What 79 owners told NHTSA about the 2020 Mercedes-benz Sprinter 2500 Crew Diesel

Sudden complete engine failures occurred in my Mercedes-Benz Sprinter van during highway operation while transporting freight, creating a serious safety hazard due to immediate and total loss of engine power in active traffic conditions. The first engine failure occurred at approximately 303,000 miles. The second failure occurred at approximately 140,000 miles after engine replacement. In both cases, there were no prior warning signs, diagnostic alerts, abnormal noises, or performance issues before sudden and catastrophic engine shutdown. Both incidents occurred while I was operating the vehicle at highway speeds during commercial freight delivery. The engine failed without warning, resulting in immediate loss of propulsion while in traffic. On both occasions, I was forced to rapidly maneuver the disabled vehicle to the shoulder under reduced control and arrange emergency towing to safely remove the vehicle from the roadway and prevent a potential collision or injury. These failures created a significant highway safety risk due to the abrupt loss of power while merging, traveling in traffic flow, and operating at speed. A sudden engine shutdown in these conditions could result in a rear-end collision, loss of control, or multi-vehicle accident, particularly in high-speed or heavy traffic environments. The repeated nature of catastrophic engine failure following engine replacement raises concern about a potential underlying defect in the engine system, components, or related assemblies, or possible unresolved mechanical or installation-related issues. The recurrence of identical failure conditions under similar operating circumstances increases concern that this may not be an isolated incident. Vehicle Information: Mercedes-Benz Sprinter used for commercial freight delivery First engine failure: ~303,000 miles Second engine failure: ~140,000 miles (replacement engine) Failure type: Sudden, complete engine shutdown with no warning at highway speed

NHTSA ODI 11737931

repeated EGR clogging and malfunction: bucking or stumbling behavior, inability to accelerate properly, disabled shifting affecting ability to slow or stop without excessive use of brakes, Limp Home Mode suddenly without warning including inability to maintain a safe speed on highway and speed minimums that the vehicle cannot keep up (20 mph max while climbing moderately), unable to downshift when going downhill - relying solely on braking to keep speed below safe limit or speed limits. EGR failed again after cleaning, in as little as 3 months. No repair seems possible, only repeated cleanings. Since this happened so much, we have been in several unsafe situations due to the sudden and unheralded degradation of performance and safe use of the vehicle. Once repaired, the condition can come back immediately due to the computer still guessing that it is still in failure (limp home mode returned suddenly without warning as we merged onto an interstate with no exit for 7 miles uphill… and only made 20mph). Check Engine light could come on, and did, but never during the actual degradation of performance - and went often after a few run cycles. Mercedes dealers have confirmed and performed all services on the EGR and related issues (malfunction once caused the aircleaner element to be sucked in and that caused a MAF to be destroyed by contaminants): 1) first signs of issue before 43,000 miles (when check engine light and/or LHM happened -repaired 18sep2023, 51,871 miles, MB service code: LI14.20-N-073867); 2) 26 DEC 2023 - EGR failure diagnosed and replaced by MB dealer. Cleaning had not fixed the issue or failure was final as found by driving by technician and not by codes! 3) 09/jul/2024 - MAF replaced, EGR codes noted - but functioning, fix by MB/Canada 4) 07/24/2024 - 70,547 miles - EGR Clean by MB Missoula MT - failed upon highway same day 5) 07/25/2025 - 70,600 miles - MB Missoula MT cleared computer 6) 88,340 MB cleaned EGR - runs ok again

NHTSA ODI 11674336

Vehicle loses power and is unable to move. Pressing the accelerator to the floor, the engine develops no power. This happens randomly at higher altitudes. We have had several instances of power loss while merging into traffic. Total loss of power left us sitting in busy intersections. This is a common issue with these vehicles with no known fix available. Mercedes should be repairing thus problem before someone is seriously injured.

NHTSA ODI 11606647

The engine stalled when running at 60mph on the interstate. Mechanically jammed.

NHTSA ODI 11572454

The contact owns a 2020 Mercedes-Benz Sprinter 2500. The contact stated while driving approximately 35 MPH, the instrument cluster lost functionality and the screen went blank. The contact stated no warning was illuminated. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle had not been diagnosed or repaired. Additionally, the contact stated that the vehicle had experienced cold start failures. The contact stated that occasionally several attempts were needed to start the vehicle. The contact stated that the failures were intermittent. The manufacturer had been informed of the failure. The contact researched online and related the instrument cluster failure to NHTSA Campaign Number: 23V204000 (Electrical System). The failure mileage was approximately 11,000.

NHTSA ODI 11537530

None responsive throttle, driving on highway and engine loses power and loses all throttle response causing rapid slowing to traffic behind the vehicle. No warning lamps and CEL’s. Problem occurs at random times with no CEL or warning.

NHTSA ODI 11519989

Serpentine belt shredded, cooling fan separated from clutch, pulley screws missing and pulley completely freed from mount and loss of power steering. This seems very similar to previous recall which my vehicle was supposedly not impacted by. Losing power steering in a large vehicle like this is extremely dangerous. Loose components in engine bay has potential to cause more problems. Fan and pulley completely free to come off and fly around bay. This problem has been seen by 10+ Revel owners in the last few weeks. This topic is being openly discussed on public forums and social media. It is currently sitting at MB of Littleton in Littleton, CO and has yet to be inspected. There were no warnings.

NHTSA ODI 11485848

I purchased my van Feb 5, 2021 with 8 miles on it. By April, it was hesitating intermittently at low speeds. It got progressively worse. MB of Athens could not diagnose it in 2 visits in May and June of 2021. By August, the Sprinter service manager at RBM of Atlanta, Charles told me on the phone that he was sure it was the EGR valve and none were available. ETA of a valve was Nov, 2021. The date then moved to Jan, 2022. It is April and there are no EGR valves in the world to be put on my van. The hesitation has progressed to higher speeds. I am going to be killed in this van, my only work van, as I never know when the hesitation will occur. It is dangerous. Mercedes knows they have a problem. I have 2 MB Customer Care complaint files and no results. This problem is a result of their faulty emissions system. I know they are fully aware and do not want to admit their issue and take liability. I bought this van on the MB reputation for quality and service as my job depends on it. I am scared to drive it, but must make a living. I need help. The public should be made aware. I know I am one on many, many with this issue and no resolve. They continue to manufacture new vans in Charleston, SC daily with EGR valves. This is wrong. Please respond. Thank you!

NHTSA ODI 11460110

Here's what I wrote: The 2019+ Mercedes Sprinter EIS (Electronic Ignition System) module is bolted under the driver side dash board to the base of the A pillar where it meets with the firewall. The electrical connector of the module is pointing straight up - this is an issue because any liquids that might spill on the dash (dash cupholder) or any humidity from windshield interior condensation will drip right down the wiring and into the EIS module causing it to short out. _ If the EIS module shorts out, the vehicle will be inoperable until a new unit is fitted. _ The EIS module retails at $1800+ from Mercedes _ Had Mercedes installed the EIS module with the connector facing DOWNWARD - this moisture related issue would not exist. _ There is no drip loop provisions in the wiring. _ Mercedes is aware of the issue as they have created a plastic bag with part number A 638 546 00 35 and they are charging $20 for it. As of right now, Mercedes refuses to fix this issue preventatively. They will only repair it AFTER the EIS module has shorted out. They are refusing to treat this as a warranty claim even though it is clearly a manufacturer defect. Please help? Thank you

NHTSA ODI 11439860

On Sept 6 2021 the engine suddenly stalled/stopped while driving on 194 west of Pullman Wa. A partial restart enabled me to move to a safer location. The Check Engine light came on. I used myOBD scanner to identify engine failure fault codes. Electrical sensor short circuits were identified. Vehicle was transported to a MB dealer in Spokane where a chaffed engine wiring harness was identified as the cause. MB engineers in Stuttgart Germany confirmed this diagnosis. I have now learned that the factory harness installation rubbing against engine components has been an ongoing problem in the Sprinter Van. This defect has contributed to engine failures as acknowledged by several MB technicians. Owners of all affected MB Sprinter Vans should receive notice of this potentially dangerous wiring harness defect. MB USA should be mandated to recall and modify the harness attachment points where abrasion of the harness cover and wiring is occurring. Preventing unexpected engine shutdowns in Highway traffic must be a priority of any vehicle manufacturer. Rear end collisions endanger the safety and lives of vehicle occupants. The defective engine wiring harness installation should be addressed immediately. Please share my report with MB USA. Accident Prevention Saves Lives

NHTSA ODI 11434506

Vehicle hesitates during acceleration. Problem occurs between 1700 and 200 rpms. Dealer has been notified and unable to repair. Dealer states that the problem is well-known by MB and will re resolved via a software update

NHTSA ODI 11429648

POWER STEERING HOSE IS NOT LONG ENOUGH, IS POORLY CONNECTED/CLAMPED, AND HAS BEEN DISCONNECTING FROM MULTIPLE OF THESE VEHICLES, CAUSING AN IMMEDIATE EMERGENCY SITUATION (LOSS OF POWER STEERING), AND AN IMMEDIATE VEHICLE BREAKDOWN. MERCEDES IS AWARE OF THIS ISSUE BUT HAS THUS FAR FAILED TO ADDRESS IT

NHTSA ODI 11414689

VEHICLE ACCELERATES UNCHARACTERISTICALLY SLOWLY UPON COLD START IN COLD TEMPERATURES / HIGH ELEVATION. MANY DOCUMENTED CASES IN PREVIOUS AND CURRENT MODEL SPRINTER WHICH USES THE SAME OM642 DIESEL ENGINE. HTTPS://SPRINTER-SOURCE.COM/FORUMS/INDEX.PHP?THREADS/71254/ THERE HAVE BEEN MULTIPLE TIMES WHERE I TRIED TO CROSS AN INTERSECTION OR MAKE A LEFT ACROSS A HIGHWAY UPON RECENT COLD START AND THE VAN ACCELERATED VERY SLOWLY, LEAVING ME MOVING VERY SLOWLY ACROSS THE OPPOSING TRAFFIC LANE(S).

NHTSA ODI 11406089

TL* THE CONTACT OWNS A 2020 MERCEDES-BENZ SPRINTER 2500. THE CONTACT STATED THAT THE COOLANT WARNING LIGHT INTERMITTENTLY ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT HAD TAKEN THE VEHICLE TO MERCEDES-BENZ OF SPRINGFIELD (295 BURNETT RD, CHICOPEE, MA 01020) WHERE THEY DISCOVERED NO FAULT WITH THE COOLANT SYSTEM HOWEVER, THE WARNING LIGHT CONTINUED TO ILLUMINATE INTERMITTENTLY. THE CONTACT THEN PERFORMED A VIN SEARCH ON THE NHTSA WEBSITE AND DISCOVERED NHTSA CAMPAIGN NUMBER: 21V055000 (ELECTRICAL SYSTEM) AND 21V152000 (SERVICE BRAKES, HYDRAULIC) HOWEVER, THE PARTS TO DO THE RECALL REPAIRS WERE UNAVAILABLE. MERCEDES-BENZ OF SPRINGFIELD (295 BURNETT RD, CHICOPEE, MA 01020, (413) 624-4100) WAS CONTACTED AND IT WAS CONFIRMED THAT THE PARTS WERE NOT YET AVAILABLE. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT STATED THAT THE MANUFACTURER HAD EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE FAILURE MILEAGE WAS APPROXIMATELY 1,000. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA ODI 11405317

MY BRAND NEW 2020 MERCEDES SPRINTER 2500 VAN JUST LIKE. EVERYONE ELSE'S ON THAT VEHICLE HAS A POWER STEERING HOSE THAT IS TOO SHORT. BECAUSE OF THIS A FAIR AMOUNT OF PEOPLE HAVE HAD THIS COME OFF AND ENDED UP STRANDED. WHEN IT COMES OFF YOU LOSE POWER STEERING. IF THIS HAPPENS WHILE DRIVING IT COULD BE DANGEROUS. I CALLED MERCEDES BENZ OF WESTMINSTER IN CO AND THEY SAID THEY CANNOT FIX THIS UNTIL THERE IS A RECALL FOR MY PARTICULAR VIN. OTHER VINS HAVE RECEIVED A RECALL ALREADY. I AM AFRAID THAT BY DRIVING THIS VEHICLE LIKE THIS IT PRESENTS A DANGER TO MYSELF AND OTHER ON THE ROAD. I AM TRYING TO BE PROACTIVE AND FIX THIS BEFORE THERE IS A BIGGER PROBLEM. I DO NOT KNOW WHAT ELSE TO DO. I THINK THEY SHOULD BE. HALTED FROM SELLING THESE VEHICLES UNTIL THIS IS FIXED. *DT*JB

NHTSA ODI 11387576