NHTSA ID Number: 10214729
Manufacturer Communication Number: 2020040008
TSB/Document Date: 2022-06-27
Summary
2020040008 Modification to the emissions control system
Emissions Campai i Emissions Campaign Bulletin
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ign
Campaign No. 2020040008, May 2022
Campa
TO: ALL MERCEDES-BENZ
and FREIGHTLINER SPRINTER CENTERS
Issions
SUBJECT: Model 906 (Sprinter)
Model Year 2010 - 2012
Modification to the emissions control system
tii)
Daimler Vans USA, LLC (“DVUSA”) and Mercedes-Benz USA, LLC (“MBUSA”) are performing an
emissions campaign on certain 906 Sprinter vehicles in order to modify to the vehicles’ emissions control
system. EPA and CARB have approved this emissions modification for these MY10 - 12 Sprinter (Model
906) vehicles. An authorized Mercedes-Benz or Freightliner Sprinter dealer will replace certain
emissions control system components and update certain software in the affected vehicles at no cost to
the owner of the vehicle.
Prior to performing this Emissions Campaign:
e Please check VMI to determine if the vehicle is involved in the emissions modification campaign and
if it has been previously repaired. Always Check VMI for any open campaigns, and perform
accordingly.
Please review the entire Emissions Campaign bulletin and follow the repair procedure exactly as
described.
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ign
Campa
Approximately 46,157 vehicles are involved.
Issions
Order No. V-RC-2020040008
THETA
tii)
This bulletin has been created and maintained in accordance with MBUSA-SLP S423QH001, Document and Data
Control, and MBUSA-SLP S424HH001, Control of Quality Records.
MA see ROSS Ue) ET: Msc eS)
8 Emissions Campaign 2020040008
Emissions Campaign 2020040008
Update May 2022
o Model: 906 Sprinter
o Model Year: 2010 - 2012
o Engine: 6-Cylinder Diesel (OM 642)
Warranty Information
Damage Code l Operation No. l Time Operation Text
Denial of AEM
49 10N 01 use operations for | up to2hr | Diagnosis time for pre-inspection if client
labor performed declines to reverse non-compliant modifications
Perform AEM
0797252 02 1218 2.4 hr Perform work package for field measure
02 1220 04h Additional labor for vehicle with auxiliary
battery in engine compartment
Additional: Mobile AEM at customer location
2181200 00 9627 +50% Mobile AEM Labor surcharge
sublet $75 travel allowance
Additional: Mobile AEM at customer location requiring overnight accommodation
21 813 00 00 9627 +50% Mobile AEM Labor surcharge
sublet $100 travel allowance
Parts Overview
NOx sensor downstream SCR catalytic NOx sensor upstream of
of SCR catalytic converter converter SCR catalytic converter
CDI Engine Control Unit
[1] Reference last page for complete list of parts to perform AEM
8 Emissions Campaign 2020040008
Scope of Work Outline
(i) Read and. follow all pages of work instructions completely! Page:
1. Safety Notes 4-18
2. Lifting and Ramps 19-21
3. Initial Quick Test 22-28
a. Upload print-out to paperless pXD
b. Evaluate pre-existing faults (see Pre-Inspection Guide below)
4. Pre-Inspection Special Procedure 29-33
a. Includes visual inspection of Exhaust Aftertreatment system (see Pre-Inspection Guide below)
5. Replacement of AEM parts 34-46
a. NOx Sensor Upstream of SCR Catalytic Converter
b. NOx Sensor Downstream of SCR Catalytic Converter
c. SCR Catalytic Converter
6. Execution of AEM Special Procedure 46-71
a. Includes guided steps to Replace CDI and Update Software of CDI, ETC, IC, and SCR
b. Fill-out and Install AEM Label
c. Result Report to verify successful completion of all AEM steps
i. Upload print-out to paperless pxD
7. Final Quick Test 71-74
a. Upload print-out to paperless pXD
b. Erase stored faults caused by the workshop
8. Parts List 76
Pre-Inspection Guide
1. Pre-existing fault codes causing a Check Engine Light (CEL):
a. If component causing fault will be replaced as part of the AEM:
i. Perform AEM - No additional action is needed
b. If component causing fault will be covered by the AEM Extended Warranty:
i. Perform AEM
ii. Perform repair of pre-existing fault
iii. Submit AEM Extended Warranty claims on a separate Repair Order after AEM claim is submitted
c. If component causing fault will not be replaced as part of AEM and not covered by AEM Extended Warranty:
Provide client with repair estimate, advise client AEM will not resolve Check Engine Light (CEL)
Document on Repair Order if client approves or declines repairs
iii. Perform AEM regardless if client approves or declines repairs
d. Alist of AEM Extended Warranty covered components is available in: XENTRY / CDI / Special Procedures /
Exhaust Aftertreatment Service Measure / Extended Warranty
2. Non-Compliant Alterations to the Exhaust Aftertreatment system found during the visual Pre-Inspection:
a. Document all non-compliant alterations to the Exhaust Aftertreatment system on the Repair Order
b. Ifaltered component(s) will be replaced as part of the AEM:
i. Perform AEM
c. If altered component(s) inhibit AEM installation or will sustainably affect the operation of the AEM:
i. Provide client with a repair estimate to reverse non-compliant alterations
1. If client approves repairs:
a. Reverse non-compliant alterations
b. Perform AEM
2. If client refuses repairs:
a. Do not perform AEM - Vehicle ineligible
b. Claim ‘Denial of AEM’ damage code and labor ops for diagnosis time performed
3. If technical assistance is needed, create a PTSS case
8 Emissions Campaign 2020040008
AEM installation Videos
Exemplary videos of the AEM installation are available via the following:
© XENTRY Workshop (XiW) / VAN / Emissions Modification Program
© Scan the QR code below with a mobile device and log-in with your XENTRY credentials
Campaign 2020040008 Video:
Emissions Campaign 2020040008
Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
k of injury. Skin or eye
injuries may result when
handling hot or glowing objects.
Wear protective gloves,
protective clothing and safety
glasses, if necessary.
Risk of injury
Contact with hot or glowing objects without suitable
protective clothing causes severe burns to skin and eyes.
When glowing objects come into contact with water, they
produce hot steam or cause the water to splash, which can
cause serious burns to skin or eyes.
If hot or glowing objects come into contact with unprotected
skin or eyes, they can cause serious and even permanent
injuries.
li)
There is a risk of fire when glowing objects come into
contact with combustible material.
Safety precautions/instructions
+ Wear protective clothing, safety glasses and heat-
resistant gloves.
+ Only transport hot or glowing objects with suitable aids.
+ Avoid the formation of sparks and contact with
combustible material when handling glowing objects.
First aid measures
+ Treat affected areas of skin with plenty of cold water
and cover with sterile dressings.
+ Consult a physician immediately.
Emissions Campaign 2020040008
Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from
working on the engine while it is being started or when it is running.
Risk of accident from vehicle
and burns) resulting from
being started or when it is
running.
starting off by itself when engine
running. Risk of injury (bruises
working on the engine while it is
Secure vehicle to prevent it from
starting off by itself. Wear
closed and snug-fitting work
clothes. Do not touch hot or
rotating parts.
Potential risks
Risk of accident
Caused by the vehicle starting off by itself during the
starting procedure
(e.g. during compression test) due to engaged gear or
with the engine running and vehicles with automatic
transmission due to selector lever position "P" or
“N" not being engaged (except for vehicles that do not
have selector lever position "P")
Risk of injury
Severe injuries can be caused by freely rotating parts in
the area of the running engine.
Because the engine heats up when operating, serious
burns can be caused by touching unshielded parts.
Safety instructions/precautions
+ In general, only work on a running engine when it is
absolutely necessary.
+ Apply parking brake before starting the engine.
+ The vehicle is to be secured against moving forwards or
backwards.
+ The person performing tests on a vehicle with the
engine running must sit in the driver's seat to be able to
prevent the vehicle from moving.
It is not permitted for persons to be in the danger zone
in front of or behind the vehicle while tests are being
performed.
Shift the gearshift lever to neutral on vehicles with
manual transmission.
On vehicles with automatic transmission, move selector
lever into position "P" or "N" (except for vehicles that
do not have selector lever position "P").
On vehicles that do not have selector lever position
the selector lever is to be secured against
unauthorized access.
Wear closed and snug-fitting work clothes.
Remove all jewelry such as necklaces, rings, etc.
Wear suitable head wear to cover long hair.
Before commencing any work on the running engine,
familiarize yourself with the location of potentially hot
parts.
When carrying out work when starting the engine or
when the engine is running, do not touch any hot or
rotating parts.
Use the exhaust extraction system.
First aid measures in the event of burns
+ Do not rub the skin areas affected; rinse with plenty of
cold water and cover skin with sterile dressings.
Consult a physician immediately.
Emissions Campaign 2020040008
Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.
Risk of injury. Moving parts
can pinch, crush or, in extreme
cases even sever extremities.
No parts of the body or limbs QWaming
should be within the operating
area of mechanical components
when moving components.
Risk of injury
When working on components that can be moved either by
hand, by means of electric motors, or hydraulically/
pneumatically via a connecting mechanism, serious injuries
can occur due to body parts being cut, pinched or crushed.
Safety instructions/precautions
+ Monitor hazard area.
Secure the operating area of mechanical components
against interference when parts are in motion.
Never touch the mechanism of a component while it is
being actuated by electric motors via the diagnosis or by
direct actuation (terminal 30).
Choose a test cable of sufficient length.
® Emissions Campaign 2020040008
Risk of death caused by vehicle slipping or toppling off of the lifting platform.
Risk of death caused by Align vehicle between vehicle lift
vehicle slipping or toppling off of | columns and position the four
the lifting platform support plates at the vehicle lift
support points specified by the
vehicle manufacturer.
Risk of accident and injury fi]
Ensure that the vehicle is ideally aligned and secured This list of hazards is not complete.
against tilting according to the general safety specifications — The safety specifications of the respective country are
and regulations. always valid. The user is personally responsible for
Non-observance of the safety specifications can cause the | complying with these.
vehicle to slip off the lift system and thereby result in life
threatening or fatal injuries.
Emissions Campaign 2020040008
Risk of burn injuries and scalding when working at AdBlue® lines and the components attached to them. Risk of injury
to skin and eyes when handling AdBlue®. Risk of poisoning caused by swallowing AdBlue®
Risk of burn injuries and
scalding when working at
AdBlue® lines and the
components attached to them.
when handling AdBlue®. Risk
of poisoning caused by
swallowing AdBlue®
Risk of injury to skin and eyes
Pour AdBlue® into suitable Awaming
containers only. Wait until the
pressure is released before
starting any work on the
exhaust aftertreatment system.
Potential risks
Risk of burn injuries and scalding
The AdBlue® lines and all components attached to them
are under pressure during operation and remain so after
the engine is switched off and may be hot. There is a risk of
burn injuries. There is a risk of scalding caused by
escaping hot AdBlue® when the line system is opened.
Risk of injury
There is a risk of skin irritation and eye damage on contact
with AdBlue®.
Risk of poisoning
There is a risk of poisoning if AdBlue® is swallowed.
Rules of conduct
* On vehicles with electrical delivery pump, the AdBlue®
is pumped from the line back into the AdBlue® tank
after the engine is switched off.
Safety precautions for handling removed parts and
working under the vehicle
+ Wear suitable protective gloves
+ Wear protective clothing
+ Wear safety glasses
First aid measures
Contact with skin: Wash the affected skin areas with plenty
of clean water. Change wetted clothing as quickly as
possible.
* On vehicles with a compressed air system, individual
lines are flushed with compressed air after the engine is
switched off. The engine must therefore be switched off
for at least 5 minutes before work on the exhaust
aftertreatment system may begin.
+ Open connections and plugs on the system components
slowly. Cover the connecting point with rags when
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TSB/Document ID: 2020040008
Replacement Service Bulletin Number:
MFR Communication Date: 2022-05-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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