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Mercedes Sprinter turbo rebuild
Complete in-house rebuild service for all three Sprinter generations. T1N OM612 Garrett, NCV3 OM646 BorgWarner single and bi-turbo, NCV3 OM642 V6, VS30 OM651 single and R2S bi-turbo. VGT vane cleaning on every VGT rebuild. In-house VSR balancing since 2008.
- T1N (2001-2006)
- Garrett GT2256V VGT
- NCV3 4-cyl
- BV39 Single / BV39+K04 Bi-Turbo
- NCV3 V6
- BorgWarner VGT Single
- VS30 4-cyl
- KP39 / KP39+K04 R2S Bi-Turbo
- Badges
- Mercedes / Dodge / Freightliner
- In shop since
- 2008, 17+ years
Every Sprinter generation we rebuild
The Sprinter spans three generations with multiple engine and turbo combinations. All are fully supported at Boost Lab. The Dodge Sprinter and Freightliner Sprinter use the same turbos as the Mercedes badge.
T1N (2001-2006) W901-905: OM612/OM647 2.7L I5, Garrett GT2256V VGT
The T1N Sprinter arrived in the US market in 2001 and was sold under three brands: Mercedes-Benz, Dodge, and Freightliner, depending on the selling dealer. All three badges cover the same van. The US T1N uses the OM612 2.7L five-cylinder diesel through approximately 2003 and the updated OM647 variant through 2006. Both use the Garrett GT2256V variable geometry turbocharger. The T1N is now 20-plus years old. EGR soot accumulation, extended oil intervals, and age-related bearing wear are the dominant failure causes. VGT vane sticking is common on high-mileage T1N turbos.
Applications: 2001-2006 Sprinter T1N (Mercedes / Dodge / Freightliner badges)
- A6120960099
- 709836-5003S
NCV3 OM646 single (2007-2018) W906: OM646 2.2L I4, BorgWarner BV39 VGT
Standard output OM646 applications use a single BorgWarner BV39 variable geometry unit. Part number 54399880049 / A6460900380. VGT vane sticking from EGR soot is the dominant failure cause.
Applications: 2007-2018 NCV3 Sprinter OM646 lower output (109 HP, 129 HP)
- 54399880049
- A6460900380
NCV3 OM646 bi-turbo (2007-2018) W906: BorgWarner BV39 (LP) + K04 (HP)
Higher output OM646 variants use a staged bi-turbo system. The BV39 is the low-pressure unit, the K04 is the high-pressure unit. BV39: 54399880049 / A6460900380. K04: 53049880057 / A6460901480. When one unit fails, both must be assessed. The bi-turbo staging relies on matched response from both units; a rebuilt LP turbo against a worn HP turbo produces boost anomalies the ECU cannot properly compensate for.
Applications: 2007-2018 NCV3 Sprinter OM646 higher output (150 HP, 163 HP)
- 53049880057
- A6460901480
NCV3 OM642 V6 (2007-2018) W906: OM642 3.0L V6, BorgWarner VGT single
The 3.0L V6 OM642 uses a single BorgWarner variable geometry unit. The V6 has a known oil leak issue from the rear main area and the turbocharger oil feed should be inspected for contamination from any existing V6 oil leaks before the rebuild is returned to service. Part number A6420900880.
Applications: 2007-2018 NCV3 Sprinter OM642 3.0L V6 CDI
- A6420900880
VS30 OM651 single (2019+) W907: OM651 2.1L I4, BorgWarner KP39 VGT
Standard OM651 applications use a single KP39 variable geometry unit. Mercedes part number A6510906380. Direct evolution from the BV39 used on the NCV3 with updated internals. VGT vane sticking from EGR soot remains the primary failure cause.
Applications: 2019+ VS30 Sprinter OM651 standard output
- A6510906380
VS30 OM651 R2S bi-turbo (2019+) W907: BorgWarner KP39 (LP) + K04 (HP), R2S
High-output OM651 uses BorgWarner R2S (Regulated Two-Stage) system. KP39 low-pressure unit: A6510906380. K04 high-pressure unit: A6510900880. Both units assessed and rebuilt together. The R2S system uses electronic actuators for both turbo units rather than purely pneumatic controls; actuator condition is inspected as part of every R2S rebuild.
Applications: 2019+ VS30 Sprinter OM651 higher output, R2S bi-turbo
- A6510900880
- 10009700074
Find your part number
Search by Mercedes OEM part number, BorgWarner number, Garrett number, engine code, or generation. Mercedes uses the A-prefixed format (A6460900380); the number without the A prefix is also accepted at most parts counters.
| Part Number | Turbo Model | Generation | Application | Notes |
|---|---|---|---|---|
| T1N (2001-2006) | ||||
| A6120960099 | Garrett GT2256V | T1N | 2001-2006 Sprinter T1N OM612 / OM647 2.7L 5-cyl | VGT, Dodge/Mercedes/Freightliner |
| A6120961099 | Garrett GT2256V | T1N | 2001-2006 Sprinter T1N OM612 / OM647 2.7L 5-cyl | VGT variant |
| 6120960099 | Garrett GT2256V | T1N | 2001-2006 Sprinter T1N 2.7L 5-cyl | No A-prefix format |
| 709836-5003S | Garrett GT2256V | T1N | 2001-2006 Sprinter T1N OM612 / OM647 | Garrett part number |
| 709836-0001 | Garrett GT2256V | T1N | 2001-2006 Sprinter T1N OM612 / OM647 | Garrett part number |
| 709836-0002 | Garrett GT2256V | T1N | 2001-2006 Sprinter T1N OM612 / OM647 | Garrett part number |
| A6110960599 | Garrett / OM611 | T1N | T1N OM611 2.2L 4-cyl (Europe / early) | OM611 variant |
| A6110961499 | Garrett / OM611 | T1N | T1N OM611 2.2L 4-cyl (Europe) | OM611 variant |
| NCV3 OM646 BV39 | ||||
| 54399880049 | BorgWarner BV39 | NCV3 | 2007-2018 Sprinter NCV3 OM646 2.2L, single turbo variant | VGT single, low output |
| 54399700049 | BorgWarner BV39 | NCV3 | 2007-2018 Sprinter NCV3 OM646 2.2L, single turbo variant | VGT single, complete |
| A6460900380 | BorgWarner BV39 | NCV3 | 2007-2018 Sprinter NCV3 OM646 2.2L | Mercedes OEM |
| 6460900380 | BorgWarner BV39 | NCV3 | 2007-2018 Sprinter NCV3 OM646 2.2L | Mercedes OEM no-prefix |
| 6460901280 | BorgWarner BV39 | NCV3 | 2007-2018 Sprinter NCV3 OM646 2.2L | Mercedes OEM variant |
| 49389-01043 | BorgWarner BV39 | NCV3 | 2007-2018 Sprinter NCV3 OM646 2.2L | BorgWarner number |
| NCV3 Bi-Turbo K04 HP | ||||
| 53049880057 | BorgWarner K04 HP | NCV3 | 2007-2018 Sprinter NCV3 OM646 bi-turbo, High Pressure turbo | Bi-turbo HP unit |
| 53049700057 | BorgWarner K04 HP | NCV3 | 2007-2018 Sprinter NCV3 OM646 bi-turbo, High Pressure turbo | Bi-turbo HP complete |
| A6460901480 | BorgWarner K04 HP | NCV3 | 2007-2018 Sprinter NCV3 OM646 bi-turbo, High Pressure | Mercedes OEM HP |
| 6460901480 | BorgWarner K04 HP | NCV3 | 2007-2018 Sprinter NCV3 OM646 bi-turbo, High Pressure | Mercedes OEM HP no-prefix |
| NCV3 OM642 V6 | ||||
| A6420900880 | BorgWarner VGT | NCV3 | 2007-2018 Sprinter NCV3 OM642 3.0L V6 CDI | V6 VGT single |
| 6420900880 | BorgWarner VGT | NCV3 | 2007-2018 Sprinter NCV3 OM642 3.0L V6 CDI | V6 VGT single |
| VS30 OM651 KP39 | ||||
| A6510906380 | BorgWarner KP39 | VS30 | 2019+ Sprinter VS30 OM651 2.1L, single turbo variant | VGT single |
| 6510906380 | BorgWarner KP39 | VS30 | 2019+ Sprinter VS30 OM651 2.1L, single turbo variant | VGT single no-prefix |
| 54399700106 | BorgWarner KP39 | VS30 | 2019+ Sprinter VS30 OM651 2.1L, single turbo | BorgWarner number |
| VS30 R2S K04 HP | ||||
| A6510900880 | BorgWarner K04 HP | VS30 | 2019+ Sprinter VS30 OM651 R2S bi-turbo, High Pressure turbo | R2S HP unit |
| 6510900880 | BorgWarner K04 HP | VS30 | 2019+ Sprinter VS30 OM651 R2S bi-turbo, High Pressure turbo | R2S HP no-prefix |
| VS30 R2S System | ||||
| 10009700074 | BorgWarner R2S | VS30 | 2019+ Sprinter VS30 OM651 R2S bi-turbo complete | R2S complete system |
| 10009880074 | BorgWarner R2S CHRA | VS30 | 2019+ Sprinter VS30 OM651 R2S bi-turbo CHRA | R2S CHRA |
| VS30 OM651 KP39 | ||||
| A6510905280 | BorgWarner KP39 | VS30 | 2019+ Sprinter VS30 OM651 2.1L variant | OM651 variant |
No results for your number? Contact us at sales@theboostlab.com with your year, generation (T1N / NCV3 / VS30), engine code, and Mercedes part number from the turbo tag.
Why Sprinter turbos fail
The Sprinter is a commercial workhorse. High mileage, variable maintenance, and the EGR system are behind the vast majority of failures across all three generations.
VGT vane carbon sticking
The most common Sprinter turbo failure across all three generations. The Sprinter EGR system re-circulates exhaust gas to reduce NOx emissions. This EGR gas carries soot directly into the VGT mechanism. Over high mileage the soot accumulates on the unison ring and vane pivots, causing the variable geometry to stick in a partially open or closed position. Symptoms include P0299 under-boost, P0234 over-boost, sluggish acceleration, black smoke on startup, and limp mode. VGT vane disassembly, cleaning, and inspection are part of every Sprinter turbo rebuild at Boost Lab.
Extended oil intervals on commercial vans
Sprinters in commercial service are often maintained on fleet schedules that stretch oil change intervals further than the turbo prefers. Degraded oil loses viscosity and film strength under the heat load of a turbocharged diesel in continuous operation. The BV39 and KP39 VGT units are particularly sensitive to oil quality because the vane actuator mechanism relies on clean oil for its internal passages.
Bi-turbo LP/HP imbalance
NCV3 bi-turbo (BV39 + K04) and VS30 R2S bi-turbo (KP39 + K04) systems require matched response from both units for proper staged boost delivery. The LP unit typically shows wear first since it processes all exhaust flow continuously. A worn LP against a fresh HP turbo creates boost anomalies that the ECU interprets as fueling or sensor issues, leading to misdiagnosis. We rebuild bi-turbo sets as matched pairs.
OM642 V6 oil leak contamination
The NCV3 OM642 3.0L V6 has a known tendency for oil leaks from the rear main seal area and various gasket surfaces. When engine oil leaks reach the turbocharger oil supply line, the contaminated oil accelerates bearing wear. Any V6 Sprinter turbo rebuild should include confirmation that known V6 oil leak sources have been addressed before the rebuilt turbo is reinstalled.
T1N age and soot accumulation
The T1N is the oldest Sprinter generation in service, with the youngest examples now 20 years old. Turbos that have never been serviced have accumulated two decades of EGR soot in the VGT mechanism and oil passages. The Garrett GT2256V on the T1N is a serviceable unit and parts are available, but the extent of cleaning required on a neglected T1N turbo is substantially greater than a well-maintained NCV3 unit.
VS30 R2S electronic actuator wear
The VS30 R2S bi-turbo system uses electronic actuators rather than purely pneumatic controls. Actuator failures produce specific fault codes (P003A, P003B, P2563) that can be mistaken for turbo internal failure when the turbo itself is mechanically sound. We check actuator response during inspection and include actuator condition in every VS30 R2S rebuild report.
Frequently asked questions
How do I know if I have the single or bi-turbo NCV3?
The easiest way is the HP output of your Sprinter. Lower output OM646 variants (109 HP, 129 HP) use the single BV39. Higher output variants (150 HP, 163 HP) use the bi-turbo BV39 + K04 system. You can also look under the hood: a single turbo is obvious, and the bi-turbo system has two visibly distinct turbocharger units with separate charge piping. The Mercedes engine tag on the valve cover also has the engine code (OM646.986, OM646.989, OM646.990) which cross-references to the output level. Contact us with your VIN or engine code and we can confirm before you ship.
My Sprinter is throwing P0299 under-boost. Is it the turbo?
P0299 on a Sprinter points to VGT vane sticking as the primary suspect, but not exclusively. A boost leak in the charge piping, a failed intercooler end tank, or a cracked intake boot between the turbo and intercooler can produce the same code. Before pulling the turbo, check all charge piping for cracks at the connection points and pressure test the intercooler. If the charge piping is intact and the intercooler holds pressure, the turbo vanes are the likely cause.
My NCV3 bi-turbo Sprinter: can I rebuild just the one that failed?
We recommend against it. Both the LP (BV39) and HP (K04) units in the bi-turbo system operate under the same conditions and accumulate equivalent wear. When one fails visibly, the other is typically close behind. A mismatched bi-turbo system, one fresh and one worn, produces boost staging anomalies that the ECU has limited ability to correct for. Ship both, we rebuild both to matched spec, and you get a properly balanced system back.
Does the same Mercedes part number cover NCV3 and VS30?
No. The NCV3 OM646 BV39 (A6460900380) and the VS30 OM651 KP39 (A6510906380) are different part numbers and different CHRA designs despite sharing the BV39/KP39 frame family. They are not interchangeable. Similarly, the K04 high-pressure units differ between NCV3 and VS30 applications. Always confirm the part number from the turbo tag or the Mercedes EPC for your specific vehicle before shipping.
How do I ship my Sprinter turbo?
Submit the rebuild form at repair.theboostlab.com first. Drain residual oil from the oil inlet and outlet ports. Plug all ports. For bi-turbo Sprinters, ship both units in the same box. Include a note with your generation (T1N / NCV3 / VS30), engine code (OM612 / OM646 / OM651 / OM642), whether single or bi-turbo, and the Mercedes part number from the turbo tag if visible. Double-box with foam padding. Ship via UPS or FedEx to 37833 Pineapple Ave, Unit A, Dade City, FL 33523.
Ready to rebuild?
Start your rebuild request in our repair system. T1N through VS30, single and bi-turbo, all supported. VGT vane cleaning on every rebuild. In-house VSR balancing since 2008.
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