MajorCommonEngine

Mercedes-Benz Sprinter: OM642 3.0 V6 EGR Cooler Internal Cracking

OM642 3.0 V6 EGR Cooler Internal Cracking is a common engine fault on the Mercedes-Benz Sprinter on the 2010–2018 cars, and we rate it major. Putting it right costs $1,500 to $3,800 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 15 documented faults on the Mercedes-Benz Sprinter.

Vehicle: Mercedes-Benz Sprinter
Engine: 3.0L
Years: 2010–2018
Fuel: diesel
System: Engine

This page covers the Mercedes-Benz Sprinter as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Mercedes-Benz Sprinter faults15 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the EGR valve yet. We would rather show none than show a picture of a different part.

What goes wrong

The EGR cooler fitted to the OM642 3.0-litre V6 diesel is prone to internal cracking, allowing engine coolant to enter the exhaust gas recirculation circuit and be drawn into the intake manifold. Mercedes-Benz issued Technical Service Bulletin LI14.20-N-073813 addressing EGR system faults on this engine and mandating cooler and valve replacement when electrical faults are present. Wet soot accumulation accelerates cooler deterioration. If coolant enters combustion chambers in sufficient quantity, hydrolock or head gasket damage can result.

What you would notice

White or sweet-smelling exhaust smoke from tailpipe
Coolant level dropping without visible external leak
P0400 or P0401 EGR flow fault codes on scan tool
Wet or tar-like black soot visible inside EGR pipework or intake manifold

How to check it

Where to look. EGR system in engine valley, adjacent to intake manifolds between cylinder banks

Inspect EGR cooler outlet pipework and intake manifold entry for wet or tar-like black soot — wet, oily soot is a specific indicator of coolant leaking past the cooler.
Check coolant reservoir for oil contamination and note coolant level history.
Connect scanner and read for EGR-related fault codes.
Inspect intake manifold runners for carbon or soot deposits.

Parts involved: EGR valve.

What it costs to put right

$1,500 to $3,800 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Has the EGR cooler or EGR valve been replaced?”
“Has the vehicle ever produced white smoke or lost coolant without an obvious leak?”
“Are there any stored EGR-related fault codes?”

Now check the Mercedes-Benz Sprinter you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Mercedes-Benz Sprinter buyer questions

Is om642 3.0 v6 egr cooler internal cracking serious on a Mercedes-Benz Sprinter?

We rate it major and common on the Mercedes-Benz Sprinter. The EGR cooler fitted to the OM642 3.0-litre V6 diesel is prone to internal cracking, allowing engine coolant to enter the exhaust gas recirculation circuit and be drawn into the intake manifold. Mercedes-Benz issued Technical Service Bulletin LI14.20-N-073813 addressing EGR system faults on this engine and mandating cooler and valve replacement when electrical faults are present. Wet soot accumulation accelerates cooler deterioration. If coolant enters combustion chambers in sufficient quantity, hydrolock or head gasket damage can result.

How much does it cost to fix on a Mercedes-Benz Sprinter?

$1,500 to $3,800 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Mercedes-Benz Sprinter years are affected?

Our research records this fault on the 2010–2018 Mercedes-Benz Sprinter. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

Inspect EGR cooler outlet pipework and intake manifold entry for wet or tar-like black soot — wet, oily soot is a specific indicator of coolant leaking past the cooler. Check coolant reservoir for oil contamination and note coolant level history. Connect scanner and read for EGR-related fault codes. Inspect intake manifold runners for carbon or soot deposits. Look here: EGR system in engine valley, adjacent to intake manifolds between cylinder banks