: $200 - $800+ per injector depending on the extent of the damage and whether injectors need replacing.
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Whining or screeching noises from the turbo, loss of power, excessive smoke, and potential engine damage.
  • Solution: Replace the turbocharger. Diagnose and address any underlying causes, such as oil starvation or foreign object damage.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found
• EGR Valve Issues
  • Description/Symptoms: Rough idling, poor acceleration, check engine light illumination, and potential stalling. Carbon buildup can cause the EGR valve to stick open or closed.
  • Solution: Clean or replace the EGR valve.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Gasoline V6

No Issues Found

Transmission

There was only one transmission available for the 2004 Sprinter: the NAG1 5-speed automatic transmission.

NAG1 5-Speed Automatic Transmission

• Torque Converter Failure
  • Description/Symptoms: Shuddering during shifts, especially under load, slipping between gears, and potential stalling.
  • Solution: Replace the torque converter. Inspect the transmission for any other damage.
  • Estimated Cost to Fix: $800 - $2,000+
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Harsh or delayed shifting, erratic shifting behavior, and potential limp mode.
  • Solution: Replace or rebuild the valve body.
  • Estimated Cost to Fix: $500 - $1,500+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Breakage
  • Description/Symptoms: Rear end sagging, reduced load capacity, and potential cracking or breaking of leaf springs.
  • Solution: Replace the leaf springs, typically in pairs.
  • Estimated Cost to Fix: $400 - $1,000+
  • Recalls: None Found
• Ball Joint Wear
  • Description/Symptoms: Noises such as creaking and popping from the front suspension when turning or going over bumps. Play in the steering. Uneven tire wear.
  • Solution: Replace the worn ball joints. An alignment may be needed afterward.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Electrical

• Glow Plug Failure
  • Description/Symptoms: Hard starting, especially in cold weather, excessive smoke upon start-up, and check engine light illumination.
  • Solution: Replace the faulty glow plugs. Consider replacing all glow plugs at the same time.
  • Estimated Cost to Fix: $100 - $400+
  • Recalls: None Found
• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as malfunctioning lights, sensors, or accessories. Corrosion or chafing of wires can be a common cause.
  • Solution: Inspect and repair the wiring harness. This may involve replacing damaged wires or connectors.
  • Estimated Cost to Fix: $100 - $1,000+ depending on the extent of the damage.
  • Recalls: None Found
• SAM (Signal Acquisition Module) Failure
  • Description/Symptoms: Various electrical malfunctions, including issues with lights, wipers, and other systems controlled by the SAM unit.
  • Solution: Replace the SAM module. Requires programming.
  • Estimated Cost to Fix: $500 - $1,500+
  • Recalls: None Found

Exterior

• Sliding Door Roller Failure
  • Description/Symptoms: Difficulty opening or closing the sliding door, grinding noises, and potential damage to the door track.
  • Solution: Replace the worn or damaged sliding door rollers.
  • Estimated Cost to Fix: $100 - $500+
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: The blower motor stops working, resulting in no airflow from the vents. This can affect both heating and air conditioning.
  • Solution: Replace the blower motor.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2004 Mercedes-Benz Sprinter, while a practical and versatile van, can present owners with a range of issues. The diesel engine is prone to problems like injector seal leaks and turbocharger failures, which can be costly to repair. Electrical gremlins, particularly related to the SAM module and wiring harness, are also common. Suspension and transmission issues can add to the ownership expenses. Overall, potential buyers should be aware of these common problems and factor in potentially high maintenance costs when considering a 2004 Sprinter. Pre-purchase inspections are strongly recommended.