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Service bulletin 2020040002

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

The communication, as NHTSA indexes it (as of 2026-10-19)
TypeService bulletin
NHTSA id10220288
Published by NHTSA2022-09-19
Manufacturer's number2020040002
Manufacturer's date2022-08-08
NHTSA componentENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

NHTSA's summary

2020040002

The document

The document is the manufacturer's. This site does not hold it. NHTSA files a document at one of these two addresses; we have not asked NHTSA which.

Components

Engine, Exhaust and emissions

Vehicles listed
MERCEDES-BENZ SPRINTER 25002016 (the catalog's model; the bulletin names a series or trim of it)

Listing a model year does not mean every vehicle of it is concerned: the document says which.

Other bulletins for the same vehicles and component
LI4910-N-0609692026-05-02. Service bulletin. Complaint Rattling noise from underneath the vehicle. Cause One or more of the following conditions may be present: 1. The exhaust bracket from the DPF to the transmission is cracked or broken. • See Pic. 1 for an example of a broken bracket. 2. Transmission bell housing cracked or broken at the exhaust mounting area. • See Pic. 2 for an example of bell housing damage. 3. Exhaust bracket from DPF to engine (cylinder crankcase) cracked or broken. • See EPC OM651 #217 for bracket location. 4. Diesel Particulate Filter (DPF) pipe cracked at a weld joint. • Cracking may be present at bracket welds or along the DPF housing seams. • This can cause rattling noises and secondary exhaust bracket stress. • Perform a visual inspection of the DPF pipe and weld joints. Remedy Inspect all related components and repair or replace as required. Inspection and Repair 1. Inspect the exhaust bracket from the DPF to the transmission. • Check the bracket for cracks or complete separation. • See Pic. 1 for a failed example. • See EPC OM651 #550 and Pic. 3 for bracket location. • If damaged, replace the bracket. • See Pic. 4, Pic. 5, and Pic. 6 for the updated bracket design and identification. 2. Inspect the transmission bell housing. • Inspect the bell housing at the exhaust mounting point for cracks or structural damage. • See Pic. 2 for an example of bell housing damage. • Replace the transmission if damage is confirmed. 3. Inspect the exhaust bracket from the DPF to the engine (cylinder crankcase). • Inspect the bracket for cracks or broken mounting points. • See EPC OM651 #217 for bracket location. • Replace the bracket if damaged. 4. Inspect the DPF pipe. • Inspect the DPF for cracks at weld joints, especially near mounting points. • If cracking is found, replace per current aftertreatment guidelines. Correct positioning and tightening of the exhaust system are critical to prevent repeat failures. Positioning the Exhaust System 1. Position and align the exhaust system before tightening. • Support and fit the exhaust system in its installed position. • Push the exhaust system forward. • Install the DPF‑to‑transmission bracket and lightly tighten the mounting bolt. • Install the engine mount and V‑mount bolts by hand, approximately two turns. • See “Positioning of the exhaust system” image. Tightening Sequence 1. Tighten the exhaust system in the correct sequence. • Tighten engine mounting bolts to 25 Nm. • Tighten V‑mount bolts to 25 Nm. • Tighten exhaust bracket bolts to 15 Nm. • See “Tightening sequence of the exhaust system” image. 2. Verify mounting bolt locations. • Confirm correct mounting screw positions at the transmission bracket. • See Pic. 7 and Pic. 8 for mounting screw locations.
LI14.20-N-0738672026-02-03. Service bulletin. EGR Valve Diagnosis & Cleaning (and EGR Cooler Cleaning) – OM642, Sprinter 906/907 Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the desired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function.
LI14.20-N-0738672025-06-03. Service bulletin. Complaint Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. Cause Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the desired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function.
LI14.20-N-0738672025-05-02. Service bulletin. EGR Valve Diagnosis and Cleaning Procedure using TUNAP 926® on 906, 907 Sprinter with OM642 Diesel Engine Complaint Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. NOTE: This LI supersedes LI14.20-N-073813, which is no longer valid. Cause Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the de- sired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function.
LI49.00-N-0786082024-12-04. Service bulletin. SMOG/Emissions Test fail due to one or more Readiness Monitors not set Complaint: The vehicle has failed the State Emissions Certification because one or more of the OBDII readiness monitors are not completely set. Cause: One or more of the following Readiness Monitors are not fully set within XENTRY: Misfire Monitoring - Injection System Fuel System Monitoring - Injection System, Fuel System, EGR Valve, O2 Sensor NMHC Catalyst Monitoring - NMHC/Diesel Oxidation Catalyst NOx Aftertreatment Monitoring - SCR Catalyst System Boost Pressure System Monitoring - Turbocharger, Charge Air System Exhaust Gas Sensor Monitoring - O2 Sensor, NOx Sensors Diesel Particulate Filter Monitoring - Diesel Particulate Filter System Exhaust Gas Recirculation System Monitoring - EGR Valve and system Remedy: Please complete the required driving conditions to fully set the incomplete Readiness Monitor. DO NOT: - Erase any fault codes. If fault codes are present, process these and allow the readiness drives to clear fault codes. - Flash or SCN code the CDI or SCR control units. - Perform a manual DPF regeneration, unless instructed below. - Disconnect the main battery.
LI14.20-N-073867_52024-08-03. Service bulletin. Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. NOTE: This LI supersedes LI14.20-N-073813, which is no longer valid. Cause Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the desired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function.
LI14.20-N-0738672024-06-06. Service bulletin. Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the desired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function.
2022120013-12023-04-24. Service bulletin. Emissions.
LI03.10-N-0758432023-03-03. Service bulletin. Complaint Engine runs irregularly and it shakes. Indicator lamp lights up. Information: Fault codes for injectors and/or combustion misfires may be stored in the CDI control unit: • On engine 642 cylinder 6 is affected. • On engine 651 cylinder 2 is affected. Cause Charge air from the exhaust gas recirculation is condensed after being introduced into the charge air section. Information: Under certain operating conditions, condensation that has collected in the charge air cooler can enter the combustion chamber to a damaging degree and a damage profile is then generated (connecting rod bent). Remedy Perform following testing and diagnosis operations
LI07.16-N-0755742023-01-05. Service bulletin. Problem: Vehicle fails smog test Cause In the event the Engine Control Module (CDI) detects a fault with the Water Pump Short Circuit to Battery diagnostic, Fault Code P260312 and/or P260315 may set and prevent the readiness monitor from running. Even following a successful repair and/or clearing the Fault Code(s), the readiness monitor remains deactivated and self-healing is not possible. This deactivation may prevent the vehicle from passing state emissions inspection and SMOG Test and is only resolvable by installing new engine control unit software. Remedy 1. Perform XENTRY Quick Test. 2. Check for the presence of Fault Code P260312 and/or P260315 in the CDI control module. 3. If relevant Fault Codes are present, resolve fault using standard dealer procedures. Once fault is resolved, proceed to step 5. 4. If no relevant Fault Codes are present, or the fault has been previously repaired and Fault Codes erased, proceed to step 5.