Problem With Relays On Mercedes Sprinter 06 On - Motorhome Forums, Motorhome Discussion, Motorhome Chat

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post #1 of 24 (permalink) Old 29-03-2012, 11:06 Thread Starter
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Problem With Relays On Mercedes Sprinter 06 On

We had a fault last month on our 08 sprinter. Key turned, released the steering lock and put on all the lights on the dash as normal but would not spin the engine and would not start by bump starting down a hill. The fault started very intermittantly and gradually over a couple of weeks got worse. We were in France in the alps and phoned home to our dealer who suggested we change 5 relays as they had come across this problem but only in motorhomes and very rarely, they suspect it is because of condensation. We got to a dealer in France, had to order relays, 10 mins to fit and the vehicle was perfect again.
The relays are situated above the fuses in the dash and numbered 1 to 8. We changed no 3, 5, 6, 7, & 8. In our case we had traced the fault to No 7, engine control relay which after changing opened up the old one and the contacts were burnt. I kept the other 4 relays we changed as spares. Total cost for 5 relays was 65 euro.
Hope this information might help someone else out if they have the same problem as it is something you can do yourself.
Derek
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post #2 of 24 (permalink) Old 29-03-2012, 18:25
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Thanks for this info Darach

Teemyob had starter problems with his I wonder if was same issue ?

must said you had excellent advice from your dealer !!!

could you post the MB part number here for this relay no 7
engine control relay think I may price one up & carry it as a spare
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post #3 of 24 (permalink) Old 29-03-2012, 18:41
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+1 Looks like one for the toolbox. Thanks Michael
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post #4 of 24 (permalink) Old 29-03-2012, 18:42
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found this on the MBclub forum :-


Hi there. I ended up speaking to Enza Mercedes. They turned out to have had one with just the same problem, an Ice cream van.

Turns out to be relays in the dashboard (nearside footwell) numbers 8 and 9 that they replaced. THey showed me them, the contacts had green corrosion on them and were not contacting properly. This happens when they are not used regularly, like an Ice cream van or Motorhome.

Anyway, relays cost £13 each, so save the £250 labour and replace em yourself!

Good luck
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post #5 of 24 (permalink) Old 29-03-2012, 20:01 Thread Starter
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We changed relay no 3,5,6,7, & 8.
Numbers are all marked beside relays.
No1 grey relay for the horn Part No: A0045452905
No2 Yellow " for the wiper Part No: A0025421419
No3 grey " for the fuel pump Part No: A0045452905
this was superceded to Part No: A0035420219
No4 Yellow " for wiper on/off relay Part No: A0025421419
No5 Yellow " Starter Part No: A0025421419
this was superceded to Part No: A0025427419
No6 Grey " ESP? Part No: A0025422619
No7 Grey " Engine control Part No: A0025422619
No8 Grey " T15R? Part No: A0025422619

As you can see some of the part nos are the same, so therefore if you have a problem you can swap some of the relays around to check them. (We swapped 6 & 7, engine started but ESP light came on).
For the cost of the 5 relays, it was well worth it for us to change them and now have spares.
All the relays have the part nos stamped on them, makes life easy.
Derek
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post #6 of 24 (permalink) Old 29-03-2012, 21:41
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Sprinter Cutting Out

I wonder if I am having the same problem with my 2003 2.7L 5 cylinder Sprinter with Sprintshift, Rapido 986M conversion. I have owned this vehicle for the last 5 years and has now done 34000 miles.
I always park the vehicle up after November as this is the last time we use it and then we always do our first trip in March.

The routine I always follow is keep the engine battery fully charged and run the engine every 2 weeks till engine temp is achieved. We also put moisture removers inside the van, it never ceases to amaze me how much water we have to empty out of these on a regular basis.

For the last 2 years we have had to be taken to by low loader (thank god for AA recovery) to our local heavy haulage garage,as we always take the van for a local run just to make sure and fuel up that every thing is OK before our first trip of the year in March. And on both of these runs after doing several miles doing some town driving and dual carriage way (70mph) for no reason the ESP light comes on and engine cuts out no amount of turning the engine over will start it.

The first time this happened in 2011 the local garage connected their general purpose computer code reader and it came up with fuelling problem. So they checked fuel filter changed for new one checked fuel tank, fuel pumps for pressure all seemed OK. They re-primed system, van started first time.

They said they did not know what had caused the problem and recommended to take it to a Merc dealer for full diagnostic's check. When I found out the cost of this I decided to run the van and see if the problem occurred again. We had 6 tripsUK, 1 tour of Belgium Holland, 1 journey to Croatia and back, not one beat was missed. March 2012 same procedure as above, same problem again, this time local garaged just re-primed system, started again no problem, did tour of Wales sweet as a nut.

So I am wondering if this is same problem, so if anybody could offer me some advice or had similar problem and solved it your advice would be very appreciated. Also if someone could tell me where my relays are I would change these as I think this is a cheaper option than going to the Merc dealer.
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post #7 of 24 (permalink) Old 30-03-2012, 10:29 Thread Starter
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Hi Mampy, I,m sure your fault is not the same, both chassis are different models. I don.t know the systems on the earlier chassis.
I do remember there was a problem with seals in the injectors, but the systems of that was that it was very difficult to start but once running would keep running. I you go on to a website called Sprinter-Source.com they have a pretty good forum and you could put your problem on and maybe get some answers. Hope this is of some help to you.
Derek
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post #8 of 24 (permalink) Old 30-03-2012, 13:25
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Hi darach, thank you very much for your reply, but each time the van was already running, and the garage has already checked the injectors as they are aware of the early seal problem, and said they were ok and if the seals were leaking that it would do it when the van was parked up for weeks between trips.

The reason I think that it is corroded relays is that it only happens when it is parked up over winter and that we do suffer from a lot of condensation, we live a 1000 feet above sea level and have very cold moist winters.

I will try the other forum you recomended.
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post #9 of 24 (permalink) Old 30-03-2012, 22:50
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Hi, I am currently touring in Spain and have had cause to call out recovery twice for similar symptoms.( Merc auto 3.0 litre diesel -2007). All lights come on except preglow but engine would not turn and I usually get messages-' ESP Visit workshop ABS visit workshop ASR visit workshop' - 3 messages which after starting then disappear.

The first time engine would not start, I called recovery, still would not start, arranged to be taken to Merc dealer next day. On trying to release gearstick (Auto locked in park) to get on back of truck, the preglow lamp lit and engine fired. Still took to Merc who after three hrs replaced a relay.

Three days later, 250 km further south similar problem recurred, but this time started after 3 hrs and did so for rest of the weekend, but we still chose another escorted trip to another Merc Dealer, who after 3.5 hrs advised bad contacts where battery leads meet electricals and fuse box under drivers seat, which they cleaned and sealed. Touching a lot of wood, have now been good for 10 days or so.

I wish I had known about this thread earlier - could have saved me a lot of money.

Thanks for the info Derek and hopefully not tempting fate I shall copy this thread to a document and get google to translate, then I have it available should I experience a recurrence on one of the other relays.

When I get home I shall order the relays to carry as spares.

Lancsman
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post #10 of 24 (permalink) Old 31-03-2012, 19:28
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Also had a similar problem with Merc Sprinter 58 Auto, (Auto-Sleeper Devon) turn the key and wouldn't start, used to switch it on and off a couple of times then it would go.
I took the van back to the dealer for something else and mentioned this problem. The van was sent to the Merc dealer and I am told they replaced the starter motor which was still under warranty (Just) They didn't mention relays either. So far it has started first time after the fix.
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