Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI42-45_N-048679 Date: 100201

ABS/TCS - ESP Light ON after Engine Start

ESP indicator lamp lights up after engine start

Topic number LI42.45-N-048679

Version 1

Design group 42.45 Electronic Stability Program (ESP), Stability Control (SR)

Date 02-01-2010

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

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Validity Model 906

as of VIN end number N384751, S309307 and E013853

up to VIN end number N423037, S400651 and E021145

Reason for change

Reason for block

Complaint:

ESP indicator lamp and/or ESP malfunction message in instrument cluster after engine start. The ESP indicator lamp is off when the engine is

restarted.

Cause:

25 seconds after "ignition ON" without an engine start, the fuel pump in the tank shuts down. This shutdown of the fuel pump produces an

interference pulse. Fault 4BD0 (turn rate sensor - internal fault) is stored.

Remedy:

Routing of a separate ground line from yaw rate sensor B25/15 to ground point W 1/4.

Installation site:

B 25/15, driver seat box

W 1/4, right A-pillar in footwell

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Explanation of attachment:

A: Lift cap (gray) on connector of yaw rate sensor B 25/15.

B: Unclip old ground line (pin 1) and insulate line.

C: Clip in new ground line and engage cap (gray).

D: Route new ground line parallel with frame wiring harness and fasten to W 1/4 (the ground point with fewer ground cables attached).

E: Routing in right-hand drive vehicles.

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI72-10_N-048762 Date: 100201

Body - Front Hinged Door/Holder Noisey/ Broken

Door holder of front hinged door broken / door cannot

be opened or closed / door holder makes noises

Topic number LI72.10-N-048762

Version 1

Design group 72.10 Front door

Date 02-01-2010

Validity Model 906

Reason for change

Reason for block

Complaint:

The door holder of the front hinged door is broken.

The front hinged door cannot be opened or closed. The door holder makes a lot of noise.

Cause:

The door holder/ door check of the front hinged door is broken at the mounting brackets.

Remedy:

The defective door holder must be replaced with a new door holder.

The door holder can be reinforced with gusset plates to prevent repeat damage.

Proceed as follows:

^ The web dimensions of the gusset plate are approx. 17 x 17 mm (panel thickness: 1-1.5 mm). The square plate must be divided diagonally into

two triangles.

^ In the area of the weld seam, the zinc coating on the door holder must be removed.

^ In addition, the two attachment plates of the door holder must be aligned level with the attachment surface.

^ The gusset plates must be welded on with a tacked seam (see attachment). The component must be checked for welding distortion and realigned

if necessary.

^ The welds must be smoothened.

^ The welded area must be coated with zinc dust paint.

^ Check the mechanical components for ease of movement.

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

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^ The reinforced door holder must be installed as described in WIS.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI83-50_N-048689 Date: 100201

A/C - Water Entry Via Roof Air Conditioning

Water entry via roof air conditioning (HH7)

Topic number LI83.50-N-048689

Version 1

Design group 83.50 Rear air conditioning

Date 02-01-2010

Validity Model 906.6 and 906.7

Reason for change

Reason for block

Complaint:

Water enters vehicle interior via roof air conditioning (code HH7).

Cause:

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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1. Leak between cover and evaporator unit on vehicle roof. (with production date before January 2007)

2. Leak between evaporator unit and vehicle roof.

Remedy:

Check the cover for damage. If there is no damage on the cover, remove the cover panel from the roof air conditioning.

If there are traces of water in the evaporator unit (see picture 1), the water is entering the air conditioning via the bolt holes of the cover panel.

Remedy 1: See WIS document SM83.50-D-0001AK

If no traces of water are visible, the water may have entered the vehicle interior due to an improperly routed seal between the evaporator unit and

vehicle roof (see picture 2).

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI27-60_N-048766 Date: 100201

A/T - Limp-Home Mode And DTC 0002 'Undervoltage' Stored

ESM (electronic selector lever module) fault 0002 "Undervoltage"

Topic number LI27.60-N-048766

Version 1

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Page 96

Design group 27.60 Gearshift, control

Date 02-01-2010

Validity Sprinter model designation 906 with code G40

Reason for change Extended for MBUSA

Reason for block

Complaint:

The vehicle enters limp-home mode and has stored the fault 0002 "Undervoltage" in the ESM control module.

Cause:

The undervoltage fault is stored as an event in the ESM control module and causes the automatic transmission to enter limp-home mode.

Remedy:

Check and, if necessary, process possible causes and remedies as described in the DAS.

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Load new software for the ESM control unit.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI14-20_N-048802 Date: 100201

Computer/Controls - Noises After Engine Is Switched Off

Noises during engine run-on / EGR valve cleaning function

Topic number LI14.20-N-048802

Version 1

Design group 14.20 Exhaust gas recirculation

Date 02-01-2010

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Page 105

Validity Model 906 with OM646 or OM642

Reason for change

Reason for block

Complaint:

Noises after engine is switched off.

Cause:

The noises during engine run-on are caused by the cleaning function of the EGR valve.

Remedy:

No remedy required because the cleaning function is the series production configuration. Sample noises which correspond to the series production

configuration are attached.

Replacing the EGR valve may only be carried out if a corresponding fault code is entered in the engine control unit.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI64-30_N-048760 Date: 100201

Body - Side Wall Seam Above Rear Lamps Cracked

Side wall seam above rear lamps cracked

Topic number LI64.30-N-048760

Version 1

Design group 64.30 Corner paneling

Date 02-01-2010

Validity Sprinter model designation 906.6##

Reason for change

Reason for block

Complaint:

1. The PVC sealing seam above the rear lamps is cracked.

2. Visible corrosion above the rear lamps at the transitions from the D-pillars to the rear side walls.

Cause:

The sealing seams were applied up to the area above the rear lamps and may have been penetrated by moisture.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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Remedy:

Swift implementation of the necessary repair work prevents subsequent damage at a later date and can be performed without damage to the

paintwork. For this reason we would ask you to perform the necessary repair work as quickly

as possible!

Remove/install the rear lamps on both sides of the vehicle. Remove the sealing seams above the rear lamps from the joint to a height of approx. 20

cm. The adjacent paint surfaces should be masked with two layers of fabric tape to prevent

damage. Any existing corrosion features in the joints must be eliminated if necessary in accordance with MB guidelines. To do this, use primer

and filler materials from the paint partners approved in the warranty systems. Then remove the fabric tape and re-mask the exposed joints with

masking tape. Then prime the joints. Next, renew the masking tape again and apply a new sealing seam to the joints. Mold the new sealing seams and

extend then into the recesses for the rear lamps (see Fig. 1).

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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A corresponding WIS document is being prepared.

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI64-30_N-048760 Date: 100201

Body - Side Wall Seam Above Rear Lamps Cracked

Side wall seam above rear lamps cracked

Topic number LI64.30-N-048760

Version 1

Design group 64.30 Corner paneling

Date 02-01-2010

Validity Sprinter model designation 906.6##

Reason for change

Reason for block

Complaint:

1. The PVC sealing seam above the rear lamps is cracked.

2. Visible corrosion above the rear lamps at the transitions from the D-pillars to the rear side walls.

Cause:

The sealing seams were applied up to the area above the rear lamps and may have been penetrated by moisture.

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Remedy:

Swift implementation of the necessary repair work prevents subsequent damage at a later date and can be performed without damage to the

paintwork. For this reason we would ask you to perform the necessary repair work as quickly

as possible!

Remove/install the rear lamps on both sides of the vehicle. Remove the sealing seams above the rear lamps from the joint to a height of approx. 20

cm. The adjacent paint surfaces should be masked with two layers of fabric tape to prevent

damage. Any existing corrosion features in the joints must be eliminated if necessary in accordance with MB guidelines. To do this, use primer

and filler materials from the paint partners approved in the warranty systems. Then remove the fabric tape and re-mask the exposed joints with

masking tape. Then prime the joints. Next, renew the masking tape again and apply a new sealing seam to the joints. Mold the new sealing seams and

extend then into the recesses for the rear lamps (see Fig. 1).

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

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A corresponding WIS document is being prepared.

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI54-30_N-048825 Date: 100201

Instruments - Load Compartment Door Opens Without Signal

Electric load compartment sliding door opens without acoustic

signal after obstacle detection has been activated

Topic number LI54.30-N-048825

Version 1

Design group 54.30 Instrument cluster/display instruments/warning devices

Date 02-01-2010

Validity Model 906 with electric sliding door (T55 and/or T56) and

pixel matrix display in the instrument cluster (JK3) as of

production date September 2009

Reason for change

Reason for block

Complaint:

After obstacle detection has been activated, the electric load compartment sliding door opens automatically without acoustic signal

Cause:

Software release in instrument cluster.

Remedy:

Replacing parts does not remedy the issue!

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

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Note:

A new flashware will be available for the instrument cluster around May 2010.

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI14-20_N-048802 Date: 100201

Computer/Controls - Noises After Engine Is Switched Off

Noises during engine run-on / EGR valve cleaning function

Topic number LI14.20-N-048802

Version 1

Design group 14.20 Exhaust gas recirculation

Date 02-01-2010

2010 Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Page 105

Validity Model 906 with OM646 or OM642

Reason for change

Reason for block

Complaint:

Noises after engine is switched off.

Cause:

The noises during engine run-on are caused by the cleaning function of the EGR valve.

Remedy:

No remedy required because the cleaning function is the series production configuration. Sample noises which correspond to the series production

configuration are attached.

Replacing the EGR valve may only be carried out if a corresponding fault code is entered in the engine control unit.

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI27-60_N-048766 Date: 100201

A/T - Limp-Home Mode And DTC 0002 'Undervoltage' Stored

ESM (electronic selector lever module) fault 0002 "Undervoltage"

Topic number LI27.60-N-048766

Version 1

2010 Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Page 96

Design group 27.60 Gearshift, control

Date 02-01-2010

Validity Sprinter model designation 906 with code G40

Reason for change Extended for MBUSA

Reason for block

Complaint:

The vehicle enters limp-home mode and has stored the fault 0002 "Undervoltage" in the ESM control module.

Cause:

The undervoltage fault is stored as an event in the ESM control module and causes the automatic transmission to enter limp-home mode.

Remedy:

Check and, if necessary, process possible causes and remedies as described in the DAS.

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

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Load new software for the ESM control unit.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI07-08_N-048806 Date: 100201

Engine Controls - MIL ON And Vehicle In Limp-Home Mode

Engine in limp-home mode and engine diagnosis indicator lamp lights up

Topic number LI07.08-N-048806

Version 1

Design group 07.08 Control modules

Date 02-01-2010

Validity Model 906 with engine OM642, OM646, OM651 and diesel

particulate filter

Reason for change

Reason for block

Complaint:

The vehicle is going into limp-home mode and the Check Engine Light (CEL) is being illuminated.

Cause:

The CDI control unit has detected a fault which results in limp-home mode. The limp-home mode causes certain engine functions to be deactivated

or to use default values. The control unit can no longer correctly determine the load state of the diesel particulate filter. The state of the diesel

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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particulate filter may become implausible.

Remedy:

After rectifying the cause of the fault, perform workshop regeneration of the diesel particulate filter. This resets the diesel particulate filter to a

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI42-45_N-048679 Date: 100201

ABS/TCS - ESP Light ON after Engine Start

ESP indicator lamp lights up after engine start

Topic number LI42.45-N-048679

Version 1

Design group 42.45 Electronic Stability Program (ESP), Stability Control (SR)

Date 02-01-2010

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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Validity Model 906

as of VIN end number N384751, S309307 and E013853

up to VIN end number N423037, S400651 and E021145

Reason for change

Reason for block

Complaint:

ESP indicator lamp and/or ESP malfunction message in instrument cluster after engine start. The ESP indicator lamp is off when the engine is

restarted.

Cause:

25 seconds after "ignition ON" without an engine start, the fuel pump in the tank shuts down. This shutdown of the fuel pump produces an

interference pulse. Fault 4BD0 (turn rate sensor - internal fault) is stored.

Remedy:

Routing of a separate ground line from yaw rate sensor B25/15 to ground point W 1/4.

Installation site:

B 25/15, driver seat box

W 1/4, right A-pillar in footwell

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2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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Explanation of attachment:

A: Lift cap (gray) on connector of yaw rate sensor B 25/15.

B: Unclip old ground line (pin 1) and insulate line.

C: Clip in new ground line and engage cap (gray).

D: Route new ground line parallel with frame wiring harness and fasten to W 1/4 (the ground point with fewer ground cables attached).

E: Routing in right-hand drive vehicles.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI54-30_N-048825 Date: 100201

Instruments - Load Compartment Door Opens Without Signal

Electric load compartment sliding door opens without acoustic

signal after obstacle detection has been activated

Topic number LI54.30-N-048825

Version 1

Design group 54.30 Instrument cluster/display instruments/warning devices

Date 02-01-2010

Validity Model 906 with electric sliding door (T55 and/or T56) and

pixel matrix display in the instrument cluster (JK3) as of

production date September 2009

Reason for change

Reason for block

Complaint:

After obstacle detection has been activated, the electric load compartment sliding door opens automatically without acoustic signal

Cause:

Software release in instrument cluster.

Remedy:

Replacing parts does not remedy the issue!

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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Note:

A new flashware will be available for the instrument cluster around May 2010.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI72-10_N-048762 Date: 100201

Body - Front Hinged Door/Holder Noisey/ Broken

Door holder of front hinged door broken / door cannot

be opened or closed / door holder makes noises

Topic number LI72.10-N-048762

Version 1

Design group 72.10 Front door

Date 02-01-2010

Validity Model 906

Reason for change

Reason for block

Complaint:

The door holder of the front hinged door is broken.

The front hinged door cannot be opened or closed. The door holder makes a lot of noise.

Cause:

The door holder/ door check of the front hinged door is broken at the mounting brackets.

Remedy:

The defective door holder must be replaced with a new door holder.

The door holder can be reinforced with gusset plates to prevent repeat damage.

Proceed as follows:

^ The web dimensions of the gusset plate are approx. 17 x 17 mm (panel thickness: 1-1.5 mm). The square plate must be divided diagonally into

two triangles.

^ In the area of the weld seam, the zinc coating on the door holder must be removed.

^ In addition, the two attachment plates of the door holder must be aligned level with the attachment surface.

^ The gusset plates must be welded on with a tacked seam (see attachment). The component must be checked for welding distortion and realigned

if necessary.

^ The welds must be smoothened.

^ The welded area must be coated with zinc dust paint.

^ Check the mechanical components for ease of movement.

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2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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^ The reinforced door holder must be installed as described in WIS.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI72-16_N-048763 Date: 100201

Body - Load Compartment Sliding Door Arrester Inoperative

Load compartment sliding door arrester inoperative

Topic number LI72.16-N-048763

Version 1

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898) Page 54

Design group 72.16 Sliding doors

Date 02-01-2010

Validity 906.6## - 906.7##

Reason for change

Reason for block

Complaint:

When open, the load compartment sliding door does not lock in the end position.

Cause:

The position of the arrester at the bottom of the C-pillar prevents it from engaging in the lower sliding carriage of the load compartment sliding door.

The lower sliding carriage does not engage in the arrester.

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2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

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Remedy:

Loosen the arrester and fit two washers at the upper threaded connection (only) between the bodywork and the arrester (see attachment). The bolts

must be tightened to a torque of 13 Nm.

Preparatory work: Remove step as described in WIS AR 72.16-D-7816A.

Do not replace any parts.

2010 Mercedes Benz Truck Sprinter 3500 Cab (906.153) V6-3.0L DSL Turbo (642.898)

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI07-08_N-048806 Date: 100201

Engine Controls - MIL ON And Vehicle In Limp-Home Mode

Engine in limp-home mode and engine diagnosis indicator lamp lights up

Topic number LI07.08-N-048806

Version 1

Design group 07.08 Control modules

Date 02-01-2010

Validity Model 906 with engine OM642, OM646, OM651 and diesel

particulate filter

Reason for change

Reason for block

Complaint:

The vehicle is going into limp-home mode and the Check Engine Light (CEL) is being illuminated.

Cause:

The CDI control unit has detected a fault which results in limp-home mode. The limp-home mode causes certain engine functions to be deactivated

or to use default values. The control unit can no longer correctly determine the load state of the diesel particulate filter. The state of the diesel

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

Page 106

particulate filter may become implausible.

Remedy:

After rectifying the cause of the fault, perform workshop regeneration of the diesel particulate filter. This resets the diesel particulate filter to a

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI72-16_N-048763 Date: 100201

Body - Load Compartment Sliding Door Arrester Inoperative

Load compartment sliding door arrester inoperative

Topic number LI72.16-N-048763

Version 1

2010 Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Page 54

Design group 72.16 Sliding doors

Date 02-01-2010

Validity 906.6## - 906.7##

Reason for change

Reason for block

Complaint:

When open, the load compartment sliding door does not lock in the end position.

Cause:

The position of the arrester at the bottom of the C-pillar prevents it from engaging in the lower sliding carriage of the load compartment sliding door.

The lower sliding carriage does not engage in the arrester.

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

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

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Remedy:

Loosen the arrester and fit two washers at the upper threaded connection (only) between the bodywork and the arrester (see attachment). The bolts

must be tightened to a torque of 13 Nm.

Preparatory work: Remove step as described in WIS AR 72.16-D-7816A.

Do not replace any parts.

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

Mercedes Benz Truck Sprinter 2500 Crew (906.733) V6-3.0L DSL Turbo (642.898) Technical Service Bulletin # LI83-50_N-048689 Date: 100201

A/C - Water Entry Via Roof Air Conditioning

Water entry via roof air conditioning (HH7)

Topic number LI83.50-N-048689

Version 1

Design group 83.50 Rear air conditioning

Date 02-01-2010

Validity Model 906.6 and 906.7

Reason for change

Reason for block

Complaint:

Water enters vehicle interior via roof air conditioning (code HH7).

Cause:

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

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1. Leak between cover and evaporator unit on vehicle roof. (with production date before January 2007)

2. Leak between evaporator unit and vehicle roof.

Remedy:

Check the cover for damage. If there is no damage on the cover, remove the cover panel from the roof air conditioning.

If there are traces of water in the evaporator unit (see picture 1), the water is entering the air conditioning via the bolt holes of the cover panel.

Remedy 1: See WIS document SM83.50-D-0001AK

If no traces of water are visible, the water may have entered the vehicle interior due to an improperly routed seal between the evaporator unit and

vehicle roof (see picture 2).