# Service bulletin LI49.00\-N\-078608

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.

- Type: Service bulletin
- NHTSA id: 11011223
- Published by NHTSA: 2024\-12\-04
- Manufacturer's number: LI49.00\-N\-078608
- Manufacturer's date: 2024\-11\-28
- NHTSA component: ENGINE

## NHTSA's summary

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.

## The document

- [NHTSA's copy of the document (PDF)](https://static.nhtsa.gov/odi/tsbs/2024/MC-11011223-0001.pdf)
- [If that address does not open, try this one](https://static.nhtsa.gov/odi/tsbs/2024/MC-11011223-9999.pdf)

The document is the manufacturer's. This site does not hold it.

## Components

Engine

## Vehicles listed

- 2006 to 2009 DODGE SPRINTER 2500
- 2010 to 2014 DODGE SPRINTER 2500
- 2006 to 2009 DODGE SPRINTER 3500
- 2010 to 2014 DODGE SPRINTER 3500
- 2019 to 2020 FREIGHTLINER SPRINTER \(VS30\)
- 2007 to 2024 FREIGHTLINER SPRINTER 1500
- 2003 FREIGHTLINER SPRINTER 2500
- 2006 to 2024 FREIGHTLINER SPRINTER 2500
- 2006 to 2024 FREIGHTLINER SPRINTER 3500
- 2007 to 2024 FREIGHTLINER SPRINTER 4500
- 2015 MERCEDES\-BENZ METRIS
- 2016 to 2023 MERCEDES\-BENZ METRIS
- 2019 to 2020 MERCEDES\-BENZ SPRINTER \(VS30\)
- 2007 to 2009 MERCEDES\-BENZ SPRINTER 1500
- 2010 to 2024 MERCEDES\-BENZ SPRINTER 1500
- 2007 to 2009 MERCEDES\-BENZ SPRINTER 2500
- 2010 to 2024 MERCEDES\-BENZ SPRINTER 2500
- 2007 to 2009 MERCEDES\-BENZ SPRINTER 3500
- 2010 to 2024 MERCEDES\-BENZ SPRINTER 3500
- 2007 to 2009 MERCEDES\-BENZ SPRINTER 4500
- 2010 to 2024 MERCEDES\-BENZ SPRINTER 4500

## Recalls for the same vehicles and component

- [2020059](/recalls/tc/2020059.md), 2020-02-13: Engine
- [2020058](/recalls/tc/2020058.md), 2020-02-13: Engine
- [20V079000](/recalls/nhtsa/20V079000.md), 2020-02-12: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
- [20V078000](/recalls/nhtsa/20V078000.md), 2020-02-12: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE \(EGR VALVE\); ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
- [15V261000](/recalls/nhtsa/15V261000.md), 2015-05-05: ENGINE AND ENGINE COOLING:ENGINE:DIESEL
- [2014546](/recalls/tc/2014546.md), 2014-12-03: Engine
- [14V764000](/recalls/nhtsa/14V764000.md), 2014-12-01: ENGINE AND ENGINE COOLING:ENGINE:DIESEL
- [2010277](/recalls/tc/2010277.md), 2010-08-16: Engine
- [2010234](/recalls/tc/2010234.md), 2010-07-15: Engine
- [2008011](/recalls/tc/2008011.md), 2008-01-11: Engine

## Other bulletins for the same vehicles and component

- [Exhaust System](/bulletins/11036890.md), 2026-09-04, Warranty extension: ENGINE. Mercedes\-Benz AG \(“MBAG”\), the manufacturer of Freightliner Sprinter vehicles, has determined that on certain MY17\-18 Freightliner Sprinter vehicles, the diesel particulate filter may crack due to an insufficient weld. MBAG also determined that specific environmental influences in the form of corrosion could have a negative effect on the long\-term durability of the diesel particulate filter. This can lead to stresses within the exhaust system which could cause the diesel particulate filter to crack. In addition, in individual cases, it is possible that during repairs to the exhaust system that were unrelated to a defect of the diesel particulate filter, the exhaust system was not replaced in accordance with the MBAG specifications. Specifically, the issue might have arisen where it was necessary for the workshop to replace the exhaust system \(including the diesel particulate filter\) but that the replacement system was not fitted according to MBAG specifications. This could lead to stresses within the exhaust system which may also cause the diesel particulate filter to crack. In both cases, a fault code is stored in the engine control unit software and the engine diagnostics warning lamp \(MIL\) is activated. The driver would become aware of the issue due to noise from the exhaust system.
- [Exhaust System](/bulletins/11036889.md), 2026-09-04, Warranty extension: ENGINE. Mercedes\-Benz AG \(“MBAG”\), the manufacturer of Freightliner Sprinter vehicles, has determined that on certain MY17\-18 Freightliner Sprinter vehicles, the diesel particulate filter may crack due to an insufficient weld. MBAG also determined that specific environmental influences in the form of corrosion could have a negative effect on the long\-term durability of the diesel particulate filter. This can lead to stresses within the exhaust system which could cause the diesel particulate filter to crack. In addition, in individual cases, it is possible that during repairs to the exhaust system that were unrelated to a defect of the diesel particulate filter, the exhaust system was not replaced in accordance with the MBAG specifications. Specifically, the issue might have arisen where it was necessary for the workshop to replace the exhaust system \(including the diesel particulate filter\) but that the replacement system was not fitted according to MBAG specifications. This could lead to stresses within the exhaust system which may also cause the diesel particulate filter to crack. In both cases, a fault code is stored in the engine control unit software and the engine diagnostics warning lamp \(MIL\) is activated. The driver would become aware of the issue due to noise from the exhaust system.
- [LI09\_41\-N\-079165\_2\_en](/bulletins/11036853.md), 2026-09-04, Service bulletin: ENGINE. Complaint Low Coolant warning with possible engine misfire caused by a leaking Charge Air Cooler \(Intercooler\), accompanied by one or more of the following possible fault codes related to the coolant system: P30040B: Component 'Temperature sensor downstream of charge air cooler' has an open circuit or short circuit to positive. P25567B: Sensor 'Coolant level' has a malfunction. The fluid level is too low. Cause The potential causes for this topic are: A. A leak in the Coolant System, other than the Charge Air Cooler. B. An Internal leak of the Charge Air Cooler. C. An unapproved/aftermarket upfit or modification to the coolant system. Remedy A. A leak in the Coolant System, other than the Charge Air Cooler 1. Complete a coolant system pressure test: •Refer to WIS Doc AR20.00‑D‑1011TS ‑ Check engine cooling system for leak tightness. •Use Tester Cap 210 589 00 91 and Pressure Pump 124 589 24 21 00. •Apply test pressure to the engine cooling system. Do not exceed the specified test pressure of 1.5 Bar to prevent damage to the engine cooling system. •Perform a visual check on the top and bottom of the engine compartment and in the vehicle interior. •If coolant loss or pressure loss is present, perform suitable repair measures depending on the vehicle equipment. •If NO signs of coolant loss are found but pressure loss is present, proceed to Step B. B. An Internal leak of the Charge Air Cooler 1. Inspect the Charge Air Cooler for an internal leak: •Remove either the Throttle Valve or Charge Air Temperature Sensor to inspect for coolant loss. See attachments for the failed Charge Air Cooler. •If coolant is found inside the Charge Air Cooler: •Perform a manual compression test to confirm the absence of internal engine failures per WIS Doc AR01.00‑D‑1201TSM ‑ Check compression pressure. •Remove and clean any coolant present in the Charge Air System, Intake System, and Cylinders. •Replace the Charge Air Cooler, the glow plugs, and then conduct an oil and filter change. Refer to AR09.41‑D‑6817TSM ‑ Remove/install charge air cooler. •If coolant is not found inside the Charge Air Cooler, proceed to Step C. C. An unapproved/aftermarket upfit or modification to the coolant system 1. Inspect the Coolant system for any unapproved/aftermarket upfits or modifications: •See the Attachments for examples of non‑approved upfits or modifications. •Note: The OM654 cannot have any aftermarket modifications made to the coolant system per the Body and Equipment Guidelines \(BEG\) under 4.4.3 Engine Cooling, "Do not make modifications to the cooling system \(cooler components, air ducting, hose, and other detachable parts that are part of the cooling system\)". •If there are modifications made to the coolant system that violate the BEG, do not complete any repairs on the system under warranty until either your Vans Aftersales Business Development Manager \(VABDM\) or facing Field Service Engineer \(FSE\) reviews the vehicle.
- [LI09.41\-N\-080666](/bulletins/11034415.md), 2026-07-02, Service bulletin: ENGINE. Check engine light with reduced power –P300A6D due to charge air system contamination Complaint The check engine light is activated, accompanied by fault code 'P300A6D The boost pressure is too low', indicating reduced boost pressure. Cause Charge air system restriction due to contamination: • Oil mist from the crankcase ventilation system can enter the intake tract and deposit within the charge air system • Under high thermal load and with soot\-laden or aged engine oil, these deposits may carbonize • Carbonized deposits can loosen and accumulate in the charge air cooler and related components • This can result in partial or complete restriction of the charge air cooler, leading to underboost conditions and fault codes such as P300A6D Contributing factors may include: • High engine load operating profiles • Extended oil service intervals or degraded engine oil condition Remedy Prerequisite: Complete all guided diagnostic test steps for fault code P300A6D in Xentry Diagnostics and follow LI09.40\-N\-079144 before performing the repairs below. If carbonized oil deposits or restriction are identified within the charge air system: 1. Replace the following components as a set: • Charge air cooler • Exhaust turbocharger • Charge air pipe upstream of the charge air cooler 2. After completing repairs: • Perform engine oil and filter replacement using an approved specification oil. Approved oil specifications: • MB 229.52 SAE 5W\-30 \- BB00.40\-P\-0229\-52A • MB 229.51 SAE 5W\-30 \- BB00.40\-P\-0229\-51A 3. Perform control unit adaptations: • Reset intake air system adaptation values • Reset low\-pressure exhaust gas recirculation \(EGR\) adaptation values 4. After repair completion: • Perform a test drive • Verify that the fault code does not return 5. If the vehicle is within warranty and the charge air cooler is determined to be obstructed by debris, use damage code 50301 B2 when submitting the warranty claim. Notes: • Additional component replacement is not required unless supported by further diagnostic results. • Do not replace the charge air distributor pipe or Clean Air Line unless additional faults \(for example, air mass\-related faults\) are present. • After replacement of components, ensure proper initialization and learning procedures are completed in the control unit. • Creation of an XENTRY TIPS case is not required for this condition. • Please review the attached photos for previously identified causes of these fault codes.
- [LI05.30\-N\-080518](/bulletins/11034414.md), 2026-07-02, Service bulletin: ENGINE. OM654 Extended engine crank or starting concerns and/or poor running characteristics Complaint One or more of the following may be reported: • Extended crank or hard start • Rough idle or misfire like condition • Engine stalls during low\-speed maneuvering Cause In some cases, one or more exhaust valves may be leaking due to: • Burnt exhaust valve seat rings • Burnt valve faces • Heavy carbon buildup on the exhaust valve seat leading to poor sealing Remedy Follow the steps below in order. Do not replace components before completing verification. 1. Initial check • Perform a quick test with XENTRY Diagnosis • Check for stored or pending fault codes 2. Fuel system verification • Using XENTRY Diagnosis, monitor actual values during cranking under: “Engine start – starter turning, engine not starting” • Check rail pressure during cranking Evaluation: • If rail pressure is below specification: diagnose fuel system per WIS • If rail pressure is within expected range \(approximately 250 to 300 bar\): proceed with mechanical checks 3. Compression evaluation Perform compression test per WIS \(engine at operating temperature if possible\): • Manual compression test per WIS doc AR01.00\-D\-1201TSM • If compression is out of specification, continue to leak down testing 4. Cylinder leakage test • Perform cylinder leakage test on all cylinders per WIS doc AR01.00\-D\-1300TSM • Ensure test equipment is calibrated before testing Evaluation: • Leakage confirmed through exhaust path → suspect exhaust valve sealing • Leakage into crankcase → do not proceed; submit TIPS case for further direction 5. Additional validation \(if needed\) • Smoke test may be used to confirm leakage path Repair If leaking or burnt exhaust valves are confirmed: • Replace the complete cylinder head assembly with valves pre\-installed Do not attempt partial repair of affected valves or seats.
- [LI07.16\-N\-080731](/bulletins/11034406.md), 2026-07-02, Service bulletin: ENGINE. Complaint The customer reports an exhaust odor from the engine compartment, potentially accompanied by a check engine light and/or engine misfire. Cause The injector hold\-down may fracture due to material\-related factors, allowing the injector to lift from its seat and resulting in combustion gas leakage past the sealing interface. Remedy Carry out repair measures in accordance with the extent of damage determined during inspection. Replace only tho\-se components identified as faulty or compromised by the failure, including the fuel injector, sealing ring, injector hold\-down, hold\-down bolt, high\-pressure fuel line\(s\), and, if required, the fuel distributor \(rail\). All work involving fuel injector removal and installation must be carried out in accordance with WIS document AR07.16\-D\-1020TSM. Particular attention must be given to the proper preparation of the injector bore and sealing in\-terface. All carbon deposits, combustion residue, and surface contamination must be fully removed to ensure correct injector seating and sealing integrity, thereby preventing combustion gas blow\-by and repeat failure.
- [LI4910\-N\-060969](/bulletins/11031943.md), 2026-05-02, Service bulletin: ENGINE. 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.
- [LI4920N078838](/bulletins/11029273.md), 2026-03-03, Service bulletin: ENGINE. Check engine light or Adblue warning with fault codes P206B31, P203B31, or P300494 present in AdBlue \(SCR\) control unit \(N118/5\) Complaint The check engine light or AdBlue warning is activated, accompanied by one or more of the following fault codes related to the AdBlue tank: P206B31: Malfunction of the concentration sensor for AdBlue; the signal is absent. P203B31: Malfunction of the AdBlue fill level sensor; the signal is absent. P300494: The quality of the AdBlue is insufficient. Cause A. The software for the AdBlue \(SCR\) control unit \(N118/5\) is outdated. B. The concentration of AdBlue is either above or below the Mercedes\-Benz specifications, which can lead to premature freezing. C. Frozen or partially frozen AdBlue can cause the AdBlue level sensor to misread levels. D. The AdBlue level sensor is damaged.
- [LI4920N075995](/bulletins/11029272.md), 2026-03-03, Service bulletin: ENGINE. Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset with fault code P13DF00 or P300685 Complaint Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset. Information: All fault codes in the AdBlue® \(SCR\) control unit have been processed and corrected; however, fault codes P13DF00 and P300685 remain active and stored in the AdBlue® \(SCR\) control unit. Cause The procedure for resetting the SCR/AdBlue® warning message with XENTRY Diagnosis has not been carried out. Information: Before resetting the SCR/AdBlue® warning message for SCR Generation 4, the AdBlue® system must be in proper working condition and tested.
- [LI49.20\-N\-080011](/bulletins/11028120.md), 2026-02-03, Service bulletin: ENGINE. Complaint The check engine light is on, with a possibility in a reduction of power, with no soot present in the exhaust system. Fault codes: P300E5F The fill level of the diesel particulate filter is too high. \(Early warning\) P300E5E The fill level of the diesel particulate filter is too high. Regeneration of the diesel particulate filter is disabled. Additional information: No additional fault codes related to the Diesel Particulate Filter \(DPF\) system or the Exhaust Gas Recirculation \(EGR\) system may be present for this LI to apply. Cause These fault codes may be triggered due to unfavorable driving conditions, such as: •Frequent short\-distance trips •Extended idle periods •Infrequent highway driving •Incomplete regeneration cycles These conditions can lead to excessive soot accumulation in the Diesel Particulate Filter \(DPF\), resulting in elevated fill levels and regeneration lockout.

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