markxengineering
Active member
I had been chasing codes related to intake pressure sensor and O2 sensor for the past year. Replacing the components did not help. The problems were intermittent, and each time I checked the signals or the harness everything seemed fine. I could clear the CEL, be fine for a anywhere from 1 minute to several months, but always CEL and codes would return.
Finally, about a week ago, I stalled on the highway, luckily in a non-dangerous spot. The engine would re-start after key-off, then stall again a few minutes later. Codes at that point were as shown here (Cylinder 5 injector was the only new one)
I removed the injector cover, wiggled all the wiring I could, including harness stalk down by the fuel filter, and magically everything was fixed. But clearly I needed a new harness.
Here is the old harness, with a couple problem locations identified.
A new harness from a local Mercedes dealer was $560 or so, wholesale price, they had it next day. It would have been over $800 from dodge for the same part. Installation was time consuming, took me longer than it took some, but I'm a bit meticulous and have big hands. I'd say 1.5 complete days for me. The most difficult connector to figure out was the AC compressor. It's the only connector without a "clip" to release, you just pull/pry it straight out. I spent a while looking for the non-existing clip. The rest were all easy, just some tight spaces and making sure not to damage brittle, old plastic.
This is the only wiring failure of this type I've seen, and the only time I've had a vehicle shut off entirely for such a silly reason. IMO this contributes to the "finicky" reputation of the Sprinter- too bad they couldn't have done a better job with disabling only the failing injector circuit (much safer than engine shut off) or built a better harness in the first place. I guess this is an issue with other diesel's as well, but all my prior experience is in gasoline engines, never seen anything like this.
keywords 2030-002 2026-002 2036-001 2036-002 0205-008
Finally, about a week ago, I stalled on the highway, luckily in a non-dangerous spot. The engine would re-start after key-off, then stall again a few minutes later. Codes at that point were as shown here (Cylinder 5 injector was the only new one)
I removed the injector cover, wiggled all the wiring I could, including harness stalk down by the fuel filter, and magically everything was fixed. But clearly I needed a new harness.
Here is the old harness, with a couple problem locations identified.
A new harness from a local Mercedes dealer was $560 or so, wholesale price, they had it next day. It would have been over $800 from dodge for the same part. Installation was time consuming, took me longer than it took some, but I'm a bit meticulous and have big hands. I'd say 1.5 complete days for me. The most difficult connector to figure out was the AC compressor. It's the only connector without a "clip" to release, you just pull/pry it straight out. I spent a while looking for the non-existing clip. The rest were all easy, just some tight spaces and making sure not to damage brittle, old plastic.
This is the only wiring failure of this type I've seen, and the only time I've had a vehicle shut off entirely for such a silly reason. IMO this contributes to the "finicky" reputation of the Sprinter- too bad they couldn't have done a better job with disabling only the failing injector circuit (much safer than engine shut off) or built a better harness in the first place. I guess this is an issue with other diesel's as well, but all my prior experience is in gasoline engines, never seen anything like this.
keywords 2030-002 2026-002 2036-001 2036-002 0205-008
Last edited:
vic
