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Service bulletins for the 2023 Freightliner Sprinter

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.

75 on file from NHTSA, as of 2026-10-19.

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LI09_41-N-079165_2_en2026-09-04. 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-0806662026-07-02. 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-0805182026-07-02. 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-0807312026-07-02. 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.
LI4920N0788382026-03-03. 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.
LI4920N0759952026-03-03. 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-0800112026-02-03. 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.
LI49.20-N-0759952026-02-03. Service bulletin. ENGINE. 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.
LI14.30-N-0758822026-02-03. Service bulletin. ENGINE. Complaint Check engine warning light is active. The following fault codes may be present in the engine control unit: • P3007F1 Leak detected in the intake air system or • P3007F2 Mass air flow malfunction in the intake air system (cylinder bank 1) or • P300CA8 Leak detected in the intake air system or • P300CA9 Mass air flow malfunction in the intake air system (cylinder bank 1) or • P300CA9 and P3007F1: Faults are present simultaneously in the quick test In addition, the customer may report: • An “air leak” type noise from the engine compartment/intake air area, and/or • A “chugging” noise, especially during acceleration or under load. These noise complaints can be present with or without the above fault codes. Cause Causes for FC P3007F1 or P300CA8: Faults are set if: • If there is a leakage upstream of the exhaust gas turbocharger (see "Dichtring_Sealant.jpg"). • If the housing intermediate flange at the high-pressure EGR valve (where the exhaust back pressure sensor connects) is carbonized or clogged, or if there is carbonization/incomplete sealing of the high-pressure or lowpressure EGR valves. (See “Gehaeusezwischenflansch_intermediate_flange.jpg” and verstopfter_Gehaeusezwischenflansch_clogged_Intermediate_Flange.jpg.”) • Note: Only relevant if the correction value in load range 1 is less than -8%. • If the intake manifold (charge air distribution line) or charge air cooler is carbonized (see "Saugrohr_intake_manifold.jpg"). • If engine timing is misadjusted. • There is a defective hot film mass air flow sensor or a hot film mass air flow sensor that is affected by incorrect airflow (this can be due to a clogged or deformed air filter). Refer to the attached file "Luftfilter_air_filter." Cause of fault code combination P300CA9 AND P3007F1: Faults are set if: • There is carbonization or incomplete closure of the high-pressure exhaust gas recirculation valve, especially in the housing intermediate flange at the EGR valve (linked to the exhaust back pressure sensor). Charleston Plant Identification – VIN 11th Digit “T”: For vehicles produced at the Charleston Plant (identified by “T” in the 11th digit of the VIN) with a production date on or after 12/20/2023: • If fault code P3007F1 or P300CA8 is set, an air leak is found, and the cause is identified as a loose or mis-installed Clean Air Line from the factory, open an Initial Field Quality (Info Only) case. • Include the current Quick Test and photos showing the Clean Air Line issue. For all other vehicles, continue diagnosis as per the standard instructions.
LI14.20-N-0738672026-02-03. Service bulletin. ENGINE. 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.
LI54.21-N-069524_72025-12-03. Service bulletin. ENGINE. Diverse messages in the instrument cluster, vehicle will not start, gears cannot be engaged Complaint Vehicle cannot be started, various messages in instrument cluster, gears cannot be engaged, ignition cannot be switched on, central locking has malfunction. Cause Water entry or condensation on vehicle, resulting possibly in oxidation at plug and/or water/moisture entry in control unit N73/8 for Electronic Ignition Lock (EIS) and/or N127 Powertrain Control unit (CPC). Remedy Check control unit N73/8 for Electronic Ignition Lock (EIS) and N127 Powertrain Control unit (CPC) for water entry/moisture traces. If water entry / moisture traces are visible on control unit N73/8 for Electronic Ignition Lock (EIS) and/or N127 Powertrain Control unit (CPC), please localize the leaky area and rectify the leak.
LI49.00-N-0800102025-12-03. Service bulletin. ENGINE. Exhaust Gas Flap Noise Complaint Customers may report a high-pitched squealing or squeaking noise originating from the exhaust system, specifically near the exhaust gas flap. Cause The noise occurs during actuation of the exhaust gas flap. Internal movement within the flap mechanism, primarily the flap shaft and return spring, can generate friction-induced squeal. Remedy If a squealing noise is present at the exhaust gas flap, do not replace the entire exhaust gas flap assembly or exhaust system. Perform the following corrective action: 1. Confirm the noise originates from the exhaust gas flap actuator area. The squeal typically occurs when the actuator moves the flap during engine operation. 2. Solution: •Remove the Exhaust Gas Flap Controller (AR49.10-D-5507TSM - Remove/install exhaust gas flap controller). •Remove the original spring (Picture 1). •Install the new damping element in place of the spring (Picture 2 and Picture 3). -This damping element absorbs vibration and prevents squealing, eliminating the need for costly component replacements. •Reinstall the Exhaust Gas Flap Controller. •Perform initialization of Exhaust Gas Flap Controller (AD00.00-D-2000-06TS - Connect/disconnect diagnostic unit).
LI49.20-N-0784662025-11-04. Service bulletin. ENGINE. 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. 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).
LI01.40-N-0776492025-10-07. Service bulletin. ENGINE. Oil Leak at Vibration Damper Area Complaint Oil leakage observed near the vibration damper, traced to a faulty radial shaft sealing ring at the front crankshaft flange. (see photo in attachment) Cause The sealing lip of the radial shaft sealing ring has worn a groove into the front crankshaft flange. This wear compromi- ses the sealing integrity between the crankshaft and the radial shaft sealing ring in its original assembly position. Remedy Install a crankcase cover equipped with a design-optimized radial shaft sealing ring. This updated sealing ring features a revised lip structure that relocates the sealing surface outside the worn area of the crankshaft.
LI01.10-N-0792752025-10-07. Service bulletin. ENGINE. Internal Diesel Engine Damage or Oil Sludge Formation Complaint Customer reports that the vehicle will not start, is difficult to start, or is making unusual noises. Inspection Findings: Upon inspection, engine bearings—including crankshaft, connection rod, and camshafts—exhibit significant signs of wear. Engine oil shows evidence of sludging, characterized by the presence of thick, gel-like, or semi-solid deposits within the engine. This condition is indicative of oil degradation and/or contamination. Cause Internal engine wear and starting issues are a result of oil sludging. This sludging occurs due to oil degradation and/or contamination. Common contributing factors include: •Failure to perform maintenance on time as indicated by the ASSYST PLUS system •Use of non-OEM (aftermarket) parts or fluids •Addition of incorrect fluids (e.g., AdBlue, washer fluid, coolant) to the engine oil, which can severely compromise lub- rication and engine operation Important: Under no circumstances should any non-engine fluids—such as AdBlue, washer fluid, or coolant—be ad- ded to the engine oil or crankcase. The introduction of these fluids, even in small amounts, can cause severe engine damage. This damage is not covered under warranty. Always verify that only approved engine oil and additives are used during service.
LI07.02-N-0795732025-08-01. Service bulletin. ENGINE. 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: The shaft seal (radial sealing ring) at the high-pressure fuel pump is not leak-tight, resulting in external oil leakage. Remedy: Install new high-pressure pump together with design-optimized sealing ring. 1. Replace the high-pressure fuel pump. 2. Discard the 2.5 mm O-ring included with the new pump. 3. Install the updated 2.6 mm O-ring (P/N: A0009973819). 4. Verify the repair using crack detection spray (P/N: A0009890359) around the pump mounting area. 5. If the leak reappears, submit a TIPS case to the Powertrain inbox with reference photos.
LI14.30-N-075882_62025-07-01. Service bulletin. ENGINE. Check engine light active - Fault P3007F1, P3007F2, P300CA8, or P300CA9 present in CDI control unit Complaint Check engine warning light active. The following fault codes may be present in the engine control unit: • P3007F1 Leak detected in intake air system or • P3007F2 Mass air flow malfunction in intake air system (cylinder bank 1) or • P300CA8 Leak detected in intake air system or • P300CA9 Mass air flow malfunction in intake air system (cylinder bank 1) or • P300CA9 and P3007F1: Faults are present simultaneously in the quick test Cause Causes for FC P3007F1 or P300CA8: Faults are set if: • If there is a leakage upstream of the exhaust gas turbocharger (see "Dichtring_Sealant.jpg"). • If the housing intermediate flange at the high-pressure EGR valve (where the exhaust back pressure sensor connects) is carbonized or clogged, or if there is carbonization/incomplete sealing of the high-pressure or low- pressure EGR valves. (See “Gehaeusezwischenflansch_intermediate_flange.jpg” and “verstopfter_Gehaeuse- zwischenflansch_clogged_Intermediate_Flange.jpg.”) • Note: Only relevant if correction value in load range 1 is less than -8%. • If the intake manifold (charge air distribution line) or charge air cooler is carbonized (see "Saugrohr_intake_mani- fold.jpg"). • If engine timing is misadjusted. • There is a defective hot film mass air flow sensor or a hot film mass air flow sensor that is affected by incorrect airflow (this can be due to a clogged or deformed air filter). Refer to the attached file "Luftfilter_air_filter." Cause for FC P3007F2 or P300CA9: Faults are set if: • There is a leak downstream of the exhaust gas turbocharger. • The charge air distribution line (intake manifold) is heavily carbonized (see "Saugrohr_intake_manifold.jpg"). • There is carbonization or incomplete closure of the high-pressure exhaust gas recirculation valve, especially in the housing intermediate flange at the EGR valve (linked to the exhaust back pressure sensor). • There is a defective hot film mass air flow sensor, or it is affected by incorrect airflow due to a clogged or defor- med air filter (see "Luftfilter_air_filter"). Cause of fault code combination P300CA9 AND P3007F1: Faults are set if: • There is carbonization or incomplete closure of the high-pressure exhaust gas recirculation valve, especially in the housing intermediate flange at the EGR valve (linked to the exhaust back pressure sensor). Charleston Plant Identification – VIN 11th Digit “T”: For vehicles produced at the Charleston Plant (identified by “T” in the 11th digit of the VIN) with a production date on or after 12/20/2023: • If fault code P3007F1 or P300CA8 is set and the cause is identified as a loose or mis-installed Clean Air Line from the factory, open an Initial Field Quality (Info Only) case. • Include the current Quick Test and photos showing the Clean Air Line issue. For all other vehicles, continue diagnosis as per the standard instructions. Remedy In the case of fault code P3007F1 or P300CA8: 1) Check for Required ECU Software Update (Applies to P300CA8 only)
LI14.20-N-079253_32025-07-01. Service bulletin. ENGINE. Check engine light with fault code P300E55 with H12 Complaint The check engine light is activated, accompanied by the following fault code related to the Exhaust gas recirculation cooler (low pressure): •P300E55 The efficiency of component 'Exhaust gas recirculation cooler (low pressure)' is not sufficient. Cause The issue is attributed to an error in the coding of the climate control unit software (HVAC177). Remedy Software Update Instructions Please proceed as follows for the different variants:
LI01.10-N-079275_12025-07-01. Service bulletin. ENGINE. Internal Diesel Engine Damage or Oil Sludge Formation Complaint Customer reports that the vehicle will not start, is difficult to start, or is making unusual noises. Inspection Findings: Upon inspection, engine bearings—including crankshaft, connection rod, and camshafts—exhibit significant signs of wear. Engine oil shows evidence of sludging, characterized by the presence of thick, gel-like, or semi-solid deposits within the engine. This condition is indicative of oil degradation and/or contamination. Cause Internal engine wear and starting issues are a result of oil sludging. This sludging occurs due to oil degradation and/or contamination. Common contributing factors include: •Failure to perform maintenance on time as indicated by the ASSYST PLUS system •Use of non-OEM (aftermarket) parts or fluids •Addition of incorrect fluids (e.g., AdBlue, washer fluid, coolant) to the engine oil, which can severely compromise lub- rication and engine operation Important: Under no circumstances should any non-engine fluids—such as AdBlue, washer fluid, or coolant—be ad- ded to the engine oil or crankcase. The introduction of these fluids, even in small amounts, can cause severe engine damage. This damage is not covered under warranty. Always verify that only approved engine oil and additives are used during service. Remedy To thoroughly diagnose internal engine wear or oil sludging, follow these guidelines: Maintenance History •Verify maintenance intervals: Check that all maintenance has been performed on schedule as indicated by the ASSYST PLUS system in the Instrument Cluster and according to WIS. (Refer to Attachments) •Review records: Examine the vehicle’s service history using resources like VMI, CarFax, and any documentation pro- vided by the customer. •Validate parts and fluids: Confirm all maintenance was carried out using OEM-approved parts and fluids as specified in the Owner’s Manual and Maintenance Booklet.
LI49.20-N-0791572025-06-03. Service bulletin. ENGINE. Complaint The check engine light is activated, accompanied by one or more of the following fault codes related to the Adblue System: •P20F409: The Adblue consumption is too low. There is a component fault. •P202E84: The Adblue metering valve 1 (Motor side) has a malfunction. There is a signal below the permissible limit value. Cause The potential causes for these fault codes are: A. A leak in the Adblue System B. An internal fault with the Adblue Injection Valve #1 (Motor side) C. An air pocket forming in the Adblue Injection Valve #1 (Motor side) Adblue Injector Line Remedy --Prior To Production Date 08/01/2024 Code XY4 = MY24-- A. A Leak in the Adblue System 1. Complete the Guided Tests for P20F409 or P202E84: •Perform a thorough inspection of the Adblue Tank, the Adblue Pump, the Adblue Line, and both Adblue Injectors for leaks. •Ensure the Adblue line is properly installed, securely fastened in all clips, and not in contact with the exhaust system. •Remove both Adblue Injection Valves and complete 2-3 pressure build-ups and inspect for Adblue leakage. •If a leak is identified, repair it and retest. B. An internal fault with the Adblue Injection Valve #1 (Motor side) 1. Process Other Fault Codes First: •If there are other fault codes for the Adblue Injection Valves, address these first. •If the Adblue Injection Valve #1 (engine side) fails the guided tests, replace it and retest. C. An air pocket forming in the AdBlue Line (Motor side) 1. If Guided Tests Pass and No Leaks are Found: •Do not replace any components. •Germany has identified the root cause of fault code P20F409 and is working on a solution. The design of the MY23-24, Code XY4 = MY24, OM654 AdBlue Line (A907 470 01 01) is causing air pockets in the system, resulting in fault code P20F409. Depending on the size of the air pocket, you may also encounter fault code P202E84 AdBlue Metering Valve 1 (Motor side). •The guided tests for fault code P20F409 have been updated to include the resetting of learned values for component ‘A103m1 (AdBlue delivery pump)’ and to release the vehicle back to the client.
LI14.20-N-0792532025-06-03. Service bulletin. ENGINE. Complaint The check engine light is activated, accompanied by the following fault code related to the Exhaust gas recirculation cooler (low pressure): •P300E55 The efficiency of component 'Exhaust gas recirculation cooler (low pressure)' is not sufficient. Cause The issue is attributed to an error in the coding of the climate control unit software (HVAC177). Remedy A software update to correct the coding error is currently in the process of release for the Aftersales network. In the interim, please proceed as follows: •Erase the fault memory (DTCs) from the control unit. •Return the vehicle to the customer. •No further diagnostic or repair procedures are required at this time.
LI14.20-N-0738672025-06-03. Service bulletin. 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. 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.
LI49.20-N-0791572025-05-02. Service bulletin. ENGINE. Check engine light with possible Adblue warning with fault code P20F409 or P202E84 Complaint The check engine light is activated, accompanied by one or more of the following fault codes related to the Adblue System: •P20F409: The Adblue consumption is too low. There is a component fault. •P202E84: The Adblue metering valve 1 (Motor side) has a malfunction. There is a signal below the permissible limit value. Cause The potential causes for these fault codes are: A. A leak in the Adblue System B. An internal fault with the Adblue Injection Valve #1 (Motor side) C. An air pocket forming in the Adblue Injection Valve #1 (Motor side) Adblue Injector Line Remedy --Prior To Production Date 08/01/2024-- A. A Leak in the Adblue System 1. Complete the Guided Tests for P20F409 or P202E84: •Perform a thorough inspection of the Adblue Tank, the Adblue Pump, the Adblue Line, and both Adblue Injectors for leaks. •Ensure the Adblue line is properly installed, securely fastened in all clips, and not in contact with the exhaust system. •Remove both Adblue Injection Valves and complete 2-3 pressure build-ups and inspect for Adblue leakage. •If a leak is identified, repair it and retest.
LI14.20-N-0738672025-05-02. Service bulletin. ENGINE. 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.
LI09.41-N-079165_12025-05-02. Service bulletin. ENGINE. Low Coolant Warning, Potential Misfire, and Absence of External Coolant Leaks 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 po- sitive. 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 da- mage 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.

The summaries are NHTSA's. Each bulletin's page links NHTSA's copy of the manufacturer's document.