Service bulletin LI49.20-N-078838
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 | 11014728 |
| Published by NHTSA | 2025-03-04 |
| Manufacturer's number | LI49.20-N-078838 |
| Manufacturer's date | 2025-02-04 |
| NHTSA component | FUEL/PROPULSION SYSTEM |
NHTSA's summary
Complaint The check engine light or AdBlue warning is activated, accompanied by one or more of the following fault codes rela- ted 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 Cause A. The software for the AdBlue (SCR) control unit (N118/5) is outdated.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 prema- ture freezing. C. Frozen or partially frozen AdBlue can cause the AdBlue level sensor to misread levels. D. The AdBlue level sensor is damaged. Remedy A. Software 1. Verify no newer software in AdBlue® SCR control unit (N118/5). 2. Complete LI49.20-N-075995 for Adblue warning reset. --NOTE-- If there is no updated software available, proceed to step B. B. Adblue Concentration 1. Verify the AdBlue concentration according to WIS AR49.20-D-9264TS - Check the concentration of AdBlue. --NOTE-- If the AdBlue concentration is below 31.8% or above 33.2%, it must be replaced. Please note that this will be at the customer's expense. 2. If the AdBlue concentration is within the approved specifications, please proceed to step C. C. Frozen Adblue or the SCR Actual Values state 'Frozen Adblue' 1. Check if the AdBlue is frozen. If it is, let the vehicle sit in a warm place overnight and recheck. 2. Have the vehicle running and XENTRY hooked up displaying Adblue level values 3. Drain the Adblue Tank and verify fill level reflects the change in the Adblue level 4. Fill the Adblue Tank SLOWLY and do not overfill, verify fill level reflects the change in the Adblue level --NOTE-- The Fill Level Sensor 1 functions as the "empty sensor." It accurately measures the bottom 60 mm (2.3 in- ches) of the AdBlue tank. Once the tank is filled beyond the 60 mm (2.3 inch) mark, the sensor may not read accura- tely, and you might notice the displayed value fluctuating. This behavior is normal, see attachment 'Fill Level 1'. 5. Reset the Adblue Tank fill level via XENTRY --NOTE-- If the XENTRY still shows that there is frozen Adblue or the concentration is still inaccurate after draining and filling, please refer to the attachments 'Adblue Frozen' and 'Adblue Concentration' and proceed to step C. 6. Complete LI49.20-N-075995 for Adblue warning reset. --NOTE-- If the steps above do not fix the vehicle, please proceed to step D. D. Damaged Adblue Level Sensor/Concentration Sensor 1. Replace the Adblue Tank 2. With the vehicle running and XENTRY hooked up displaying Adblue level values 3. Fill the Adblue Tank SLOWLY and do not overfill, verify fill level reflects the change in the Adblue level 3. Reset the Adblue Tank fill level via XENTRY 4. Complete LI49.20-N-075995 for Adblue warning reset. --NOTE-- During LI49.20-N-075995 for Adblue warning reset, please ensure that the outside temperature sensor is reading above 10 degrees Fahrenheit. If it is not, keep the vehicle inside the shop overnight. Complete LI49.20- N-075995 again. Additionally, please note that the vehicle may need to be driven to allow the NOx sensors and SCR system to complete their self-test. Once this is finished, the P13DF00 code should be stored and can then be cleared. --NOTE-- During cold weather, when temperatures are below 32 degrees Fahrenheit, please advise the client to keep the AdBlue tank fill level between 50% and 85%. This will allow for proper fluid expansion and help prevent damage to the level/concentration sensor.
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
Fuel system
Trouble codes named
P13DF, P203B, P206B, P3004
| DODGE SPRINTER 2500 | 2006, 2007, 2008, 2009 (the catalog's model; the bulletin names a series or trim of it) |
|---|---|
| DODGE SPRINTER 2500 | 2010 to 2014 |
| DODGE SPRINTER 3500 | 2006, 2007, 2008, 2009 (the catalog's model; the bulletin names a series or trim of it) |
| DODGE SPRINTER 3500 | 2010 to 2014 |
| FREIGHTLINER SPRINTER (VS30) | 2019, 2020 (the catalog's model; the bulletin names a series or trim of it) |
| FREIGHTLINER SPRINTER 1500 | 2019, 2020, 2021, 2022, 2023, 2024 (the catalog's model; the bulletin names a series or trim of it) |
| FREIGHTLINER SPRINTER 2500 | 2003 |
| FREIGHTLINER SPRINTER 2500 | 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024 (the catalog's model; the bulletin names a series or trim of it) |
| FREIGHTLINER SPRINTER 3500 | 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024 (the catalog's model; the bulletin names a series or trim of it) |
| FREIGHTLINER SPRINTER 4500 | 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024 (the catalog's model; the bulletin names a series or trim of it) |
| MERCEDES-BENZ SPRINTER (VS30) | 2019, 2020 (the catalog's model; the bulletin names a series or trim of it) |
| MERCEDES-BENZ SPRINTER 1500 | 2019, 2020, 2021, 2022, 2023, 2024 (the catalog's model; the bulletin names a series or trim of it) |
| MERCEDES-BENZ SPRINTER 2500 | 2007 to 2009 |
| MERCEDES-BENZ SPRINTER 2500 | 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024 (the catalog's model; the bulletin names a series or trim of it) |
| MERCEDES-BENZ SPRINTER 3500 | 2007 to 2009 |
| MERCEDES-BENZ SPRINTER 3500 | 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024 (the catalog's model; the bulletin names a series or trim of it) |
| MERCEDES-BENZ SPRINTER 4500 | 2007 to 2009 |
| MERCEDES-BENZ SPRINTER 4500 | 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024 (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.
| 23V444000 | 2023-06-26. FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP |
|---|---|
| 2023353 | 2023-06-23. Fuel System |
| 2020465 | 2020-10-01. Fuel System |
| 20V595000 | 2020-09-29. FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS |
| 20V453000 | 2020-08-04. FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP |
| 2019563 | 2019-11-08. Fuel System |
| 19V798000 | 2019-11-07. FUEL SYSTEM, DIESEL |
| 17V092000 | 2017-02-10. FUEL SYSTEM, DIESEL |
| 10V294000 | 2010-06-29. FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP |
| 07V325000 | 2007-07-26. FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING |
A recall listed here may apply to some of the same vehicles. Only the manufacturer can say whether it applies to one vehicle.
| LI07_02-N-079573_2_en | 2026-09-03. Service bulletin. Oil Leak at Crankcase Near the High-pressure Fuel Pump OM654 Complaint Visible oil leak at the crankcase near the mounting area of the high‑pressure fuel pump on OM654 engines. Cause Oil leakage near the high‑pressure fuel pump may result from insufficient sealing performance of the jump shaft seal and/or reduced sealing effectiveness at the interface between the high‑pressure fuel pump and crankcase. Relative movement of the high‑pressure fuel pump within the crankcase bore may reduce sealing effectiveness at the pump‑to‑crankcase interface and promote oil migration during engine operation. Remedy Install a new high‑pressure fuel pump together with the design‑optimized sealing ring. |
|---|---|
| LI49.10-N-080528 | 2026-07-02. Service bulletin. OM642 DPF Filter Cracked or Broken Complaint Vehicle will not start or exhibits noisy exhaust. Check Engine Lamp (CEL) is on. Multiple control unit communication and system faults may be present, including but not limited to: 134800, 134900, 11B300, 11EC00, 15E100, 155700, 162500. Additional events codes may include: 134300, 102200, 163400, 16CE00. In many cases, multiple unrelated faults are stored due to electrical disruption from wiring damage rather than indivi-dual component failure. Cause The DPF filter is cracked, broken, or leaking, allowing hot exhaust gas to escape from the exhaust system. Depending on the location of the break or leak, hot exhaust gas may be directed toward the main wiring harness and/ or the SCR (Selective Catalytic Reduction) dosing valve assembly. This heat exposure can result in: • Internal melting of wiring insulation within the harness • Short to ground conditions and loss of communication between control units • Damage to the dosing valve and/or heated AdBlue line Damage to the wiring harness may not be visible externally, as the outer tape can remain intact while the internal wires are melted and fused together. Remedy Inspect the DPF assembly for cracks, separation, or leakage. Do not proceed with further diagnosis or component replacement until the exhaust leak source has been identified and confirmed. If any damage is found, replace the DPF filter assembly. Based on the location of the failure, inspect all components in the path of the exhaust leak, including the dosing valve assembly and main wiring harness. The wiring harness must be opened in any area exposed to the exhaust leak to visually inspect the individual wires. External inspection alone is not sufficient to determine harness condition. Repair or replace any damaged wiring in accordance with approved repair procedures. Replace any dosing system components that show signs of heat damage. Failure to identify and repair all heat-affected components will result in repeat faults or no-start conditions. |
| LI47_00-N-069565 | 2026-07-02. Service bulletin. Fuel Level Unchanged After Refueling Complaint The customer reports that the fuel gauge shows inaccurate readings or remains unchanged after refueling. Cause A. The Fuel Supply Control Unit (FSCU) fails to detect a refueling event B. The Fuel Level Sensor provides incorrect readings due to mechanical interference or installation issues |
| LI09.40-N-079144 | 2026-07-02. Service bulletin. Complaint The check engine light is activated, accompanied by one or more of the following fault codes related to the Boost Pressure Positioner: • P300A6D The boost pressure is too low. Charge Air Cooler. • P300974 Component 'Boost pressure positioner' has a malfunction. The boost pressure is too low. • P300DFB Component 'Boost pressure positioner' has a malfunction. • P300DE8 Boost pressure control A has a malfunction after the cold start. Cause The potential causes for these fault codes are: A. Leak or Blockage in the Intake or Charge Air System: This can prevent the proper flow of air, affecting the boost pressure. B. Insufficient Source Vacuum, Vacuum Leak, or Sticking/Weak Vacuum Component: These issues can prevent the boost pressure positioner from functioning correctly. • For Model Year 2023-Cuurent vehicles operating at approximately 4,000 ft elevation or above, reduced ambient pressure and/or high brake demand may contribute to reduced available vacuum differential and under boost com-plaints, even when no discrete vacuum component failure is identified. C. Internal Malfunction of the Boost Pressure Positioner: The component itself may be faulty. D. Internal Defect with the Variable Turbine Geometry (VTG) System inside the Turbocharger: Issues within the turbo-charger can affect boost pressure control. Remedy A. Leak or Blockage in the Intake or Charge Air System 1. Perform a Pressurized Smoke Test: •Conduct a smoke test on the intake, the charge air system, and the exhaust to identify any leaks. |
| LI07.16-N-080732 | 2026-07-02. Service bulletin. Complaint The customer reports that the engine cranks but does not start, or only starts after extended cranking. A check engine light may be present, and fault codes P300616 (The fuel pressure in the system is too low) and/or P300617 (The fuel pressure in the system is too low) may be stored, along with other fuel pressure-related fault codes. Cause Insufficient high-pressure fuel build-up during engine cranking. The fuel system does not achieve the required rail pressure of >120 bar, preventing engine start. This condition may be caused by internal leakage within the fuel injection system, inadequate fuel supply from the low-pressure circuit, or a malfunction of the high-pressure fuel pump. Remedy 1. Verify high-pressure fuel rail pressure during engine cranking using XENTRY actual values. • Evaluate the actual value “The starter turns and the combustion engine does not start” and monitor high-pressure fu-el rail pressure during cranking. (See attachment: XENTRY actual values – rail pressure not reaching >120 bar) • The system must achieve a minimum of >120 bar in order to enable engine start. → If the specified rail pressure is not achieved, perform the following checks: 2. Check low-pressure fuel supply • Verify fuel quality (color, clarity, separation, contamination) • Inspect fuel tank, fuel filter, and low-pressure fuel pump for debris, restriction, or damage • Measure low-pressure fuel supply before and after the fuel filter and confirm values are within specification • Perform a fuel volume test at the high-pressure pump inlet to ensure adequate delivery • Verify that the injector leak line is installed correctly, remains unmodified, and is not restricted or kinked → If low-pressure fuel supply is not within specification: Repair as necessary and recheck high-pressure fuel build-up 3. Check for internal leakage within the fuel injection system • Perform a fuel injector leak/return test using XENTRY • Evaluate injector leak-back during cranking NOTE: If the combustion engine does not start, perform the test by cranking the engine 3–4 times for approximately 15 seconds each, instead of allowing the engine to run for approximately 60 seconds → If injector leakage is present: Replace the affected injector(s) and perform injector teach-in 4. Check high-pressure fuel system • If no leakage is identified and low-pressure supply is sufficient, evaluate high-pressure fuel generation → If high-pressure fuel system does not generate sufficient pressure: Replace the high-pressure fuel pump 5. Final verification • Verify that rail pressure exceeds >120 bar during cranking • Confirm the engine starts normally without extended crank • Clear fault codes and perform final validation |
| LI49.20-N-078466_4 | 2026-06-02. Service bulletin. Check engine light with fault code P3005CA in MRD1 (CDI) Complaint The check engine light is on, with a possiblility in a reduction of power and the presence of soot in the exhaust system. Fault code P3005CA: The diesel particulate filter efficiency is insufficient. Additional information: Additional fault codes may be present, related to the Diesel Particulate Filter (DPF) system or the Exhaust Gas Recirculation (EGR) system. Cause This fault code sets due to the following factors: 1. Damage to the Diesel Particulate Filter (DPF) unit. 2. The N74 (Soot Particulate Sensor Control Unit) identifies soot or debris located downstream of the SCR Catalyst (underbody). Remedy Note: The guided tests for fault code P3005CA have been revised in the XENTRY unit. It is important to complete these guided tests thoroughly. TIPS cases are NO longer required unless there is an absence of soot at the outlet of the Diesel Particulate Filter (DPF) unit. If there are any other fault codes present for component 'N74 (Soot Particulate Sensor Control Unit)', process these first. 1. Damage to the Diesel Particulate Filter (DPF) unit. • Complete the XENTRY guided tests: • Check the Exhaust system for leaks - Perform a visual inspection of the exhaust system from the Combustion Engine to Diesel Particulate Filter (DPF). Verify that there are no external damages and that all clamps and sensors are installed and leak-free. • Check component 'Exhaust pipe and Filter screen of Exhaust Gas Recirculation (low pressure)' for carbon fouling. If no soot is present at the Tailpipe outlet, recommended to separate the exhaust pipe downstream of the Diesel Particulate Filter (DPF) at the outlet to inspect. |
| LI4700N069565 | 2026-05-02. Service bulletin. Complaint The customer reports that the fuel gauge shows inaccurate readings or remains unchanged after refueling. Cause A. The Fuel Supply Control Unit (FSCU) fails to detect a refueling event. B. The Fuel Level Sensor provides incorrect readings. |
| LI49-20-N-080376 | 2026-04-02. Service bulletin. The check engine light is illuminated, or the AdBlue warning is active, with recorded faults related to AdBlue quality or concentration. Complaint Customer reports an illuminated check engine light and or an AdBlue system warning indicating AdBlue quality out of specification. The vehicle may enter reduced performance mode. One or more of the following fault codes related to the AdBlue tank may be stored: 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. Background AdBlue must meet ISO 22241 quality requirements. ISO 22241 urea content limits for AdBlue are 31.8 percent to 33.2 percent by mass. AdBlue begins to crystallize and freeze at approximately 12 degrees F. Freeze-thaw does not degrade the product when uncontaminated, and the bulk concentration returns to normal after complete thaw and mixing. Cause In cold soak conditions and during freeze thaw exposure, the tank contents may not be uniform at the time of sampling or system checks. During freezing and partial thaw, ice formation can temporarily create concentration gradients in the tank. As a result, urea percent readings can vary based on sample location and the state of thaw and mixing, which can produce apparent out of range readings even though the bulk fluid returns to normal after mixing. Remedy Testing Do not use a single urea percent reading taken from frozen, partially frozen, or not fully mixed AdBlue to make a repair or responsibility decision. Confirm full thaw and ensure tank contents are mixed before sampling. 1. Confirm full thaw - Confirm the AdBlue tank and associated components are fully thawed before sampling. - Do not sample slushy or partially frozen fluid. 2. Mix tank contents - Perform a road drive intended to mix the tank contents before sampling. - Idle time alone is not a reliable substitute for mixing. 3. Sample and measure - Take the sample and measure with the MB refractometer per the MB tool instructions. - Record the urea percent value. 4. Interpret the result against ISO 22241 limits - Within specification is 31.8 percent to 33.2 percent urea by mass. 5. Repeat if out of specification - If out of specification, repeat after an additional mixing drive to reduce sampling variation. - If still out of specification after full thaw, mixing, and repeat measurement, treat as a true out of specification result and proceed with further diagnosis per applicable MB guidance. Acceptance criteria AdBlue is within the ISO 22241 specification when the urea percent is between 31.8 percent and 33.2 percent by mass. Values outside this range are out of specification and require further diagnosis after completing the full thaw and mi-xing procedure above. Cross reference For vehicles with fault codes P206B31, P203B31, or P300494, refer to LI49.20-N-078838 for the detailed diagnostic and repair procedure. If a SCR or AdBlue warning reset is required after correction, refer to LI49.20-N-075995. Complete the diagnostic and corrective steps first. Perform the warning reset only after the underlying fault condition has been corrected. Warranty information and claim handling |
| LI49-20-N-078838 | 2026-04-02. Service bulletin. 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 AdBlue concentration is outside ISO 22241 limits (below 31.8 percent or above 33.2 percent). C. Frozen or partially frozen AdBlue can cause the AdBlue level and concentration functions to report inaccurate values. D. The AdBlue level and concentration sensing functions in the tank are damaged. E. Cold soak and freeze thaw exposure can temporarily create concentration gradients in the tank and lead to sampling dependent readings until fully thawed and mixed. Important Before evaluating any AdBlue concentration result, follow LI49.20-N-080376 to confirm full thaw, perform a mixing drive, and retest. Do not use a single urea percent reading taken from frozen, partially frozen, or not fully mixed AdBlue for a repair or responsibility decision. Remedy A. Software 1. Verify no newer software is available for the AdBlue (SCR) control unit (N118/5). 2. If a software update is available, program the control unit per XENTRY guidance. 3. Only after the system is in proper working condition, complete LI49.20-N-075995 for AdBlue warning reset. Note: If there is no updated software available, print the XENTRY screen indicating this and proceed to section B. B. AdBlue concentration 1. Confirm full thaw and mixing per LI49.20-N-080376, then verify AdBlue concentration. a. Check concentration using the MB refractometer per the MB tool instructions and applicable WIS guidance. b. Use freeze frame data when applicable. 2. If AdBlue concentration remains below 31.8 percent or above 33.2 percent after full thaw, mixing drive, and retest, AdBlue replacement is required. Warranty and responsibility decisions must follow LI49.20-N-080376 warranty handling guidance and standard war-ranty policy. 3. If AdBlue concentration is within specification, proceed to section C. C. Frozen AdBlue or SCR actual values indicate frozen AdBlue 1. Check if AdBlue is frozen. If frozen, allow the vehicle to sit in a warm environment overnight and recheck. 2. With the vehicle running and XENTRY connected, display the actual AdBlue level values. 3. Drain the AdBlue tank and verify the displayed fill level reflects the change. 4. Fill the AdBlue tank slowly. Do not overfill. Verify the fill level reflects the change. Note: For model years 23 to 25, Fill Level Sensor 1 functions as the empty sensor and accurately measures only the bottom portion of the tank. Once the level is above the measurement range, the displayed value may fluctuate. This is nor-mal. 5. Reset the AdBlue tank fill level via XENTRY. Print the XENTRY pages showing that the fill up completed success-fully. 6. Only after the system is in proper working condition, complete LI49.20-N-075995 for AdBlue warning reset and print the XENTRY pages confirming the reset completed successfully. Note: If XENTRY still indicates frozen AdBlue or the concentration remains inaccurate after drain and refill and the thaw, mix, retest requirements were completed, proceed to section D. D. Damaged AdBlue level and concentration sensing functions 1. Replace the AdBlue tank as required by applicable MB guidance. 2. With the vehicle running and XENTRY connected, display the actual AdBlue level values. 3. Fill the AdBlue tank slowly. Do not overfill. Verify the fill level reflects the change. 4. Reset the AdBlue tank fill level via XENTRY. 5. Only after the system is in proper working condition, complete LI49.20-N-075995 for AdBlue warning reset. |
| LI49.20-N-078838 | 2025-04-03. Service bulletin. Check engine light or Adblue warning with fault codes P206B31, P203B31, or P300494 when outside temperatures are below 32 degrees Fahrenheit. SCR Gen4 (KP7) Complaint: The check engine light or AdBlue warning is activated, accompanied by one or more of the following fault codes rela- ted 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 prema- ture freezing. C. Frozen or partially frozen AdBlue can cause the AdBlue level sensor to misread levels. D. The AdBlue level sensor is damaged. |