Mercedes Benz Sprinter 209/219/309/319 CDI Engine ReplacementCompare Prices & Get Quotes
Get quotes today from trusted UK Mercedes Benz Sprinter 209 CDI, 219 CDI, 309 CDI and 319 CDI engine specialists. Compare prices on reconditioned, rebuilt and used OM646 and OM642 diesel engines for the W906 generation - supply & fit available nationwide with fast turnaround for commercial operators.
Supply & Fit Available
12-Month Unlimited Mileage Warranty
Nationwide Delivery
100+ Suppliers
From £2,200 to £6,200
Used from £1,200 · Reconditioned from £2,200 · Common codes: OM646.984, OM642.896, OM642.898
From £1,200
Tested, bare/short engine
From £2,200
Rod bearings addressed, tested
From quote
Upgraded bearings, full teardown, revised valvetrain
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3 Simple Steps3 Simple Stepsto Finding the Best Mercedes Benz Sprinter 209/219/309/319 CDI Replacement Engineto Finding the Best Mercedes Benz Sprinter 209/219/309/319 CDI Replacement Engine
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Variant HistoryMercedes Benz Sprinter 209/219/309/319 CDI - Engine History & Specs at a Glance
The W906 Sprinter launched in 2006 with the OM646 2.1-litre four-cylinder diesel powering entry-level 209/309 CDI variants, while the OM642 3.0-litre V6 diesel was introduced in 2009 for heavy-duty 319 CDI applications. The 209 CDI produced 88hp (65kW) from the OM646.984 engine, while the 319 CDI delivered 190hp (140kW) from the OM642.896 V6. These engines represented the entry-level and premium diesel options in the Sprinter range, with the OM642 V6 reserved for high-payload, towing, and passenger shuttle applications requiring superior mid-range torque. Production continued through to 2018 when the VS30 generation introduced the OM654 engine and updated OM642 variants.
Variant HistoryMercedes Benz Sprinter 209/219/309/319 CDI - Engine History & Specs at a Glance
The W906 Sprinter launched in 2006 with the OM646 2.1-litre four-cylinder diesel powering entry-level 209/309 CDI variants, while the OM642 3.0-litre V6 diesel was introduced in 2009 for heavy-duty 319 CDI applications. The 209 CDI produced 88hp (65kW) from the OM646.984 engine, while the 319 CDI delivered 190hp (140kW) from the OM642.896 V6. These engines represented the entry-level and premium diesel options in the Sprinter range, with the OM642 V6 reserved for high-payload, towing, and passenger shuttle applications requiring superior mid-range torque. Production continued through to 2018 when the VS30 generation introduced the OM654 engine and updated OM642 variants.
Mercedes Benz Sprinter 209/219/309/319 CDI
Fuel TypeDiesel (common-rail turbocharged four-cylinder and V6)
Engine Size Range2.1L-3.0L (OM646: 2,148cc; OM642: 2,987cc)
Power Output Range88-190hp across the variant's historyEngine History Timeline
OM646.984 2.1L four-cylinder diesel, 88hp (209 CDI, 309 CDI, W906 launch)
OM642.896 3.0L V6 diesel, 190hp (319 CDI, W906 V6 introduction)
OM642.898 3.0L V6 diesel BlueTEC (319 CDI BlueTEC, Euro 5 compliance)
End of W906 production; OM646 replaced by OM654 in VS30 generation
OM642.899 3.0L V6 diesel (319 CDI, VS30 generation)
Key Specs Snapshot
Fuel TypeDiesel (common-rail turbocharged four-cylinder and V6)Engine Size Range2.1L-3.0L (OM646: 2,148cc; OM642: 2,987cc)Power Output Range88-190hp across the variant's historyYears Produced2006-2018Every engine fitted to the Mercedes Sprinter 209 CDI, 219 CDI, 309 CDI and 319 CDI is covered below, with UK rebuilt pricing and known failure points - from OM646 injector seal leaks and crankshaft sensor issues to OM642 turbocharger oil seal leaks, oil cooler seal degradation and injector cup leaks.
Mercedes Sprinter 209/219/309/319 CDI Engine Codes - Specifications & Replacement CostMercedes Sprinter 209/219/309/319 CDI Engine Codes - Specifications & Replacement Cost
2.1L Turbo Diesel (2006-2009)
Power Output88 hp (65 kW) @ 3,800 rpmTorque220 NmYears Fitted2006-2009Displacement2,148ccCylindersInline 4, DOHC, 16-valveEngine CodeOM 646.984
Compatible Trim Levels
- 209 CDI
- 309 CDI
- 509 CDI (W906)
Find your exact engine code, specs and UK replacement cost guide.
Used
Tested, ready-to-fit engine
£1,200-£1,800
Reconditioned
Addressed known issues, tested
£2,200-£3,000
Rebuilt
Full teardown, upgraded internals
£2,600-£3,600
Common Failure
Injector seal leakage (Black Death) causing carbon buildup and compression loss. Crankshaft position sensor failure causing no-start or cutting out. Turbocharger wastegate actuator sticking causing power loss. Fuel pressure regulator and high-pressure fuel pump issues causing hard starting. Typical failure mileage: 80,000-120,000 miles.
The Sprinter 209 CDI's OM646 four-cylinder and the 319 CDI's OM642 V6 diesel are two very different engines - the OM646 is a robust entry-level workhorse, while the OM642 is a refined, torquey V6 designed for heavy-duty applications. However, both have well-documented weaknesses that can lead to significant repair costs. The OM646 suffers from injector seal leakage (Black Death), crankshaft sensor failure, and turbo actuator issues, while the OM642 is prone to oil cooler seal degradation, turbocharger oil seal failure, and injector cup leaks. Every rebuilt engine supplied through EnginesMarket includes upgraded components addressing these original failure points, plus a minimum 12-month unlimited-mileage warranty.
The 209 CDI's Most Common Weakness
Affected Vehicles
Mercedes Sprinter 209 CDI, 309 CDI (OM646.984, 2006-2009)
Typical Failure Mileage
80,000-120,000 miles
Root Cause
Copper injector seals fail over time, allowing high-pressure combustion gases to blow past the injector. The leaking gases bake into a hard, tar-like carbon crust around the injector - "Black Death". Left long enough, the injector becomes welded into the head. Carbon buildup leads to compression loss, rough running, and eventual cylinder head damage.
Why It Happens
Copper injector seals fail over time, allowing high-pressure combustion gases to blow past the injector. The leaking gases bake into a hard, tar-like carbon crust around the injector - "Black Death". Left long enough, the injector becomes welded into the head. Carbon buildup leads to compression loss, rough running, and eventual cylinder head damage.
Dealer (parts + labour)
£250-£400
Specialist (parts + labour)
£150-£250
What it involves
Replace copper sealing washer, clean injector bore, leak-off test
Suitability
Effective if caught early before injector seizes
1 - 2 daysDealer (parts + labour)
£800-£1,200
Specialist (parts + labour)
£500-£800
What it involves
Replace all four copper sealing washers, clean injector bores, new hold-down bolts
Suitability
If multiple injectors are leaking or preventative maintenance
1 - 2 daysDealer (parts + labour)
£1,500-£2,500
Specialist (parts + labour)
£900-£1,600
What it involves
Specialty pullers, head work, injector seat machining
Suitability
If injector has seized and requires extraction
1 - 2 daysDealer (parts + labour)
£4,000-£5,500
Specialist (parts + labour)
£2,600-£3,600
What it involves
Supply & fit rebuilt OM646 with new injectors and seals, 12-month warranty
Suitability
If injector damage has caused cylinder or head damage
1 - 2 daysAll prices are indicative UK market ranges based on current UK specialist supplier data.| Repair Tier | Dealer (Parts + Labour) | Specialist (Parts + Labour) | What It Involves | Suitability | Estimated Time |
|---|---|---|---|---|---|
 Minor - Injector seal replacement (single) Minor | £250-£400 | £150-£250 | Replace copper sealing washer, clean injector bore, leak-off test | Effective if caught early before injector seizes | 1 - 2 days |
 Intermediate - Injector seal replacement (all four) Best Value | £800-£1,200 | £500-£800 | Replace all four copper sealing washers, clean injector bores, new hold-down bolts | If multiple injectors are leaking or preventative maintenance | 1 - 2 days |
Major - Injector extraction & head repair Best Value | £1,500-£2,500 | £900-£1,600 | Specialty pullers, head work, injector seat machining | If injector has seized and requires extraction | 1 - 2 days |
Full Replacement - Rebuilt OM646 engine Best Value | £4,000-£5,500 | £2,600-£3,600 | Supply & fit rebuilt OM646 with new injectors and seals, 12-month warranty | If injector damage has caused cylinder or head damage | 1 - 2 days |
Vehicle Value Check
Vehicle Value Check
A typical 2006-2009 Sprinter 209/309 CDI is worth approximately £3,000-£8,000 depending on condition and mileage. A rebuilt OM646 engine costing £2,600-£3,600 typically extends vehicle life by 80,000-120,000 miles, making replacement significantly more economical than purchasing a new or used replacement van.
Our Recommendation
Our Recommendation
Injector seal leaks on the OM646 are common but manageable. If you notice diesel fumes in the cabin or see carbon buildup around the injectors, have a specialist inspect the seals immediately. Caught early, resealing an injector is a £150-£250 job. Caught late, extracting a seized injector can require specialty pullers and head work. On a commercial Sprinter worth £3,000-£8,000, preventative injector seal replacement is always the better investment.
Don't Let Injector Seal Leaks, Oil Cooler Failure, or Turbo Issues Write Off Your Mercedes Sprinter 209-319 CDI
Whether you're facing OM646 injector seal leaks on your Sprinter 209 CDI, OM642 oil cooler seal degradation on your 319 CDI, or turbocharger issues, EnginesMarket makes it simple to compare quotes from trusted UK Mercedes diesel specialists. Every rebuilt engine in our network carries upgraded components addressing the original design weakness - new injector seals, Viton oil cooler seals, and bench-tested turbos - plus a minimum 12-month unlimited mileage warranty with nationwide delivery and supply & fit options. Don't pay main dealer premiums. Compare prices from independent Mercedes specialists who know these commercial engines inside out.
Compare rebuilt OM646 Mercedes Sprinter 209 CDI engine prices
12-Month Minimum
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Best Price GuidanceImportant Information
Important Information
"All prices are indicative UK market ranges based on historical quote data and repair requests from our network of engine specialists. Dealer pricing is estimated based on published main dealer labour rates and genuine OEM parts pricing. Specialist pricing reflects actual quote data from EnginesMarket's UK network. Actual costs vary depending on damage severity, vehicle condition, variant, and workshop location within the UK. Use our free comparison tool to get tailored quotes for your specific Mercedes Sprinter 209 CDI, 219 CDI, 309 CDI or 319 CDI. Every engine supplied through EnginesMarket carries a minimum 12-month unlimited mileage warranty - always confirm exact terms with your chosen supplier."
Mercedes Sprinter 209/219/309/319 CDI Engine ReplacementFrequently Asked Questions
Question 1How much does a Mercedes Sprinter 209-319 CDI engine replacement cost in the UK-
Short summary: A rebuilt OM646 engine for the Sprinter 209 CDI costs £2,600-£3,600 supply-only; a rebuilt OM642 V6 engine for the Sprinter 319 CDI costs £4,200-£6,000 supply-only. Supply-and-fit adds £450-£850 labour depending on complexity - V6 work requires specialist knowledge.
- Sprinter 209/309 CDI (OM646.984): rebuilt unit £2,600-£3,600; used engine from £1,200
- Sprinter 319/419/519 CDI (OM642.896/898): rebuilt unit £4,200-£6,000; used engine from £1,800
- OM642 oil cooler seal replacement (labour only): £1,200-£1,800 at specialist
- OM646 injector seal replacement: £150-£250 per injector at specialist
Question 2What are the signs of injector seal failure on a Mercedes Sprinter 209 CDI-
Short summary: Diesel fumes in the cabin and carbon buildup around the injectors are the classic warning signs on the OM646 engine. The copper sealing washers fail over time, allowing combustion gases to escape ("Black Death"). If ignored, injectors can seize in the head.
- Diesel smell in the cabin - first warning sign
- Carbon crust ("Black Death") around the injector body
- Tapping or chuffing sound from the injector area
- If caught early, resealing costs £150-£250 per injector
Question 3What are the signs of oil cooler seal failure on a Mercedes Sprinter 319 CDI (OM642)-
Short summary: A burning oil smell from the engine bay or oil pooling in the V of the engine is the classic warning sign on the OM642 V6. The seals are located under the intake manifold and require significant labour to replace.
- Burning oil smell from the engine bay
- Oil pooling in the valley between V6 cylinder banks
- Oil dripping onto the exhaust system
- If caught early, Viton seal replacement costs £1,200-£1,800 at specialist
Question 4Is the Mercedes Sprinter 319 CDI V6 engine (OM642) reliable-
Short summary: The OM642 V6 is a fundamentally strong and refined engine, found across Mercedes' commercial and passenger vehicle ranges. However, it has well-documented weak points: oil cooler seal degradation, turbocharger oil seal failure, and injector cup leaks. With upgraded Viton seals and regular maintenance, these engines routinely exceed 150,000 miles.
- OM642 is fundamentally robust with proven durability
- Oil cooler seal degradation is the dominant failure - £10 part, £1,200 labour
- Turbocharger oil seal failure causes blue smoke and oil consumption
- Well-maintained OM642 engines exceed 150,000 miles
Question 5How long do Mercedes Sprinter 209-319 CDI engines last-
Short summary: Properly maintained OM646 engines routinely reach 150,000-200,000 miles before major work. The OM642 V6 can achieve similar mileage but may require oil cooler seal attention between 80,000-130,000 miles.
- OM646 (209/309 CDI): 150,000-200,000 miles with regular servicing
- OM642 (319 CDI): 150,000-200,000 miles - oil cooler seals from 80k miles
- Service interval is 10,000 miles or 12 months - use Mercedes-spec low-SAPS oil
- Late oil changes accelerate oil cooler seal degradation and turbo wear
Question 6Is it worth replacing the engine in my Mercedes Sprinter 209-319 CDI-
Short summary: Yes, if the Sprinter is otherwise in good condition with no structural rust or major transmission faults. A rebuilt OM646 costs £2,600-£3,600 - far less than replacing a £3,000-£8,000 vehicle. The OM642's higher value (£5,000-£15,000) makes replacement even more financially justifiable.
- Sprinter 209/309 CDI values: £3,000-£8,000 depending on condition
- Sprinter 319 CDI values: £5,000-£15,000 - V6 variants retain strong values
- Rebuilt engine with upgraded components fixes original weak points
- Supply & fit typically £3,000-£6,850 depending on engine code
- New engine includes 12-month unlimited mileage warranty
Why Choose UsCompare Mercedes Sprinter 209-319 CDIEngine PricesToday
500+ OM646 and OM642 diesel engines supplied through our network
12-Month Unlimited Mileage Warranty on every rebuilt Sprinter 209-319 CDI engine
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supply & fit available for OM646 and OM642
Comparing quotes for your Mercedes Sprinter 209 CDI, 219 CDI, 309 CDI or 319 CDI is completely free, with no obligation and no pressure. Enter your registration above to get tailored quotes from UK Mercedes diesel specialists who understand the OM646 four-cylinder and OM642 V6 engines inside out. Whether you need a used engine, a reconditioned unit, or a full rebuilt engine with upgraded seals, injectors, and turbo components, we'll connect you with the right specialist for your exact Sprinter - with a minimum 12-month unlimited mileage warranty on every engine supplied.
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