2010 Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # 20100090005 Date: 101001

2010 Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # 20100090005 Date: 101001

Campaign - Repl. DEF (AdBlue(R)) System Line

FILE: SERVICE:

GROUP 00 OF SERVICE INFORMATION BINDER

PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER

Campaign No. 2010090005, October 2010

TO: ALL MERCEDES-BENZ CENTERS

SUBJECT:

Model 906.1, Model Year 2010

Replace Diesel Exhaust After-treatment Fluid (AdBlue) System Line

Daimler AG (DAG), the manufacturer of Freightliner and Mercedes-Benz Sprinter vehicles, has determined that the metering line at the diesel

exhaust after-treatment fluid (AdBlue) tank may leak in the area of the connector due to production quality issues at the supplier. Through capillary

action the reducing agent contained in the AdBlue tank may travel through the connector and into the wiring harness, and possibly into the AdBlue

control module. This may lead to electrical signal distortions in the diesel exhaust after-treatment system.

Daimler Vans USA, LLC (DVUSA) and Mercedes-Benz USA, LLC (MBUSA) therefore has initiated a campaign of all potentially affected

vehicles described above. The service campaign will be conducted to replace the AdBlue Exhaust After Treatment System Lines. In addition the

AdBlue wiring harness and AdBlue control module will be checked for the presence of AdBlue and if found will be replaced.

Attached is a sample copy of a letter which owners of the affected vehicles will receive.

Prior to performing this Service Campaign:

^ Please check VMI to determine if the vehicle is involved in the Campaign and if it has been previously

repaired.

^ Please review the entire Service Campaign bulletin and follow the repair procedure exactly as described.

Please note that Recall and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.

Approximately 325 vehicles are affected.

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Procedure

Note:

^ For vehicles where AdBlue fluid line and connector are not accessible (vehicles body is blocking access) proceed to Subject A.

^ For vehicles with chassis only proceed to Subject B

A. Replace AdBlue Fluid Line and Check Harness (Fluid Line Connector and Harness to AdBlue Pump are Not Accessible)

Caution!

For information on preventing damage to electronic components due to electrostatic discharge; refer to:

WIS: AH54.00-P-0001-01A

1. Disconnect electrical connector at AdBlue control module (4, Figure 1) refer to WIS:

AR14.40-D-2020S steps 1-5 only.

WARNING!

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; refer to

WIS document: AS14.40-Z-0001-01A.

For notes on use, material properties and handling of AdBlue; refer to WIS document:

AH14.40-N-0001-01AB.

2. Disconnect electrical connector (Arrow, Figure 1) of AdBlue line (1) to frame wiring harness (3):

^ Unclip AdBlue frame wiring harness clips (A, Figure 1) from frame.

^ Remove AdBlue fluid line mounting clip (B Figure 1) from frame stud.

^ Loosen AdBlue tank (2, Figure 1) to allow access to AdBlue frame wire harness connector (arrow) (do not remove tank); refer to WIS:

AR14.40-D-2014SA steps 1-5, 7.

^ Disconnect electrical connector (arrow, Figure 1) of AdBlue line (1) to frame wiring harness (3).

Note:

Allow a drying time of 4 hours to determine if AdBlue crystal formations appear on the electrical connectors (disconnected in steps 1 and 2).

During this time proceed to step 3 of this procedure.

3. Replace AdBlue fluid line (1, Figure 1); refer to WIS document: AR14.40-D-2001SA then continue with Procedure.

Note (regarding above WIS instructions):

^ For AdBlue line connector (C, Figure 1) removal from AdBlue pump fitting: Slightly twist /rotate the AdBlue line connector (C) on the

AdBlue pump fitting before removing (refer also to above WIS instructions for complete information). Be careful not to break the

AdBlue pump fitting

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^ An AdBlue fluid line mounting clip (Arrow, Figure 2) is located above storage box (A, Figure 3) under right seat. Remove this clip by

prying it off from the mounting stud (do not remove storage box [A}).

^ Ensure that frame mounting clip (arrow, Figure 2) is transferred from old Adblue fluid line to new fluid line in the same position on the

line. The new line will have white paint marks indicating the mounting

clips location.

^ Do not remove AdBlue injection valve (A, Figure 4) from exhaust pipe. Pull back insulation (B) near end of AdBlue line and remove

retaining clip (arrow) to disconnect line. Installation is in reverse order. Be to sure roll back insulation over Adblue line when installing

new AdBlue line.

Note:

Perform service work on other vehicles during the 4 hour AdBlue drying time on the connectors.

4. Check for crystal formation on AdBlue control module (4, Figure 1) connectors after 4 hours of drying time:

^ If crystal formation can be seen on connectors (4, Figure 1):

Replace AdBlue control module (4); refer to WIS document: AR14.40-D-2020S then proceed to step 5.

Note:

Anticipated replacement rate for control module replacement is very low; ensure replacement criteria is met.

^ If no crystal formation can be seen on connectors (4, Figure 1):

Proceed to Step 5.

5. Check for crystal formation on electrical connectors of AdBlue line (1, Figure 1) to frame wiring harness (3):

^ If crystal formation can be seen on electrical connectors:

Replace frame wiring harness (3) then continue with procedure.

Note:

Anticipated replacement rate for frame wiring harness replacement is very low; ensure replacement criteria is met.

^ If no crystal formation can be seen on electrical connectors:

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Continue with Procedure.

6. Reassemble in reverse order. Top-off AdBlue tank.

7. Perform SCN coding of in instrument cluster, refer to WIS: AR54.21-P-0013-02X

8. Read out fault memory; refer to WIS document: AD00.00-D-2000-04SD.

B. Replace AdBlue Fluid Line, Check Harness on Chassis

Caution!

For information on preventing damage to electronic components due to electrostatic discharge; refer to:

WIS: AH54.00-P-0001-01A

1. Disconnect electrical connector at AdBlue control module (4, Figure 5) refer to WIS:

AR14.40-D-2020S steps 1-5 only.

2. Disconnect electrical connector (arrow, Figure 5) of AdBlue line (1) to frame wiring harness (3).

Note:

Drying time of 4 hours must be allowed to determine if AdBlue crystal formations appear on the electrical connectors (disconnected in steps 1

and 2). During this time proceed to step 3 of this procedure.

WARNING!

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.

Refer to WIS document: AS14.40-Z-0001-01A.

Note:

For notes on use, material properties and handling of AdBlue; refer to WIS document:

AH14.40-N-0001-01AB.

3. Replace AdBlue fluid line (1, Figure 5); refer to WIS document: AR14.40-D-2001SA then continue with Procedure.

Note (regarding WIS AR14.40-D-2001SA):

^ For Adblue line connector (A, Figure 5) removal from AdBlue pump fitting: Slightly twist /rotate the AdBlue line connector (A) on the

AdBlue pump fitting before removing (refer also to above WIS instructions for complete information). Be careful not to break the AdBlue

pump fitting.

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^ An AdBlue fluid line mounting clip (arrow, Figure 6) is located above storage box (A, Figure 7) below right seat. Remove this clip by

prying it off from the mounting stud (do not remove storage box [A]).

^ Ensure that frame mounting clip (arrow, Figure 6) is transferred from old Adblue fluid line to new fluid line in the same position on the line.

The new line will have white paint marks indicating the mounting clips location.

^ Do not remove AdBlue injection valve (A, Figure 8) from exhaust pipe. Pull back insulation (B) near end of AdBlue line and remove

retaining clip (arrow) to disconnect line. Installation is in reverse order. Be sure to roll back insulation over Adblue line when installing new

AdBlue line.

Note:

Perform service work on other vehicles during the 4 hour AdBlue drying time on the connectors.

4. Check for crystal formation on AdBlue control module (4, Figure 5) connectors after 4 hours of drying time:

^ If crystal formation can be seen on connectors (4, Figure 5):

Replace AdBlue control module (4); refer to WIS document: AR14.40-D-2020S then proceed to step 5.

Note:

Anticipated replacement rate for control module is very low; ensure replacement criteria is met.

^ If no crystal formation can be seen on connectors (4, Figure 5):

Proceed to Step 5.

5. Check for crystal formation on electrical connectors of AdBlue line (1, Figure 5) to frame wiring harness (3):

^ If crystal formation can be seen on electrical connectors:

Replace frame wiring harness (3) then continue with procedure.

Note:

Anticipated replacement rate for frame wiring harness is very low; ensure replacement criteria is met.

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^ If no crystal formation can be seen on electrical connectors:

Continue with Procedure.

6. Reassemble in reverse order. Top-off AdBlue tank.

7. Perform SCN coding of in instrument cluster, refer to WIS: AR54.21-P-0013-02X

8. Read out fault memory; refer to WIS document: AD00.00-D-2000-04SD.

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Primary Parts Information

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2010 Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898)