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Maybe low compression? How's your oil consumption? My '02 with 98k miles still averages ~22.5 and blows a quart of oil into the charge (& out of the EGR) in 15k miles.

The shaking on acceleration between 45-60 mph sounds similar to a vibration that others have found a tranny fluid flush will fix - did you try a fluid flush? I have an '02 and recently bought an '06 owner's manual figuring it might include lessons learned in the meantime. That manual included...

My '02 has DRL, so the low beams are always on when the van is running. Mine has 96k miles and I think I've replaced each side twice now. The last one blew right after startup - was at night, so I could see it go. I also always see a voltage spike (lights get brighter momentarily) right after...

That's called the auxiliary heater option. My '02 passenger came with the cold weather package which includes a switch to turn the Espar on w/o the engine running for a max 2 hrs (newer vans can have a 7-day timer so you don't have to go out to turn it on). Mine also has a heater core mounted...

Maybe yours are different, but my front rotors will reach discard thickness (0.748") well before the pads will.

Having just inspected the front brakes and planning to replace the front rotors and pads on my '02 (probably at 110k miles), I'm wondering if I should repack the front wheel bearings as well. My service manual and owner's manual are silent on this point, but, from what I can see and read in the...

We have an '02 Sprinter 140 high top passenger with 89k miles as a personal vehicle and I've noticed a 10% increase in fuel economy during the last 3400 miles. This driving was done starting from the end of August to now. Mileage has gone from my long time average (all miles to 85.5k/all fuel)...

I have an '02 (same as '03) with 85k miles and have successfully (so far) cleaned the EGR every 30k miles. But, I do not idle any more than absolutely necessary (based on traffic conditions). I have no personal experience with your main issue, but you might get some help if you post on the...

Some think it might be due to the phase-in of ultra low sulfur diesel.

"Chattering" on heavy load, or light acceleration/deceleration? If under heavy load, then a fluid flush should have cured it. If under light acceleration/deceleration, then DC says there is no known fix (even though my service manual says a new valve body should cure it) and it is not a...

I haven't operated in weather that cold, but no problem maintaining normal engine temp in 10 F for me if running at speed. In slow-moving traffic, the engine cools off. Many Sprinters have an Espar diesel-fired water heater as a booster for the engine. That can be used in cold weather to keep...

RE: Say you were in charge of Ford, Chrysler, GM, My '02 passenger Sprinter has a 12v cigarette lighter-like socket on the center console AND an actual cigarette lighter in the ashtray below that center console. I don't know if there were changes in newer models.

Just thinking that if you have a bad injector like I did maybe you could tell at low idle by looking at the exhaust? If low idle is 600 rpm, that's 10 revs/sec. In a 4 cycle engine, you get an exhaust stroke from each piston every other rev. Or, an exhaust stroke from any one piston 5...

Did your idle stick and the new EGR valve solve your smoking problem (smoking after long idle and a smoke screen when you pulled out onto the interstate)?

Interesting points about the effects of extended idle. I don't know if letting it sit after idling would have a negative effect or not. But, maybe the gum, gunk, and steel-hard deposits described in previous posts here are due to deposits formed during extended low idle? I'm thinking soot...

Retorquing injectors sounds like it might be a good thing to do, but to what torque? My service manual installation procedure says to use new tensioning claw screws and torque them to 62 in-lbs followed by 90 degrees more. The final torque on a newly-installed screw will certainly be much...

Re your $9k question, see dieseldoctor's 1st post in the sprinter smoking thread.

A complete overhaul of the engine? How could injectors cause an engine to overheat? Thinking of maintenance, maybe too much soot in the oil could cause what you seem to describe? I have an '02 and have only recently fully realized that the level of EGR flow in the Sprinter engine can cause...

Sprinter sold on Ebay a while back that had reached 561k miles. Probably a good one. The condition note said the transmission was slipping at the 2-3 shift and had been since 250k. Probably means they didn't put any significant $ into it to keep it going.

Thanks for your quick reply. Don't know about the injectors, mine was replaced under warranty. I need to tell you a little more about the soot/oil in the intake manifold. There is no surface deposit in the upper half of the flow cross section. It seems to be limited to the part of the...