2020040008 Service Bulletin/Repair Instructions

Campaign No. 2020040008, August 2022
TO:
ALL MERCEDES-BENZ and FREIGHTLINER SPRINTER CENTERS
SUBJECT:
Model 906 (Sprinter)

Model Year 2010 - 2012

Modification to the emissions control system
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:

•
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.
Approximately 46,157 vehicles are involved.
Order No. V-RC-2020040008

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.
a
Emissions Campaign 2020040008
Emissions Campaign 2020040008

Update August 2022
o

o

o
Model: 906 Sprinter

Model Year: 2010 - 2012

Engine: 6-Cylinder Diesel (OM 642)
Warranty Information

Damage Code

Denial of AEM

49 10N 01

Perform AEM

07 972 52
Operation No.
Time
Operation Text
use operations for

labor performed
up to 2 hr
Diagnosis time for pre-inspection if client

declines to reverse non-compliant modifications
02 1218

02 1220
2.4 hr

0.4 h
Perform work package for field measure

Additional labor for vehicle with auxiliary

battery in engine compartment
Additional: Mobile AEM at customer location

21 812 00

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

of SCR catalytic converter
SCR catalytic

converter
NOx sensor upstream of

SCR catalytic converter
CDI Engine Control Unit
Reference last page for complete list of parts to perform AEM
1
a
Emissions Campaign 2020040008
Scope of Work Outline

1.

2.

3.
4.

5.
6.
7.
8.
Read and follow all pages of work instructions completely!

Safety Notes

Lifting and Ramps

Initial Quick Test

a. Upload print-out to paperless pXD

b. Evaluate pre-existing faults (see Pre-Inspection Guide below)

Pre-Inspection Special Procedure

a. Includes visual inspection of Exhaust Aftertreatment system (see Pre-Inspection Guide below)

Replacement of AEM parts

a. NOx Sensor Upstream of SCR Catalytic Converter

b. NOx Sensor Downstream of SCR Catalytic Converter

c. SCR Catalytic Converter

Execution of AEM Special Procedure

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

Final Quick Test

a. Upload print-out to paperless pXD

b. Erase stored faults caused by the workshop

Parts List
Page:

4-18

19-21

22-28
29-33

34-46
46-71
71-74
76
Pre-Inspection Guide

1.
2.
3.
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:

i. Provide client with repair estimate, advise client AEM will not resolve Check Engine Light (CEL)

ii. Document on Repair Order if client approves or declines repairs

iii. Perform AEM regardless if client approves or declines repairs

d. A list of AEM Extended Warranty covered components is available in: XENTRY / CDI / Special Procedures /

Exhaust Aftertreatment Service Measure / Extended Warranty

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. If altered 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

If technical assistance is needed, create a PTSS case
2
a
Emissions Campaign 2020040008
AEM installation Videos

Exemplary videos of the AEM installation are available via the following:

o

o
XENTRY Workshop (XiW) / VAN / Emissions Modification Program

Scan the QR code below with a mobile device and log-in with your XENTRY credentials
ĂŵƉĂŝŐŶϮϬϮϬϬϰϬϬϬϴsŝĚĞŽ͗
3
a
Emissions Campaign 2020040008
Risk 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. Skin or eye

injuries may result when

handling hot or glowing objects.
aWarning
Risk of injury
Safety precautions/instructions
Contact with hot or glowing objects without suitable

protective clothing causes severe burns to skin and eyes.
•
Wear protective clothing, safety glasses and heatresistant gloves.
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.
•
Only transport hot or glowing objects with suitable aids.
•
Avoid the formation of sparks and contact with

combustible material when handling glowing objects.
If hot or glowing objects come into contact with unprotected

skin or eyes, they can cause serious and even permanent

injuries.
First aid measures

•
i

There is a risk of fire when glowing objects come into

contact with combustible material.
Treat affected areas of skin with plenty of cold water

and cover with sterile dressings.
•
Consult a physician immediately.
4
a
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.

Secure vehicle to prevent it from aWarning

starting off by itself. Wear

closed and snug-fitting work

clothes. Do not touch hot or

rotating parts.
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.

•
It is not permitted for persons to be in the danger zone

in front of or behind the vehicle while tests are being

performed.
Caused by the vehicle starting off by itself during the

starting procedure
•
Shift the gearshift lever to neutral on vehicles with

manual transmission.
(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
•
On vehicles with automatic transmission, move selector

lever into position "P" or "N" (except for vehicles that

do not have selector lever position "P").
"N" not being engaged (except for vehicles that do not

have selector lever position "P").
•
On vehicles that do not have selector lever position "P",

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.
Potential risks

Risk of accident
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.

---------------------------------------------------------------------------
First aid measures in the event of burns

•
•
Consult a physician immediately.
Do not rub the skin areas affected; rinse with plenty of

cold water and cover skin with sterile dressings.
5
a
Emissions Campaign 2020040008
Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.
No parts of the body or limbs

aWarning

should be within the operating

area of mechanical components

when moving components.
Risk of injury. Moving parts

can pinch, crush or, in extreme

cases even sever extremities.
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

•
•
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.
Monitor hazard area.
6
a
Emissions Campaign 2020040008
Risk of death caused by vehicle slipping or toppling off of the lifting platform.
Align vehicle between vehicle lift aDanger

Risk of death caused by

vehicle slipping or toppling off of columns and position the four

support plates at the vehicle lift

the lifting platform.

support points specified by the

vehicle manufacturer.

Risk of accident and injury

Ensure that the vehicle is ideally aligned and secured

against tilting according to the general safety specifications

and regulations.

Non-observance of the safety specifications can cause the

vehicle to slip off the lift system and thereby result in life

threatening or fatal injuries.
i

This list of hazards is not complete.

The safety specifications of the respective country are

always valid. The user is personally responsible for

complying with these.
7
a
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®

Pour AdBlue® into suitable

containers only. Wait until the

pressure is released before

starting any work on the

exhaust aftertreatment system.
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®

Potential risks
•
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

opening.
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

12 3 4 5 6

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