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Mercedes Benz Sprinter 2.2 CDi 311 2009 - Injector fault - Fixed #

Posted by Paul Manning on September 7, 2013, 5:15 pm

Year of Manufacture *: 2009
Engine Size and Code *: 2200
( Optional ) ECU Type: Bosch
( Optional ) Scanner Used: Launch

This is my own personal camper van.
2 weeks ago, 60 miles from Inverness, on holiday pulls into a lay by, all is well, stops for 2 hrs, restarts engine and Suprised to see a misfire, got my Launch Diagun with me so reads the codes to find No 4 Injector, general error, calls RAC, who come and confirm my findings, results in a 6 swap 14 hr Relay 420 miles back home. Jumped in car and spent week in B&B in Scarborough after all that, so got a holiday of sorts.
After hols removes injectors, dead easy considering the van has only done 15,600 miles, sends injectors to TT Automotive for full test. Returned 2 days later, 3 injectors fine, one fails test on solenoid resistance, so service exchange fitted, Genuine Bosch unit, fitted and road tested, new unit fitted in no 4 cylinder, takes for day out, vans a bit reluctant to start, starts second key turn, but surges for 15 secs seems to be getting fuel up after air lock., but after all is well. Then again on startup the engine runs for 15 secs, the abruptly stops, puts light on on dash, Reads code, guess what No 4 cylinder Injector general error, this cylinder now holds the service exchange unit, do Merc number their cylinders differently, do we have a Ecu fault caused by faulty injector, it should be added that the fault has been cleared and light goes out, the engine now runs fine but seems to surge briefly on start up, wonder if it might have small air leakage somewhere.. Anyone out there can cast any light on this subject would be welcomed. Are Mercedes and Bosch Piezo injectors really that bad that they fail at this mileage, if so its time to change the camper again.

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Ian Baxter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1560' width='330' height='300' border=0 style='border:none;'> on September 8, 2013, 11:31 am, in reply to "Mercedes Sprinter Injectors 311 CDI"

Hello Paul,
Did you code in the replacement injector? Also
as you said the injectors come out easily and not seized,Why don't you swap No,4 injector with one of the known good ones, and see if the fault moves.

Ian

Re: Mercedes Sprinter Injectors 311 CDI

Posted by aidan birley <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2879' width='330' height='300' border=0 style='border:none;'> on September 8, 2013, 3:36 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Aidan Birley

Paul
>> do Merc number their cylinders differently <<

I don't think so but I would try pulling (engine switched off) an injector wire off to see what cylinder fault was logged on.

Do you have a fault code ? may be able to get a better description.

If it helps your are welcome to call over with it and try with my scanner (FOC) to see if comes up with a more informative description & code.

Cheers Aidan

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on September 8, 2013, 9:12 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Mark Carter

Aren't wiring looms common on this vehicles?

Mark

Modern cars, Its all wizardry and witchcraft

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Kev Gundry <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5245' width='330' height='300' border=0 style='border:none;'> on September 9, 2013, 10:41 am, in reply to "Mercedes Sprinter Injectors 311 CDI"
Kevin Gundry

Hi Paul, is this an OM646 engine or OM651?

Did you code the new injector back in?

The earlier OM611 injectors were prone to injector failure and wiring loom fault

What codes did you retreive?

was P0204 in which case check wiring loom where its cable tied to ns engine mount

i have had quite a few injectors back from
refurbing that dont work, so i always go the Oem route.

HTH

Kev Gundry

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Paul Manning <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5278' width='330' height='300' border=0 style='border:none;'> on September 9, 2013, 6:15 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Paul Manning

The original fault code was 0204-008 Y76/4 Injector Cylinder 4 general error, this was the first failure in Scotland, Faulty injector replaced, service unit installed in Cyl 4, Now we seem to alternate between the Fault code for cylinder 1 as well as 4.
Spoken to TT today, I will take the injectors out again tomorrow night and return them for testing, they are going to repeat the test to see if there maybe a fault with the Service unit which as yet has not been on any test equipment.
If anyone is interested the test figures for solenoid resistances were 179.8, 178.0, 171.2, 138.0 ohms.
Specified resistance is 200 to 170 Ohms, thats the data from TTs Bosch Test Bench printout, all 8 pages of it!!!!

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on September 10, 2013, 12:07 am, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Mark Carter

>>> 0204-008 Y76/4 Injector Cylinder 4 general error <<<

The word "General" is making me think that you may have to widen your net.

Mark

Modern cars, Its all wizardry and witchcraft

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Kev Gundry <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5245' width='330' height='300' border=0 style='border:none;'> on September 10, 2013, 10:40 am, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Kevin Gundry

Paul, i have have just checked this code for you the P0204 is a code for Cyl4 the - 008 part relates to a wiring fault between the ecu and the injector, so i would carefully check the wiring loom, these are troublesome at times

if you drive the Vehicle does it cut out when you are pulling up hill for instance

you could try swapping 2 injectors to see if the fault moves

Hth

Kev Gundry

P.S. if you give me a chassis no i can check the pin outs for you

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Paul Manning <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5278' width='330' height='300' border=0 style='border:none;'> on September 10, 2013, 8:06 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"

As requested VIN is WDB9066352S115936
Eng. no 64698551240115.
If this proves to be a wiring issue, its going to be traded in for a Horse and Cart

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Paul Manning <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5278' width='330' height='300' border=0 style='border:none;'> on September 10, 2013, 8:37 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"

Just a bit extra, yesterday van went 400 yards from my place to bodyshop, for a small touchup, did not run well at all. brought back today started missing and brought light on, read codes, this time just code 0204 Injector Cylinder 4 Intermittant, checked to make sure I coded injectors correctly. Removed all 4 again and sending back for retest tomorrow, so will inform you when I know better.

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on September 10, 2013, 9:37 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Mark Carter

I would be looking at the wiring.

Mark

Modern cars, Its all wizardry and witchcraft

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Kev Gundry <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5245' width='330' height='300' border=0 style='border:none;'> on September 11, 2013, 11:04 am, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Kevin Gundry

Hi Paul, this is a wiring fault, unplug it from the Ecu and check all along its length they tend to rub through at the back of the head between the rail and cover

i had over 30 of that model on fleet and never had any issues with injectors other than high mileage 300k+ smoking yours @15K is only just run in

Pin 1 on injector 4 goes to pin 1 ecu white wire 1.0mm cross section
Pin 2 on injector 4 goes to pin 50 ecu green wire 1.0mm cross section

i normally unplug both ends check for continuity then check both wires to see if they are earthing then load with a 50w bulb briefly to if the wire is capable of a load

A new wiring loom for the engine is availible

Part no
A6461504933

£271

So its worth trying to repair it before spending any more money

HTH

Kev Gundry

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Keith Simpson <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1240' width='330' height='300' border=0 style='border:none;'> on September 11, 2013, 7:48 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"

Had a 2009 2.2 Sprinter 313 in on Monday this week with none start when cold, but started with a light sniff and run perfectly. Tested Delphi Injectors No 1 and 4 excessive leak off. Smooth running Cyl 1 -86 and Cyl 4 -73

Part numbers EMBR00002D £300 each won't fit recons advised customer to fit all four but because of cost he opted for the two.

Fitted and coded the two and faults now changed to Cylinder two and three and running like a dog.

Eventually after wasting half a day we fitted the other two injectors and all is now OK.

In my opinion these Delphi injectors should be fitted as a complete set, otherwise your asking for trouble. The only good thing about them is they were not seized in the head.

Regards

Keith

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Paul Manning <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5278' width='330' height='300' border=0 style='border:none;'> on September 12, 2013, 8:14 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"

Injectors went for a retest, and guess what, they failed the brand new injector for having no back leakage, not the kind of thing to cause a misfire apparently.
This point has been proved tonight by refitting all injectors with the new one again in cyl 4, recoded and start up, runs ok for 1 min then cuts out, no cough or splutter just immediate stop. Restarts with a distinct misfire, reads code and no 4 injector is mentioned again, so it seems as Kev and Mark have pointed out, that I will be removing a wiring loom over the weekend if it will stop raining long enough, just need to have a word with the German who designed the tamper proof cap for the Ecu plugs, will have to see if there is a blade in the angle grinder.
Did a brief multimeter check between the Ecu as close to the plug as I can get, and the injector plug, found no fault good continuity and no crosstalk between the wires, but as I said was only a brief check with time and light running out. Being as this my own van I think I will probably end up replacing the loom for a new one, despite how much it galls me to shell out on a van of this age, but considering we have also seen a no1 injector code a repair would seem to be futile. Once again I will update you when I have more news, and spent more money at Mertrux.

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on September 12, 2013, 8:25 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Mark Carter

>>> they failed the brand new injector for having no back leakage, not the kind of thing to cause a misfire apparently <<<

WRONG !!! ZERO back leakage can cause a misfire because the control chamber will not be working correctly.

Have you swapped Injector 4 with any other and looked at the fault code again yet?

Mark

Modern cars, Its all wizardry and witchcraft

Re: Mercedes Sprinter Injectors 311 CDI

Posted by Paul Manning <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5278' width='330' height='300' border=0 style='border:none;'> on September 12, 2013, 8:50 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"

Point noted thanks Mark, will swap 3 and 4 around when I get a moment, may at least save a wiring loom job, cyl 4 has got the second new unit in it at the moment.

Fixed #

Posted by Paul Manning on September 26, 2013, 9:49 pm, in reply to "Re: Mercedes Sprinter Injectors 311 CDI"
Edited by board administrator October 2, 2013, 4:25 pm

Stripped the insulation off No 4 injector wiring and found chafed wiring where the wire had rubbed through on the cylinder head, finally bit the bullet and fitted brand new Mercedes engine wiring loom at £250 plus the vat. That made a difference but there was something still amiss it felt like the engine was lacking power and the urgency to rev up correctly. Left the van running for 20 mins and returned to find it had stopped and recorded a fault code for no 1 Injector circuit. Shame there was no leaking diesel under the van, because at that point I would have had a minor accident with a match. Borrowed a kit of ECU, EIS and Electric steering lock, started engine, totally and utterly cured, not yet got around to pricing new ECU but I assume it will need coding etc, etc bring back the days of plug and play PLEASE!!!!!
So we seem to have arrived at the end of our search, it only remains to thank all who responded, you were an enormous help. If anyone out there would like to buy a Merc Sprinter camper van, anyday soon there maybe one going cheap, or it will be on EBay breaking for spares.
Thanks to all.

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