April 1st started like any other day, with yoga and a to-do list filled with mundane errands. Hopping into my Mercedes Sprinter van, I was ready to tackle the day, but my van had other plans. Less than a hundred feet from my parking spot, the Sprinter started sputtering and abruptly stalled. Initially, I wasn’t too concerned and tried restarting it. It hesitated, coughed to life, but disappointingly, the sputtering returned within another hundred feet, making forward progress a struggle.
Luckily, I was still on a quiet residential street. My priority shifted from errands to avoiding a complete breakdown in the middle of the road. I managed to pull over to the curb and parked, keeping the engine running in neutral. The sputtering persisted, prompting a call to the nearest Mercedes-Benz service department. They advised bringing it in immediately. For a moment, the engine smoothed out, humming normally, and I almost convinced myself it was a fluke. However, just as I was about to dismiss it, the van stalled completely again.
This was the moment I reached for my AAA card and initiated the roadside assistance process. This would be only the second time I’ve had to use AAA since embracing van life, and I must commend their efficient system. (The first time, a bit more dramatically, involved locking my dog inside the van!). AAA’s online tool was impressively accurate, indicating a tow truck arrival within five minutes. This prompt service spurred me into action, quickly securing everything inside the van and gathering essentials for a couple of days, anticipating a potentially lengthy service appointment.
A crucial step before towing involved removing one of our galley drawers entirely. A push-button latch was malfunctioning, and I wanted to prevent it from flying open during towing or at the service center. Safety first! Next, I emptied the perishable food from our Dometic cooler and used the Goal Zero App to shut down the 110-volt, USB, and 12-volt plugs connected to our Goal Zero Yeti 6000x, which powers the van’s living quarters. I opted not to completely power down the Goal Zero as it was at a healthy 63% charge, with no active power draw. My thinking was that the solar panels could continue charging during the tow and while the van was at Mercedes, especially since it might be parked outdoors. If the van were to be stuck longer than expected, I could always return to fully power it down.
Just as I finished these preparations, a flatbed tow truck arrived – incredibly, within just ten minutes. The driver, experienced with towing Mercedes Sprinter Vans, hoped to start it and drive it onto the flatbed. We briefly shared optimism when he managed to coax the engine to start. Unfortunately, the van stalled again as soon as he attempted to accelerate up the ramp. Undeterred, with some skillful maneuvering and persistence, he successfully loaded the van, and it was finally on its way to Mercedes-Benz.
Shortly after the van’s arrival, a Mercedes service advisor contacted me. To my surprise and slight frustration, he reported that the van started perfectly and was idling smoothly upon arrival. I explained the intermittent nature of the issue and that the van had been stationary for three days prior, which might be relevant. Could it be fuel related? Or perhaps a filter issue, considering the van was nearing its next service interval after a busy winter, potentially leading to some build-up of grime?
The van hadn’t displayed any dashboard warning lights or error codes, which meant Mercedes would proceed with diagnostic testing. The diagnostic service alone was quoted at $299, and the uncertainty of warranty coverage for any potential repairs or parts loomed. Immediately after hanging up, I started searching my inbox for any Mercedes-Benz service coupons to soften the potential financial impact.
While awaiting a status update from Mercedes, I thought I’d share this latest van life hiccup. This isn’t our first Sprinter towing experience. Previously, our 2019 Winnebago Revel, built on a 2018 Mercedes Sprinter chassis, also required towing. That earlier experience prompted me to write an article with some helpful tips for anyone facing roadside assistance situations with their van.
Here’s a photo from the second time our Revel/Sprinter needed a tow:
April 2nd Update: Mercedes Sprinter Van Diagnosis
One of the commendable aspects of Mercedes-Benz service is the direct line of communication with your service advisor throughout the repair process. Upon your Mercedes Sprinter van being checked in, you receive a text message, enabling easy updates via text or direct calls.
This morning, I had both text and phone communication with my service advisor, Jesse. The puzzling news was that they still hadn’t been able to replicate the stalling issue! Jesse had a few troubleshooting questions, clearly trying to gather clues since the problem was elusive. He inquired about the parking situation – was the van parked on an incline? No. When was the last time I refueled? Five days prior. And importantly, when did we replace the original fuel tank with the 47-gallon fuel tank replacement from SB Filters? I clarified that Van America installed the larger tank as part of the van conversion back in November 2022.
Jesse mentioned that Sprinter van owners who let their vans sit for extended periods might encounter similar issues, but our situation seemed somewhat unique given our recent usage. I didn’t have any more insightful information to offer. Their current plan is to let the Mercedes Sprinter van sit overnight again and attempt to replicate the rough idle and stalling one more time in the morning. If they still can’t reproduce the problem, they plan to proceed with replacing the EGR valve. Since the van is still under warranty, this option is covered, making it a worthwhile step in their diagnostic process.
Apparently, replacing the EGR valve has resolved similar intermittent stalling issues in other Mercedes Sprinter vans. The theory is that carbon buildup can clog the EGR valve, leading to the symptoms our van experienced. Fingers crossed that this is the solution! I’ll be waiting for an update tomorrow to find out if the EGR valve replacement resolves the mystery of our sputtering Mercedes Sprinter van.
