Bought a Sprinter, Lots of Work Ahead

[prossett]

Hi all, just bought a 2009 Dodge Sprinter 2500 in Ontario for a DIY camper conversion and it needs some work, but it also comes with some interesting equipment!

I'd appreciate any advice as I try get it ready to pass the required safety certificate, so I can register it.

What's immediately obvious:

Engine light on with code for glow plug open circuit, cylinder 2, so I'll just try change it.

SRS light on, hoping it's the driver's seat belt wire, as the seat is badly worn - looks like a gorilla was driving regularly. Not sure how to check if the belt buckle wire is ok.

ESP light on, and I'll be looking to find a faulty wheel speed sensor, hopefully. Not sure how to check which one.

Other than that, it is filthy, heavily used, and rusty, so I'm bracing myself. However, it comes with what seems to be a powerful 2500W inverter, a bank of 4 house batteries, a diesel heater, a roof ventilator, and flashing yellow lights.

 

[dharmasprint]

Is this version a V6 or the inline 5?

You will need an MB aware scanner or Xentry diagnostic software to diagnose the various ills.

To remove a glow plug, it's best done when the engine is hot. Even then it may not come out. Prepare for heartbreak.

 

[Cheyenne]

Is this version a V6 or the inline 5?

It's a 2009 NCV3 so will have to be the V6 3.0 Litre Diesel.

The I5 was retired with the last of the T1N's in 2006.

 

[prossett]

Yes, indeed it's the V6 3.0 diesel engine.

Great suggestion for the Xentry - I had a quick look and it's just what I need.

I bring it home on Monday so I'll have a better look and post some clearer pics. I have never seen a vehicle this dirty!

 

[dharmasprint]

Yes, indeed it's the V6 3.0 diesel engine.

Great suggestion for the Xentry - I had a quick look and it's just what I need.

I bring it home on Monday so I'll have a better look and post some clearer pics. I have never seen a vehicle this dirty!

It is indeed filthy. Wonder what was used for?

 

[bcislander]

The original GP Controller installed on early NCV3s is failing in many cases, causing GP faults and erratic GP light behaviour.

The links below show the 'old' vs new GP Controller and how to change the controller, if you still have the old GP controller in your van:

Glow Plug #5 Replacement for Beginners

My 2008 has been displaying its engine check light for months. The Scan Gauge indicated a code of P0675 which is attributable to the #5 Glow Plug or its control circuit. This is what I did to fix it. I've never worked on this motor except to change oil so a lot of this will be obvious to many...

sprinter-source.com

2007 Glow Plug Module Test?

I've done as much as I can based on what is out there and on these message boards. This morning the glow plug light and check engine light stayed on. Once I got to work I scanned the van and it came back with the following codes: P0671 - Cylinder 1 Glow Plug Circuit/Open P0673 - Cylinder 3...

sprinter-source.com

2008 Glow plug lamp will not come on and will not start

The dash light doesn't come on and engine will not start. 2008 V6 turbo. I'm almost stuck in South Dakota, Badlands. Cycling the key did get it started one time. Am hoping it will start when needed but thoughts?

sprinter-source.com

 

[bcislander]

Also, check the system voltage with the engine running. The voltage should be ~14.0V to 14.2V.

A low system voltage can cause multiple fault codes as well as resulting in a battery that is never fully charged.

A voltage below 14.0V usually indicates a faulty Y-Cable and/or engine to chassis ground strap.
The original Y-Cable in 2007-2010(?) Sprinters was poorly designed and prone to failure.

Replace the Y-Cable and/or ground strap if the system voltage is below ~14.0V.

A few relevant Y-Cable search results:

Y Cable Replacement Tips?

I plan on replacing the 'infamous' Y Cable in my Sprinter sometime in the very near future. I had a quick look around & under the van to see what potential 'snags' there might be. The main difficulty I saw was accessing the alternator connection post. I couldn't see it from above, or below...

sprinter-source.com

Autopsy: Infamous "Y" cable from alternator to starter to battery

I have a NCV3 2500 3L V6 built June 2008. As preventive maintenance I replaced the infamous "Y" Cable. Attached are photos of the old cable and one of the newly installed cable. 1. Shows the 300 Amp fuse shrink wrap cut open. There is a serious design problem here. Note where my fingers are...

sprinter-source.com

ALTERNATOR Y CABLE LAST QUESTION

2007 dodge sprinter passenger van 3.0l v6 turbo diesel 2500 with air conditioning on roof. I have a 14v 220 AMP alternator I looked through the alternator threads and could not find an answer. When I searched for the Y CABLE two came up. a dodge part and a mercedes benz part but the mercedes...

sprinter-source.com

 

[prossett]

Thanks - great advice.

I think this may be the GP controller, and it looks newer than the rest of the engine. Can you tell from the numbers?

 

[Kajtek1]

Google Search

googling part number works most of the times.
I ditto checking voltage, as traction lights usually are 1st to come at low voltage.
Looks like you have powerful inverter and diesel heater.
Very nice options for starting conversion...

 

[prossett]

Google Search

googling part number works most of the times.
I ditto checking voltage, as traction lights usually are 1st to come at low voltage.
Looks like you have powerful inverter and diesel heater.
Very nice options for starting conversion...

Yes, you're right - doh, I should have done that. And yup, it's the new GP Controller, according to a post linked above here by bcislander:

New revised CONTROL UNIT; part# A 642 900 58 01 ; replaces old style control unit part# A 642 153 19 79

Monday I should get the van home and can start learning more as I set the maintenance baseline. The 2500 Watt inverter is way overkill 😂 I'll need to tow a trailer of solar panels... Actually, they prolly idled the engine all the time. I wonder if the equipment even works.

 

[Kajtek1]

The 2500W inverter is overkill on tech data, but bear in mind, in Sprinters cooling is crucial part, so bigger inverter comes with bigger cooling fins, bigger fan etc.

 

[vreihen]

SRS light on, hoping it's the driver's seat belt wire, as the seat is badly worn - looks like a gorilla was driving regularly. Not sure how to check if the belt buckle wire is ok.

A proper Mercedes-specific scan tool like Xentry or the LAUNCH Creader Elite v2.0 for Mercedes/Maybach/Sprinter (our Sprinter never leaves the driveway without the latter in it) can query the SRS system and tell you whether the buckle's wire is broken. It was $143 USD when I bought the buckle from the dealer a few years ago, and they kept it on the shelf in stock so it must be a common part to fail.....

 

[prossett]

Thanks - I agree and it's on my shopping list. I do have a generic OBD scanner, but not a Mercedes one.

Would you consider this one:
ANCEL ANCEL BZ700 OBD2 Scanner fit for Mercedes Benz Sprinter

As for seat belt wire, I'll check out the scrapyards and see if they have one. The driver's seat is badly ripped, so I'll need to either cover and hide, or replace - again at the scrappies... so it could be a way to fix the seat belt wire same time.

But first I want to poke around myself, as it may be an evident breakage, or some other easy fix - like wiggling the connector! Always the optimist 😁

BTW, I noticed a funny knob at the front of the seat base. It rotates, and dials in two-digit numbers, but doesn't seem to move the seat. Is it some sort of lumbar support? I didn't take a pic, but from Monday i can.

 

[vreihen]

Strange that I don't see the LAUNCH x431 Creader Elite v2.0 listed on the Amazon Canada site. It has been well-tested by NCV3 owners here, and is my current go-to scanner for our Sprinter.....

 

[prossett]

Also, check the system voltage with the engine running. The voltage should be ~14.0V to 14.2V.

Great advice, thanks. Checks out ok, but it's a little complex because of the extra 4 house batteries and the 2500W inverter. Plus, there's lights on the roof.

To be sure I understand, the main starting battery is under the driver's feet, and it read 14V after I accelerated. At idle it was low, as soon as I blipped the gas there was a click and the voltage jumped up. Normal?

There's another battery in the engine bay, and the specsheet does mention it, so it's stock that way. It also reads 14V with engine running. But it has a non-stock fuse so it must have been added for the 4 house batteries in the cargo area.

Then there's wires heading back into the cargo area from the driver footwell starting battery, where 4 batteries are joined in series, and then in parallel - so they were running 24V with two pairs? Sadly the readings are very low, all under 3v, so I think they are dead. I can't figure out how they were charged though, because the wires do connect to the starting batteries but can't see a switch, and there's no charge coming in as far as I can tell.

Then there's that massive inverter, super heavy, and wired into both inside and outside sockets at 110V. There's a controller on the partition, driver side, but it won't light up. There a buttons for "charge" and "invert", all unresponsive.

I'll try calling the company mentioned on the tag and see if they can help make sense of it, but I'm not interested if they wish to service. I have no plan to become a customer.

And finally, I tried 2 mystery switches added to the center console, and the roof lights - nothing happened other than the battery warning light now came on... bah.

 

[bcislander]

The 14V with the engine running at idle looks OK, but the initial low, then 'click' when revved doesn't sound normal. That behaviour may be due to the extra house batteries. It's hard to tell from the pics, but the 4 house batteries appear to be 6V each, wired in series/parallel to give 12V with double the Ah (in theory). If they are measuring only 3V, I would disconnect them from the starting battery/charging system before investigating further.

 

[dharmasprint]

Lifepo is the way to go. You just need to revamp the whole thing.

 

[prossett]

Yes, better I disconnect now and focus on preparing for the safety inspection (van is on temporary plates until it can get the certificate).

I have SRS and ESP lights on, hoping it'll be the driver side seat belt buckle and a wheel speed sensor. There's also the no.2 glow plug, but I think it isn't a requirement for the safety test. Today oil change and the garage should run me a full diagnostic. I'm still considering which scanner to get...

I'll remove the four 6V batteries (exactly right, bcislander!) and see if they'll charge overnight. Gosh, Lifepro are expensive! As always, I'm sure it's a question of "you get what you pay for". I'll get back to the electrics after the van is fully registered.

 

[ironhydroxide]

BTW, I noticed a funny knob at the front of the seat base. It rotates, and dials in two-digit numbers, but doesn't seem to move the seat. Is it some sort of lumbar support? I didn't take a pic, but from Monday i can.

You have the suspension seat.
This knob is the preload "weight" adjustment so you can match the seat to the occupant.

There's a lever on next to the knob, sit on the seat, and "twist" the lever to release the suspension latch.

 

[dharmasprint]

Yes, better I disconnect now and focus on preparing for the safety inspection (van is on temporary plates until it can get the certificate).

I have SRS and ESP lights on, hoping it'll be the driver side seat belt buckle and a wheel speed sensor. There's also the no.2 glow plug, but I think it isn't a requirement for the safety test. Today oil change and the garage should run me a full diagnostic. I'm still considering which scanner to get...

I'll remove the four 6V batteries (exactly right, bcislander!) and see if they'll charge overnight. Gosh, Lifepro are expensive! As always, I'm sure it's a question of "you get what you pay for". I'll get back to the electrics after the van is fully registered.

The glow plug is not required for the safety but if the cel is illuminated they may not pass it. Are you registering as a commercial or personal vehicle? Commercial registration has other implications.