Emissions Campaign Bulletin Emissions Campaign Bulletin
4 bo
= =
a= 2 n
@ Mercedes-Benz a
i) i=}
3
ao an
iS fe)
cos Campaign No. 2020040002, August 2022 s
Q S
= i)
Cj rot
Oo 4
2 o
Oo TO: ALL MERCEDES-BENZ and FREIGHTLINER SPRINTER CENTERS a
8 2
r= SUBJECT: Model 906 (Sprinter) a
i] Model Year 2016
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 MY16 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:
a « Please check VMI to determine if the vehicle is involved in the emissions modification campaign and m
a if it has been previously repaired. Always Check VMI for any open campaigns, and perform %
Ej accordingly. we
= « Please review the entire Emissions Campaign bulletin and follow the repair procedure exactly as o
22) described. 2
S$ °
€ pe}
= =}
Oo Approximately 22,591 vehicles are involved.
i) vow
53 I
w wo
2 =
r= Order No. V-RC-2020040002 =
Ww 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.
MEN Woe ROSS UE MEN: Mae ere Re

8 Emissions Campaign 2020040002
Emissions Campaign 2020040002
Update August 2022
o Model: 906 Sprinter
o Model Year: 2016 up to 09/2016 production
o Engine: 6-Cylinder Diesel (OM 642)
Warranty Information
Damage Code
Denial of AEM
49 10N 01 use operations for | up to2hr | Diagnosis time for pre-inspection if client declines
labor performed to reverse non-compliant modifications
0797091 Perform work package for field measure
Additional: Mobile AEM at customer location
2181200 Mobile AEM Labor surcharge
Additional: Mobile AEM at customer location requiring overnight accommodation
21 813 00 00 9627 Mobile AEM Labor surcharge
[sublet |__| $100 travel allowance
Parts Overview
NOx sensor downstream NOx sensor upstream of
of SCR catalytic converter SCR catalytic converter
[SS oe hya.m ie
aS = SSS = =|
7 > — ———
7 CE —_— = |
pt pe a on py esl See =
ae Ae fo eg
me NN nS
; SSS ae
ny elo =” =o
[i Reference last page for complete list of parts to perform AEM
1

8 Emissions Campaign 2020040002
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 29-32
a. Includes visual inspection of Exhaust Aftertreatment system (see Pre-Inspection Guide below)
5. Replacement of AEM parts 33-38
a. NOx Sensor Upstream of SCR Catalytic Converter
b. NOx Sensor Downstream of SCR Catalytic Converter
6. Execution of AEM Special Procedure 39-50
a. Includes guided steps: Software updates 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 51-58
a. Upload print-out to paperless pxD
b. Erase stored faults caused by the workshop
8. Parts List 59
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:
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. Allist 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. [faltered 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
2

8 Emissions Campaign 2020040002
AEM installation Videos
Exemplary videos of the AEM installation are available via the following:
co _XENTRY Workshop (XiW) / VAN / Emissions Modification Program
© Scan the QR code below with a mobile device and log-in with your XENTRY credentials
Campaign 2020040002 Video:
a
| el
[a] : at " - [a]
eb
re > ee era
Pie”
Lt . J it :
a
s Pa) F aie
". ee i
+ 7 J
. ie eT 7 =
a a La ln “t
=
* oo
= | om = :
‘a ” = "
3

® Emissions Campaign 2020040002
Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
Risk of injury. Skin or eye Wear protective gloves,
injuries may result when protective clothing and safety
handling hot or glowing objects. | glasses, if necessary.
Risk of injury Safety precautions/instructions
Contact with hot or glowing objects without suitable + Wear protective clothing, safety glasses and heat-
protective clothing causes severe burns to skin and eyes. resistant gloves.
When glowing objects come into contact with water, they + Only transport hot or glowing objects with suitable aids.
produce hot steam or cause the water to splash, which can, Avoid the formation of sparks and contact with
cause serious burns to skin or eyes. 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 First aid measures
injuries. + Treat affected areas of skin with plenty of cold water
il and cover with sterile dressings.
There is a risk of fire when glowing objects come into + Consult a physician immediately.
contact with combustible material.
4

® Emissions Campaign 2020040002
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 | Secure vehicle to prevent it from
starting off by itself when engine | starting off by itself. Wear
running. Risk of injury (bruises | closed and snug-fitting work
and burns) resulting from clothes. Do not touch hot or
working on the engine while it is | rotating parts.
being started or when it is
running.
Potential risks + It is not permitted for persons to be in the danger zone
in front of or behind the vehicle while tests are being
Risk of accident performed
Caused by the vehicle starting off by itself during the + Shift the gearshift lever to neutral on vehicles with
starting procedure manual transmission.
(e.g. during compression test) due to engaged gear or + On vehicles with automatic transmission, move selector
with the engine running and vehicles with automatic lever into position "P" or "N" (except for vehicles that
transmission due to selector lever position "P" or do not have selector lever position "P").
“N" not being engaged (except for vehicles that do not + On vehicles that do not have selector lever position "P",
have selector lever position "P") the selector lever is to be secured against
; ini unauthorized access.
Risk of injury
: + Wear cl -fi k cloth
Severe injuries can be caused by freely rotating parts in ear closed and snug-fitting work clothes.
the area of the running engine. + Remove all jewelry such as necklaces, rings, etc.
Because the engine heats up when operating, serious + Wear suitable head wear to cover long hair.
burns can be caused by touching unshielded parts. + Before commencing any work on the running engine,
; - familiarize yourself with the location of potentially hot
Safety instructions/precautions paris, N2e you w ' p may
+ In general, only work on a running engine when it is + When carrying out work when starting the engine or
absolutely necessary. . .
when the engine is running, do not touch any hot or
+ Apply parking brake before starting the engine. rotating parts.
+ The vehicle is to be secured against moving forwards or + Use the exhaust extraction system.
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

® Emissions Campaign 2020040002
Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.
Risk of injury. Moving parts No parts of the body or limbs
can pinch, crush or, in extreme | should be within the operating
cases even sever extremities. area of mechanical components
when moving components.
Risk of injury + Secure the operating area of mechanical components
When working on components that can be moved either by against interference when parts are in motion.
hand, by means of electric motors, or hydraulically/ + Never touch the mechanism of a component while it is
pneumatically via a connecting mechanism, serious injuries being actuated by electric motors via the diagnosis or by
can occur due to body parts being cut, pinched or crushed. direct actuation (terminal 30).
Safety instructions/precautions + Choose a test cable of sufficient length.
+ Monitor hazard area.
6

® Emissions Campaign 2020040002
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.
7

® Emissions Campaign 2020040002
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 Pour AdBlue® into suitable
scalding when working at containers only. Wait until the
AdBlue® lines and the pressure is released before
components attached to them. _| starting any work on the
Risk of injury to skin and eyes _| exhaust aftertreatment system.
when handling AdBlue®. Risk
of poisoning caused by
swallowing AdBlue®
Potential risks * On vehicles with a compressed air system, individual

. an . lines are flushed with compressed air after the engine is
Risk of burn injuries and scalding switched off. The engine must therefore be switched off
The AdBlue® lines and all components attached to them for at least 5 minutes before work on the exhaust
are under pressure during operation and remain so after aftertreatment system may begin.
the engine is switched off and may be hot. There is arisk of ~ Open connections and plugs on the system components
burn injuries. There is a risk of scalding caused by slowly. Cover the connecting point with rags when
escaping hot AdBlue® when the line system is opened. opening.

Risk of injury Only pour AdBlue® into marked containers specially

seat designated for the purpose. Do not pour AdBlue® into
There is a risk of skin irritation and eye damage on contact drinking containers
with AdBlue®.

+ Wipe up any AdBlue® spills immediately as there is a

Risk of poisoning high risk of someone slipping.
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 Contact with eyes: In the event of contact with eyes,

working under the vehicle immediately rinse eyes thoroughly with plenty of clear

+ Wear suitable protective gloves water; contact an eye doctor if necessary.

+ Wear protective clothing Ingestion rinse mouth with clean water and drink large
quantities of water. Immediately seek medical assistance.

+ Wear safety glasses

First aid Firefighting measures

irst aid measures -

" " . u . AdBlue® is not combustible. NH3 (ammonia) can be
Contact with skin: Wash the affected skin areas with plenty released in the event of fire, causing a risk of poisoning.
of clean water. Change wetted clothing as quickly as Firefighting measures must therefore be suited to the
possible. surroundings.

8

® Emissions Campaign 2020040002
Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it.
Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of
poisoning caused by skin contact with solid components of the exhaust.
Risk of burn injuries, Wear protective clothing and
suffocation and poisoning when | safety glasses. Use the
working on the exhaust system | extraction system. Move people
and the components connected | out of the hazard area
to it. Risk of suffocation and risk
of poisoning caused by
inhalation of gaseous and solid
components of the exhaust.
Risk of poisoning caused by
skin contact with solid
components of the exhaust.
Risk of burn injuries and diesel soot. To prevent skin contact on hands, wear
The exhaust system and all components connected to it nitrile gloves.
are very hot during operation and remain so after the First aid
engine is switched off. Do not touch hot parts. rst aid measures
In the event of inhalation:
Move victim from the hazard area to fresh air without
Risk of suffocation and poisoning endangering yourself and consult a physician immediately.
Exhaust gases may also cause cancer.
At higher concentrations, irritation of mucous membranes After contact with skin:
and headaches may occur Carbon monoxide may cause Immediately wash affected areas of the body with plenty of
famage to unborn children. soap and water. Employees who have experienced skin
Avoid inhalation of exhaust gases; wear respiratory contact must consult a physician immediately.
protection.
Use the exhaust extraction system. After contact with eyes:
Risk of injury Rinse eyes thoroughly with running water for at least ten
Risk of injury to the eyes, skin, and respiratory paths due to minutes with the eyelids wide open and contact an eye
contact with exhaust residues such as diesel particulates ‘octor immediately
9

® Emissions Campaign 2020040002
Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of
injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
Risk of explosion from No fires, sparks, open flames or
explosive gas. Risk of smoking. Wear acid-resistant
poisoning and caustic burns | gloves, clothing and glasses.
from swallowing battery Only pour battery acid into
electrolyte. Risk of injury suitable and appropriately
through burns to skin and eyes | marked containers.
from battery acid or when
handling damaged lead-acid
batteries

Potential risks ring), become hot in seconds and red hot/liquid metal

sprays are released.

Risk of explosion

When charging lead batteries with battery electrolyte Risk of burn injuries

containing sulfuric acid, a highly explosive oxyhydrogen In the event of a short circuit from the battery positive to

gas mixture is created that ignites by means of fire, sparks, ground, battery terminals and conductive objects causing

open flames and smoking. short circuit, e.g. tool or jewelry (watch band or ring),
become hot in seconds and cause burns.

Risk of injury
The battery electrolyte contains diluted sulfuric acid that Risk of poisoning
causes caustic burns to the skin, eyes and mucous If battery electrolyte is swallowed, this can result in
membranes in the event of contact. Bonded electrolyte is symptoms of poisoning such as headache, dizziness,
just as caustic as liquid electrolyte. Battery electrolyte mist stomach ache, respiratory paralysis, unconsciousness,
causes caustic burns to the eyes. If inhaled, this can result vomiting, caustic burns and cramps. Absorption of lead in
in caustic burns to the mucous membranes and respiratory _ the body through contact with leaded components (battery
paths. In the event of a short circuit from the battery terminals, lead plates in damaged batteries) damages the
positive to ground, battery terminals and conductive objects _ blood, nerves and kidneys; lead compounds are also toxic
causing short circuit, e.g. tool or jewelry (watch band or for reproduction.

Safety precautions/instructions + Only fill liquid battery electrolyte into suitable and

+ Wear acid-resistant gloves and clothing and safety appropriately marked containers.
glasses with side guards. + Only store, transport and install batteries with liquid

* Only charge lead batteries in well ventilated rooms with battery electrolyte horizontally, otherwise battery
appropriate voltage and appropriate current with electrolyte can escape from the degassing holes
approved chargers, taking into account the instructions + Ensure that at least one degassing hole at the battery is
of the battery and battery charger manufacturers. not sealed, as otherwise overpressure builds that leads

+ No fire, sparks, open flames and smoking. to bursting of the battery.

+ Switch on the battery charger only after connecting to . Ensure proper connection of the degassing line to the
the terminals; switch off the battery charger before degassing hole.
disconnecting from the terminals. + Ensure the degassing line does not have any kinks and

* Do not place any conductive objects on the battery and is not blocked at any point.
do not wear any conductive jewelry (risk of short circuit). + Observe the instructions for use for the respective lead

+ Always disconnect the negative terminal first; always batteries and the operator's manual of the vehicle.
connect the positive terminal first (risk of short circuit + The battery housing may become brittle over time,
caused by tool). therefore do not expose the battery to direct sunlight.

* Strict caution is required when handling damaged + Discharged batteries may freeze and are thereby
batteries (removing from vehicle damaged in accident) damaged, therefore always store batteries at a location
because of the sharp edges on the fractured housing protected against frost.
and escaped electrolyte

+ Keep batteries and battery electrolyte away from
unauthorized persons (especially children).

10

® Emissions Campaign 2020040002
Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury
through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
First aid measures Swallowing battery electrolyte
Contact with eyes + Have the person affected drink plenty of water with

activated charcoal supplement.
+ Rinse eyes immediately with plenty of water.
. . As a general rule, the person affected should consult a
Contact with skin medical service or physician after first aid has been
+ Remove wet clothing. rendered.
+ Immediately neutralize battery electrolyte on the skin or —_ Fire protection measures

clothing with acid neutralizer or soapy water and rinse itabl ti ishi tt

off with plenty of water Suitable extinguishing agents
+ Wash off lead on the skin immediately with water and * C02 and dry extinguishing agent

soap.

Inhalation of battery electrolyte mist
+ Take the affected person out into the fresh air.
6S | A (Ca
Warning notes for lead batteries with battery electrolyte containing sulfuric acid
1 No fire, sparks, open flames or 4 Risk of caustic burns 6 Keep away from children
smoking
2 Risk of explosion 5 Wear eye protection 7 First aid
3 Observe operating instructions
4

® Emissions Campaign 2020040002
Risk of injury caused by contact with battery gel when handling damaged lead-gelbatteries
Risk of injury caused by No fires, sparks, open flames or
contact with battery gel when smoking. Wear acid-resistant
handling damaged lead- gloves, clothing and glasses.
gelbatteries
Potential risks + Do not place any tool or other conductive object on the
. —. lead-gel battery (risk of short circuit!)
Risk of poisoning + Disconnect and remove lead-gel batteries for charging.
Swallowing battery gel can cause symptoms of poisoning . 7 . . .
such as headaches, dizziness, stomach aches, respiratory Aways disconnect the negative terminal first and
paralysis, unconsciousness, vomiting, caustic burns and always connect the positive terminal firs
cramps. + Only switch on the battery charger after connecting to
The absorption of lead in the body can cause damage to the terminals and switch off before disconnecting.
blood, nerves and kidneys; in addition, lead compounds are * Keep lead-gel batteries away from unauthorized
considered to represent a reproductive hazard. persons (especially children).
Risk of inj + Pay attention to instructions for use of the particular
ISK of Injury lead-gel battery and the operator's manual for the
The bonded electrolyte set free is just as caustic as a vehicle.
liquid electrolyte that can cause heavy caustic burns to skin, Wear acid-resistant clothing and safety glasses with
and eyes. Strict caution is required when handling side guards
damaged lead-gel batteries (e.g. removing from vehicle . . . .
damaged in accident) because of the sharp edges onthe *_ Only pour acid gel into suitable and appropriately
fractured housing and direct contact with the lead plates marked containers.
Safety precautions and rules of conduct
+ No fires, sparks, open flames or smoking.
First aid measures Swallowing battery gel
Contact with eyes + Have the person affected drink plenty of water
supplemented with activated charcoal
+ Rinse out eyes immediately with plenty of water.
| | After performing first aid, always consult medical
Contact with skin service or a physician.
+ Remove moistened clothing. . .
Fire protection measures
+ Immediately neutralize drops of acid or gel on skin or
clothing with acid neutralizer or soapy water and rinse Suitable extinguishing agents
off with plenty of water. * CO? and dry extinguishing agent
12

® Emissions Campaign 2020040002
Notes on avoiding damage through contamination and foreign objects
Notes on avoiding damage
through contamination and
foreign objects
Information on affected component parts
With each maintenance and repair work to the engine as Before assembling or finalization work all components
well as to the ancillary assemblies and detachable parts are to be checked for soiling, left-over foreign objects and
comes the danger of property damage caused by
contamination and foreign bodies any fluids, and if any are found they are to be removed
Particularly at risk are: Information on cleaning
+ Exhaust gas turbocharger For cleaning, use only clean tools and clean, lint-free rags.
+ Hot film mass air flow sensor Residues of cleaning agents and removed contaminants
+ Compressor must be cleared from the engine, ancillary assemblies and
detachable parts.
+ Emission control system
+ All components involved in gas exchange ®
Do not use compressed air for removing any soiling.
Notes on removal/installation Otherwise, components (e.g. the hot-wire element of the
. . a . . hot film mass air flow sensor) could be damaged or
Openings through which soiling or foreign objects are
introduced into the engine, its ancillaries or detachable contamination could enter the engine, ancillary assemblies
parts, must be sealed immediately and detachable parts without being noticed.
For this purpose, suitable, clean covers and plugs or clean,
lint-free rags are to be used.
Do not forget to remove all covers, plugs or rags when
assembling or when finalizing the work.
This avoids any damage and complaints about engine
running characteristics.
13