2009 Mercedes-Benz Boxer 40

The 2009 Mercedes-Benz Sprinter 40, also known as the Boxer 40 in some markets, is a versatile van popular for commercial and recreational purposes. Available engine options included diesel engines such as the 2.1L CDI diesel and the 3.0L CDI diesel. The 2.1L CDI produced around 109 hp and 207 lb-ft of torque, while the 3.0L CDI generated approximately 184 hp and 295 lb-ft of torque. Owners generally appreciate the Sprinter’s spacious cargo area and fuel efficiency (for a van), but common complaints often revolve around maintenance costs and certain mechanical issues.

Engine

2.1L CDI Diesel

• Fuel Injector Issues
  • Description/Symptoms: Rough idling, misfires, black smoke from the exhaust, and difficulty starting.
  • Solution: Replacing faulty fuel injectors.
  • Estimated Cost to Fix: $400 - $1200+
  • Recalls: None Found
• EGR Valve Problems
  • Description/Symptoms: Reduced engine power, poor fuel economy, and the engine warning light illuminating.
  • Solution: Cleaning or replacing the EGR valve.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

3.0L CDI Diesel

• Turbocharger Failure
  • Description/Symptoms: Whining noises from the engine, reduced power, and the engine warning light coming on.
  • Solution: Replacing the turbocharger.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found
• Oil Cooler Leaks
  • Description/Symptoms: Oil leaks near the oil filter housing or around the engine block. Oil may be found in the coolant.
  • Solution: Replacing the oil cooler and associated seals.
  • Estimated Cost to Fix: $800 - $2000+
  • Recalls: None Found

Transmission

• Valve Body Issues
  • Description/Symptoms: Harsh or delayed shifting, slipping between gears, and general transmission malfunction.
  • Solution: Replacing or rebuilding the valve body.
  • Estimated Cost to Fix: $800 - $2500+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: The rear of the van sits lower than normal, and there may be visible cracks or damage to the leaf springs. This causes the vehicle to handle poorly when loaded.
  • Solution: Replacing the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Electrical

• Glow Plug Failure
  • Description/Symptoms: Difficulty starting in cold weather, rough idling, and the engine warning light illuminating.
  • Solution: Replacing the faulty glow plugs.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Wiring Harness Problems
  • Description/Symptoms: Intermittent electrical issues, such as lights not working, sensors malfunctioning, and the engine cutting out.
  • Solution: Repairing or replacing the affected section of the wiring harness.
  • Estimated Cost to Fix: $200 - $1000+ depending on the severity.
  • Recalls: None Found

Exterior

• Sliding Door Issues
  • Description/Symptoms: Difficulty opening or closing the sliding door, the door getting stuck, and excessive noise during operation.
  • Solution: Adjusting the door alignment, lubricating the rollers, or replacing worn rollers/components.
  • Estimated Cost to Fix: $100 - $800+
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: The HVAC blower motor stops working or only works intermittently, resulting in no or weak airflow from the vents.
  • Solution: Replacing the blower motor.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Summary

The 2009 Mercedes-Benz Sprinter 40, while generally reliable, can experience several issues, particularly with its engine, transmission, and electrical systems. The severity of these issues ranges from minor inconveniences like EGR valve problems to more significant problems such as turbocharger failures or transmission valve body malfunctions. The estimated costs for repairs vary widely depending on the specific issue, but some repairs can be quite expensive, potentially costing thousands of dollars. Potential buyers should be aware of these common problems and consider having a thorough inspection performed before purchasing.