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Spuffington

Original Poster:

1,207 posts

169 months

Thursday 9th July 2015
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Doh! Doh! Triple-Doh!

Just got off the phone to the Merc dealership and they have traced the issue down to the turbocharger itself. Hopefully it'll be covered by the warranty, but actually the cost wouldn't bother me even if I did have to pay it myself (albeit, it would hurt) but it's more the fact it won't be ready until Wednesday next week and we're booked on the ferry on Saturday! frownfrownfrown

Gutted.

Looks like our first big adventure is thwarted at the first moment.

Spuffington

Original Poster:

1,207 posts

169 months

Friday 10th July 2015
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Thanks chaps. Yes, it is feeling a little cruel at the moment.

Unfortunately I can't rebook the holiday since we're only a small team at work and all of our holiday has been carefully dovetailed to allow sufficient overlap whilst each of us is away. If I delay now, I'll have to postpone until September.

Also just heard from Mercedes, the warranty company is playing hardball and won't authorise any work until they've had the turbo investigated by one of their approved refurbishers. They say if it is faulty then they'll pay for a reconditioned unit but if they can't see any issue them I'm lumbered with the cost of dismantling the van to get the turbo out and put back together. So far not impressed with the warranty company whatsoever, since they refused the first claim and now making life difficult on this one. I certainly won't be renewing the warranty and I will be chasing Travelworld if I'm left with yet another bill since the warranty at the moment seems less than the value of the paper its written on.

Currently muchos pissod off.

Spuffington

Original Poster:

1,207 posts

169 months

Monday 20th July 2015
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Thanks kneetrembler - sadly we had to come away in the 118d, which I will confess has done a sterling job but rather limited our travels whilst down here. V disappointing.

What's more disappointing than that is Travelworld's radio silence - not having had a response on this for over two weeks and I'm now getting to the stage of transporting the van to their premises and forcing the issue of resolution.

I love the van but the fact we haven't been able to use it as planned and there's seemingly no-one willing the take responsibility for the issue means I'm feeling somewhat let down.

Spuffington

Original Poster:

1,207 posts

169 months

Wednesday 22nd July 2015
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Have now agreed that I will drop the vehicle off on Saturday and leave it with them to carry out the work required (both getting to the bottom of this turbo issue and also repairing the main hab window and awning light).

Fingers crossed we're making progress and we'll be able to properly use Harry for what he's designed. It's been really saddening to tour France seeing not only all the other motor homes but also how well set up the country is for motor homes.

Spuffington

Original Poster:

1,207 posts

169 months

Friday 24th July 2015
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So, in fairness to Travelworld, I've just returned home from France to find three voicemails from their Service Manager trying to contact me last week before I eventually managed to get hold of him, so they were trying.

Unfortunately, just having endured a 750mile return drive to Blighty as well all the delays at Calais with the ferries, none of us can summon the energy to head from Essex to Telford tomorrow, so will postpone until next Saturday.

Picked up the van from Mercedes today, however, and more light shed on the problem. Mercedes tracked the issue down to a kinked actuator and coking on the pivot which controls the variable vane geometry. So it is a new turbo needed, in their opinion. Sounds like a far more straightforward assessment to what we had feared. But I'll leave with Travelworld and their local Merc dealer to sort it out (and pay for it).

In spite of everything still remaining unsolved, felt great to get back in Harry today. We had considered chopping him in for a 2009 Merc Hymer at Travelworld whilst we were away mulling things over, but I'm now far more keen on just getting him sorted and enjoying him as I believe there is a really solid van under all the niggles.

Spuffington

Original Poster:

1,207 posts

169 months

Tuesday 4th August 2015
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So, just received a call from Travelworld which was not entirely as I suspected. The van was delivered to them on Saturday together with a copy of an invoice from Mercedes main dealer, confirming that the route cause of all of my issues was the turbo, which they had recommended to be replaced. It turns out that upon plugging in the diagnostics, the ECU was showing "Low Boost Pressure". Upon physical examination of the turbo, the control arm was NOT bent(!) but one of the intercooler pipes was loose and the jubilee clip which would secure it was missing. There was also evidence of an oil leak, which would've been sucked from the sump by the turbo (which would also explain why it had been loosing a bit of oil).

They re-secured the intercooler pipe, plus jubilee clip and took it on a roadtest - 40miles to Shrewsbury and back (from Telford) and did an ongoing diagnostics check which showed 2bar of turbo pressure during the run and no fault codes were thrown. Problem solved, it seems and evidently the van "pulls like a train", which is what these vans should be doing, which is interesting as I had noticed a bit of shove missing against my old van - I'd just put this down to a heavier base vehicle.

Anyway, I also mentioned that mpg had been dismal and the Tech suggested that now it is burning cleaner, it should show a slightly better mpg (I'm guessing around the 25mpg mark).

So this leaves me with a sporty conversation to be had with Mercedes main dealer in Essex, who it appears have gone for the most expensive (nuclear) option of turbo replacement without checking the basics. Travelworld will be supplying me with all their supporting documentation so that I can claim back the money I paid to Mercedes for the incorrect diagnosis. I don't think I'll get away with getting the boost valve controller money back but given that's a weak point in the system, good to know that is new and shouldn't cause any issue going forward.

On other matters, the n/s main window locking unit was a bit knackered when we bought it and they'd promised to replace the mechanism but now going to replace the whole window. The awning light will be replaced and the buzzer warning for the step extension has been sorted too. Problem is, they have to wait for the former parts from Germany, which will not come for 10 days and we won't be picking up the van until next Saturday at the earliest. frown

But fair play to Travelworld at this stage for getting the van sorted.

Spuffington

Original Poster:

1,207 posts

169 months

Thursday 6th August 2015
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Thanks KT.

I'm stupidly excited about getting Harry back now. The wait for it to be ready is bad enough (ready on the 15th) but unfortunately we're going to be away already which means I'm going to have to wait until 22nd to pick him up. But at least we'll have an opportunity to stay over that weekend and make the most of it. Shame to have missed most of the summer though, but at least it'll be in tip-top condition.

Isn't Düsseldorf great? I've not been to the trade show but I've got a big client who is based there and spent a lot of time in the Altstadt and sampling the Altbier! smile

Spuffington

Original Poster:

1,207 posts

169 months

Friday 21st August 2015
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So a little ditty by way of update (also to vent)!

Spent this morning getting excited about picking up Harry tomorrow. Van was supposed to be ready last Wednesday but due to other arrangements, we couldn't get to Travelworld until this coming Saturday (which they were aware of). So, I put in a courtesy call this lunchtime to let them know a) we'd be there before lunchtime and b) could they plug it in to cool the fridge. Well, firstly I was fobbed off from the chap I had been speaking with and relegated to leaving a message with the receptionist, but then I get a call to say "Get here by lunchtime and we'll cool the fridge". All good.

So you can then imagine my surprise, shock, amazement, disappointment, anger (delete as appropriate) when I get a further call from the Receptionist to tell me a) the melted awning light wasn't fixed (ok, so I can do this myself once in receipt of the part and b) the new window hasn't been fitted yet!

Both of which I'm clearly disappointed about, but what seems to be lost on Travelworld, is the fact nobody had thought to inform me of these delays until I called to let them know I was coming. I shudder to think how Mrs Spuff would've reacted tomorrow after a 3.5hr drive to find the van wasn't fixed and we'd either have to come home or bring it back at another time!

I'm just shocked at the lack of customer service and yet again makes me wonder if I have spent 100k too little to be worthy of any basic form of customer service.

I'm off to write a stern email to them and shall certainly be thinking twice before making any recommendations of buying from them.

Spuffington

Original Poster:

1,207 posts

169 months

Friday 28th August 2015
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Thanks Jody, very kind! smile

Sadly, I think you're right. After a bit of research and talking to others I think you're right that most are bad and Travelworld is better than most but they still have much room for improvement.

I'm currently on my way up to Telford on the train now after having received an email first thing this morning to let me know the van is ready and that everything is complete. The email itself was a great display of customer service, I just wish I hadn't had to have the spat with them last week and have received a few emails which shook my confidence in the work carried out.

I will be going over everything with a fine toothcomb when I collect and then praying that the turbo is indeed sorted since I've just realized I'll be doing battle with pre-bank holiday weekend traffic on the way home! Sadly I couldn't bring the family up to collect and enjoy a weekend away as my daughter now has chicken pox! frown

Hey ho, just want to get it home and be done with the sorry exercise and start enjoying it.

Got another thing to look forward to - we're moving house before Christmas and will finally have a driveway for Harry and a hookup for him, we'll be able to properly keep tabs on him and enjoy last minute getaways (if my new enormous mortgage allows!). smile

Spuffington

Original Poster:

1,207 posts

169 months

Friday 28th August 2015
quotequote all
Needn't have got too excited...........went into limp mode three times on the way back home. frown

Off to write an email to their MD.

Really struggling to work out what to do now. I'm thinking a rejection is the best way forward.

Spuffington

Original Poster:

1,207 posts

169 months

Sunday 30th August 2015
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As much as my logical side tells me to go about rejecting, the emotional side of me is keen to get it sorted.

I have put the following to Travelworld. As Jody says, they're all in Dusseldorf until next week, but hopefully it will be taken seriously upon their return.....

Have my local Mercedes Dealer go about stripping down the engine, removing the turbo and sending this away to a turbo specialist. If there is something wrong with the turbo, a reconditioned one will be returned and the whole thing underwritten by MB&G warranty. However, if the turbo is not deemed at fault, then I wish Travelworld/Mercedes to underwrite this cost of dismantling and putting back together.

I'm also wondering if all the turbo hoses need replacing? If Travelworld agree to underwriting the cost of the above, then I'll offer to cover the new turbo hoses - that way they can see I have some skin in the game.

I think I also need to think about whether, in advance of the start of this work, I get Travelworld to agree that if the new turbo / hoses route doesn't work, then they buy the van back off me with a full refund.

I have spent £££ on a new water filter, turbo boost valve, additional catches, shelf stays, vents to get the van almost perfect, which is why I'm keen on working through all the avenues, but I can't be left with having spent £26k (plus extras) and not having a van fit for purpose.

Spuffington

Original Poster:

1,207 posts

169 months

Sunday 30th August 2015
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Rosscow said:
nagsheadwarrior said:
Any experienced Motorhomer knows to order parts a good couple of months before they break.
Sorry, but that's one of the most ridiculous hings I've ever read on Pistonheads!!!!
If I know Jody, that was meant tongue in cheek!

Spuffington

Original Poster:

1,207 posts

169 months

Sunday 30th August 2015
quotequote all
After having done a bit of googling around, intercooler pipes can pop off due to excess pressure in the turbo circuit; most likely culprit it seems is the variable vane technology and in most cases, the actuator rod which controls this.

This seems to dovetail in with Mercedes original findings of "kinked actuator and coking on the pivot of the variable vane"

Hmmmmm, maybe they were on to something!

I'm more certain now, having found these references, that this could be the ultimate problem and even more keen to get it sorted.

Spuffington

Original Poster:

1,207 posts

169 months

Monday 31st August 2015
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nagsheadwarrior said:
I think I mentioned this when you were going through the decision making process but despite their teutonic reputation I've consistently had more issues with Sprinter based vans than anything else over the years.
Aye, that you did. Problem is, when it's on song, it's an absolutely brilliant van and that 5-cylinder is more powerful and smooth than any of Fiat's offerings from the same period.

In my mind, I'm 90% convinced that this issue is down to the turbo itself and exactly the diagnosis that Mercedes made back in July. I've presented my case to Drew, Erik and Annabel and requested they underwrite the cost of getting the turbo extracted and sent off to MB&G's specialist for inspection and hopefully exchange for a new one. If not, rejection will be the only route open to me.

Spuffington

Original Poster:

1,207 posts

169 months

Monday 31st August 2015
quotequote all
nagsheadwarrior said:
Tis a peachy engine,I'm anti diesel but even I like that.
I'd say thats the best approach and very reasonable,I'm down there during the week i'll give em a kick.
Thanks Jody, would appreciate that.

Fact is, as much as we like the current one, in due course I am sure we'll buy another once the funds are there but if Harry doesn't go as planned, Mrs Spuff will never entertain another van and particularly not from Travelworld. IMO to safeguard my >30yrs+ of business, it's a small concession they need to make now for a longterm positive outcome.

Spuffington

Original Poster:

1,207 posts

169 months

Tuesday 1st September 2015
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Ok, so I've spent about 3hrs reading various posts dotted around the internet on the issue. It seems this issue is not limited to Sprinters but plenty of Mercedes applications - S, E & C classes where the Garrett GT22V VNT (variable nozzle turbo) was installed.

The fault code mine threw last time it was in at Travelworld was "P1470-016" Low Boost Pressure, the diagnosis for which is suggested as the following:-

- check all vacuum & boost pipes (visually and pressure test)
- check EGR valve
- boost valve controller (turbo transducer), which I now understand is vacuum operated on my model year, only moving to electrical controllers from 2004.
- variable vane actuator

I'm presuming due to Mercedes taking a few hundred quid off me for a new turbo transducer in May, that the pipework has already been checked. But then again, Travelworld found a disconnected intercooler hose when they saw the van. Which is fine, but clearly not the crux of the issue. I'm also slightly concerned as the Tech at Travelworld mentioned "sticking wastegate" when I spoke to him on the phone when it happened on the M6 Toll - this Garrett turbo doesn't have a wastegate as the pressure is controlled by way of the variable nozzle technology.

Anyway, all of the above and research undertaken suggests that the issue is with the variable vane actuator (as previously assumed). It turns out that it can become corroded or coked up (Mercedes original diagnostic), which leads to intermittent operation. I presume where a demand is made quickly for power, it struggles to move in time, which is what trips LHM. Although some suggest that it can be half disconnected, have GT85 applied and greased at the bottom of the pivot, the "proper" way of dealing with this is to replace the turbo, given the actuator rod has to be calibrated from factory.

Tech from Travelworld has confirmed receipt of my email and will be discussing with his Service Manager tomorrow and calling me in the afternoon with their suggestion for next steps.

All of this makes me far more positive that this issue is resolvable.

Edited by Spuffington on Tuesday 1st September 11:17

Spuffington

Original Poster:

1,207 posts

169 months

Wednesday 2nd September 2015
quotequote all
Thanks KT.

I'm half way there. I'm not sure whether they've just missed the point or have done it as part of their strategy, but I had a phonecall today telling me to go ahead with getting the van booked in with the Mercedes dealer and get them working on replacing the turbo, together with MB&G warranty. This wasn't what I was looking for, since I wanted Travelworld to underwrite the labour cost should MB&G for whatever reason decline the turbo replacement. BUT, I'm getting to the point now where I just don't care and want to get something sorted.

Since the turbo actuator is the most likely problem (after all my research, albeit there is still a question mark over whether brake pedal & clutch switch could also be a problem), I'm just going to bite the bullet, get the thing booked in (already done and going in on 15th Sept) and just try and get the blasted thing sorted.

If I end up carrying a bill for the work, then so be it, I'll then be challenging Travelworld to refund this money and if they refuse or there's a protracted delay, then I'll engage the services of a Solicitor to reclaim it via whatever legals means available to me. The good thing is, the whole sorry saga is recorded on here so at least from a chronology perspective, it's un-arguable.

On the one hand, I'm really positive about getting it functioning again, but Travelworld's inability to either comprehend what I'm asking for or the lack of any formal apology for all the hassle is what leaves me wondering if I'm doing the right thing trying to get it resolved. We love the van (and it's a good job we do) because otherwise I'd have rejected it long ago. But I wonder sometimes how much they're playing on our attachement to it.

We'll see.

All I can say is - watch this space. I do hope this is the end of the matter, but I remain unconvinced.

Spuffington

Original Poster:

1,207 posts

169 months

Friday 11th September 2015
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So, dropped off and collected Harry today! The chap at All Klasse Autos was totally honest and told me he couldn't, hand on heart, tell me what the problem was.

The diagnostics showed multiple "Low Boost Pressure" fault codes but nothing else. None of the vacuum or boost hoses were loose or split and the turbo actuator, when running on the diagnostic test programme, didn't stick or show any evidence of problems.

They took it on a 4mile road test with live diagnostics and all the parameters are within range and drives as it should.

The only one thing he could see was that the wiring to the boost sensor was very tight and was pulling on the plug. He therefore removed the plug and rerouted the wiring so as to give it more slack. The thought being that tension on it might make for a weak connection and that could be what's throwing the fault code.

Other than that, the ECU fault memory was completely erased and the van is driving very well indeed.

Although it would've been nice to find a split hose or sticky actuator, I'm pleased the chap seems to have done far more investigative work than either Travelworld or Mercedes and totally honest - given what I told him, he could've screwed me for a new turbo. Big respect, only £54 down for what would've cost me 3-4x as much with Mercedes.

Here's hoping he's sorted it. But in any event, would have no issue recommending All Klasse Autos at Bishops Stortford in future.

Filled up with derv on the way home and averaged 23.4mpg on last tank which wasn't bad considering a lot was local stuff. Reckon 25mpg is do-able for a lazy motorway journey.

Have bought a K&N panel filter to pop in but have subsequently read negative stories on its filtration ability and wondering whether or not to install it now. Anyone with any first hand experience?

Spuffington

Original Poster:

1,207 posts

169 months

Sunday 27th September 2015
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So, not really had a chance to categorically test whether the reroute of the boost pressure sensor cable has worked, but we have had three trips totalling 30miles, completely without incident, so I'm hoping that we can put that one behind us.

But as one problem is solved, another rears its ugly head! frown

Today we took Harry just for a quick day trip to Hertford so he could stretch his legs and so could my daughter at the playground and fields. She fell asleep on the way there, so once we go to the site, I pulled down the overcab bed to get her memory foam topper for the sofa for her to sleep on. Sopping wet! The whole bloody thing, and the duvet on top of it and our mattress (to a lesser extent) below it!

A quick hand wipe of the Remis skylight confirmed it was coming from the leading edge of the skylight housing and had obviously been doing so for a while. We haven't slept in Harry for a good month or so, so it could've been coming in since then.

So, add to that the problem that the flush pipes are leaking above the toilet cassette and dripping a small but significant enough amount of water into the cassette well upon flushing and the shower tray has begun to crack around the base of the toilet, I'm pretty pissed off.

I'll check the van into M&G caravans this week to get all of it looked at. I think the roof light just needs removing, aperture and window frame cleaning, reseating and resealing. I'm pretty sure the leak will be a case of tightening some jubilee clips but I've not got a scooby now to get to them, and I guess the interim solution to the cracked floor tray is to open it a little and stick some bathroom sealant in there until such time as I can afford to get someone else to replace the floor or brave enough to tackle it myself. Gggrrr.

I guess at some point in the near future, everything will work as it should and we'll actually enjoy using it!

In the meantime, it's costing a fortune and proving to be a bit of a millstone around our necks.

I'm hoping things will change soon and also once we get into our new house in the next few weeks, we'll have more chance to either keep on top of things or use him more often.

Watch this space.......

Spuffington

Original Poster:

1,207 posts

169 months

Wednesday 30th September 2015
quotequote all
Thanks chaps. I'm feeling a little more pragmatic about it now. I think you're right that it's inevitable that things need tinkering and fettling to get right and we're still in a bedding in phase with the motorhome and getting to know it. At some point we'll be on top of most of these things and we can set about enjoying it. Unfortunately, we're in the process of buying a new house too and having had a survey come back telling of damp on that and needing remedial work, we're pretty fed up with all things house at the moment - whether mobile or fixed!

That said, I took Harry to M&G caravans in Royston yesterday and they've been fab. Booked me in quickly and did all the required work yesterday. Unfortunately I couldn't get to pick it up but in the evening but will be collecting tonight. I can wholeheartedly recommend them both in terms of their setup aswell as their location if you need to get into London - 10mins walk to the station and 50mins into KingsX.

Work done was:

- removed, cleaned, re-bedded and sealed the over-cab skylight
- replaced the seal on the toilet bowel around the disc which drops into the cassette
- fettled flush pipework to stop leak into the cassette surround
- installed new catches for the fridge (which I bought ages ago and not got around to fitting)

330quid in total. I've added on top of that a Thetford Fresh-Up kit since the cassette itself had a bit of a leak and find it repulsive the idea of replacing seals on that. Rather just get a new unit.

Other good news (and I hope this continues to be the case tonight on the way home) is that I've now done about 80miles in Harry since it was looked at by All Klasse Autos and not had another episode of Limp Home Mode. So I'm very much hoping we may be able to draw a line under that. Hope I don't live to regret that comment!!