2016 Mercedes-Benz Boxer 40

The 2016 Mercedes-Benz Sprinter, also known as the Boxer 40 in some markets, is a popular commercial van known for its versatility and cargo capacity. Engine options include a 2.1L inline-4 diesel engine producing around 161 horsepower and 266 lb-ft of torque, and a 3.0L V6 diesel engine producing approximately 188 horsepower and 325 lb-ft of torque. Both engines are generally reliable, but owners have noted some common problems. People appreciate the Sprinter’s spacious interior and comfortable ride, but some dislike the relatively high cost of maintenance and repairs.

Engine

2.1L Inline-4 Diesel

• Diesel Particulate Filter (DPF) Issues
  • Description/Symptoms: Frequent DPF regeneration cycles, DPF light illumination, reduced engine performance, potential for engine damage if ignored.
  • Solution: Forced DPF regeneration by a mechanic, DPF cleaning, or DPF replacement. Ensure proper engine maintenance to prevent future issues.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found
• EGR Valve Problems
  • Description/Symptoms: Rough idling, poor acceleration, black smoke from exhaust, engine warning light.
  • Solution: EGR valve cleaning or replacement.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

3.0L V6 Diesel

• Oil Cooler Leaks
  • Description/Symptoms: Oil leaks, coolant leaks, low coolant level, engine overheating. This is a common issue on the OM642 engine.
  • Solution: Replacement of the oil cooler and associated seals. This is a labor-intensive job.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found
• Turbocharger Issues
  • Description/Symptoms: Loss of power, whistling noise from the engine, excessive smoke, engine warning light.
  • Solution: Turbocharger inspection, repair, or replacement.
  • Estimated Cost to Fix: $1500 - $3500+
  • Recalls: None Found

Transmission

• 7G-Tronic (722.9) Transmission Issues
  • Description/Symptoms: Harsh shifting, slipping between gears, failure to shift, transmission warning light. Often caused by valve body issues or conductor plate failure.
  • Solution: Transmission fluid flush (if problem is minor), valve body replacement, conductor plate replacement, or complete transmission rebuild/replacement.
  • Estimated Cost to Fix: $400 (fluid flush) - $5000+ (transmission replacement)
  • Recalls: None Found

Suspension

• Front Strut/Shock Absorber Failure
  • Description/Symptoms: Bouncy ride, excessive body roll, poor handling, noises from the front suspension.
  • Solution: Replacement of front struts/shock absorbers.
  • Estimated Cost to Fix: $400 - $1000+ (for both sides)
  • Recalls: None Found

Electrical

• Glow Plug Failure
  • Description/Symptoms: Hard starting, especially in cold weather, engine misfires, engine warning light.
  • Solution: Replacement of faulty glow plugs.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, warning lights, sensor malfunctions. Can be caused by rodents or corrosion.
  • Solution: Inspection and repair of damaged wiring harnesses.
  • Estimated Cost to Fix: $200 - $1000+ depending on the extent of the damage.
  • Recalls: None Found

Exterior

• Sliding Door Problems
  • Description/Symptoms: Difficulty opening or closing the sliding door, sticking, noises, broken rollers or cables.
  • Solution: Repair or replacement of sliding door components (rollers, cables, latches).
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: No air blowing from vents, intermittent fan operation, unusual noises from the blower motor.
  • Solution: Replacement of the HVAC blower motor.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2016 Mercedes-Benz Sprinter, while a capable and popular van, has some common issues that potential buyers should be aware of. Engine issues, particularly with the diesel particulate filter, oil cooler, and turbocharger, can be costly to repair. Transmission problems, especially with the 7G-Tronic, are also a concern. Other issues like suspension wear, electrical faults, and sliding door problems can add to the overall cost of ownership. While some repairs are relatively inexpensive, major engine or transmission work can be significant.