When you smell burning under the hood of your brand-new Sprinter, don’t panic. It’s probably your first Diesel Particulate Filter (DPF) regeneration cycle. During the first regen, the filter reaches very high temperatures and burns off any paint, body undercoat, or Waxoyl that might have dripped on it during manufacturing.
The owner’s manual is light on details about DPF regeneration. They say that if you mainly drive short distances, you should drive on a highway for 20 minutes every 300 miles. That suggests that the regeneration cycle happens about every 300 miles, but in real life we’ve found it to be between 500 and 750 miles typically.
So you’re likely to encounter your first regeneration at about 500 miles. You’ll smell burning, and if you get out of the van and stop the engine you’ll hear the click-click-click of hot metal cooling down.
Mercedes would never admit that their vans stink, so you won’t see anything about smoke or noxious fumes in the manual. However, these are quite likely during the first couple of regeneration events.
Basically, the Diesel Particulate Filter is heating up and burning soot out of the particle filter. It’s not the soot that you smell, just any rubber body undercoat or Waxoyl (the yellow coating they spray on exposed metal) that dripped on the unit during manufacture. Once it’s burned off, the smell will stop.
Ironically, if you do what most sane drivers would do when they smell burning, you probably stopped the engine and thus stopped the regen cycle mid-flow. That means it’ll have to try again later to finish the cycle.