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.
By type
By component
By trouble code
By topic
| LI49-20-N-078838 | 2026-04-02. Service bulletin. FUEL/PROPULSION SYSTEM. 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 Cause A. The software for the AdBlue (SCR) control unit (N118/5) is outdated.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. |
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| LI49-20-N-075995 | 2026-04-02. Service bulletin. UNKNOWN OR OTHER. Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset with fault code P13DF00 or P300685 Complaint SCR or AdBlue warning message cannot be reset. All fault codes in the AdBlue (SCR) control unit have been processed and corrected, however fault codes P13DF00 or P300685 remain active and stored. Cause The procedure for resetting the SCR or AdBlue warning message with XENTRY Diagnosis has not been carried out. Note: If AdBlue quality or concentration related fault codes are present, such as P300494, P203B31, or P206B31, complete the applicable diagnostic procedure first. This includes the thaw, mixing drive, and retest requirements in LI49.20-N-080376 and the detailed diagnosis and re-pair steps in LI49.20-N-078838 as applicable. Do not attempt to reset the SCR or AdBlue warning message until the underlying fault condition has been corrected. Remedy Note: Do not replace any parts for an incorrectly executed reset procedure. 1. Connect the battery charger •Maintain adequate voltage throughout the procedure per applicable guidance. 2. Connect the diagnostic device •Use the latest version of XENTRY Diagnosis and Add-Ons. 3. Reset the SCR or AdBlue warning message using XENTRY Diagnosis •Quick test view → N118/5 – Selective Catalytic Reduction (SCR GEN4) → Special processes → Reset SCR/AdBlue® warning message. Note: Ensure all 5 listed processes are completed successfully, indicated by Actual value: "successfully completed". 4. Complete the disconnect and sleep mode initiation procedure •Disconnect XENTRY. •Refer to manual AD00.00-D-2000-06TS for the correct procedure to disconnect the diagnostic device from Model 907. •Disconnect the Battery Charger •Refer to manual AR54.10-D-1127TS for instructions on safely disconnecting the battery charger from Model 907. •Turn off the ignition. •Remove the key. •Lock the vehicle and wait approximately 15 minutes to allow the CAN bus system to enter sleep mode. 5. Post sleep mode vehicle start •After the 15-minute waiting period, start the vehicle. Note: The "starts remaining" message will remain on the Instrument Cluster (IC), but the vehicle will not be in the 5mph de-rate mode. 6. Drive for system self-test •Drive the vehicle for 5 to 10 miles to enable the SCR system to perform a self-test. Note: During the warning reset process, ensure the outside temperature sensor is reading above 10 degrees Fahrenheit. If not, keep the vehicle inside and repeat the reset. The vehicle may need to be driven to allow NOx sensors and the SCR system to complete their self-test before fault codes can be stored and then cleared. 7. Confirm and erase fault codes •Verify warning messages. •Ensure relevant fault codes are stored. •Erase fault memory if necessary. 8. Disconnect the Diagnostic Device •Refer to manual AD00.00-D-2000-06TS for the correct procedure to disconnect the diagnostic device from Model 907. 9. Disconnect the Battery Charger •Refer to manual AR54.10-D-1127TS for instructions on safely disconnecting the battery charger from Model 907. |
| Differential Pressure | 2026-03-03. Warranty extension. UNKNOWN OR OTHER. In our continuing efforts to assure the proper performance of our products and to ensure the satisfaction of our customers, the warranty for the low pressure EGR differential pressure sensor in the vehicles listed below has been extended from 5 years/100,000 miles to 15 years/150,000 miles, whichever occurs first. Mercedes-Benz AG has determined that on Sprinter (907 platform) vehicles, under certain circumstances iodine corrosion might take place on the bonded connection of the low-pressure Exhaust Gas Recirculation (EGR) differential pressure sensor, which could lead to an electrical fault. In the potentially affected vehicles iodine corrosion on the bonded connection of the low pressure EGR differential pressure sensor might be caused by the release of iodine from rubber parts if the vehicle is exposed to excessive temperatures from sun exposure or in the event of significant heat accumulation due to long idle phases. The released iodine might promote electro corrosion on the sensor’s bonding. As soon as the iodine corrosion has progressed to the point where there is no longer an electrical connection, this would be correctly recognized by the low pressure EGR differential pressure sensor diagnostics as a hardware failure, the corresponding error code would be stored and the Malfunction Indicator Light would illuminate (2-trip MIL). Furthermore, corresponding error replacement reactions (e.g. deactivation of EGR and DPF regeneration, blocking of OBD-relevant diagnostics, and activation of limp home mode) would be initiated. As a result of the error replacement reactions, exhaust emissions might be increased. Due to the illumination of the MIL as well as the activation of the replacement reactions (including limp home mode), it is anticipated that customers would visit a workshop promptly. |
| LI5410N080207 | 2026-03-03. Service bulletin. UNKNOWN OR OTHER. Xentry Battery Tester results do not match with workshop Complaint The result from the XENTRY battery test does not match the current state of the battery. Cause The XENTRY battery tester uses the stored on-board electrical system data in the SAM module to access the health of the 12 volt battery. The XENTRY battery test may not take into account a single discharge event because the SAM or EZS cannot record the data if the battery is discharged. Note: A discharged battery does not necessarily need to be replaced. A discharged battery may be recovered with no permanent damage. |
| LI4920N078838 | 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 | 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 | 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. |
| LI49.20-N-075995 | 2026-02-03. 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-075882 | 2026-02-03. 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-073867 | 2026-02-03. 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. |
| LI28.00-N-063339 | 2026-01-02. Service bulletin. POWER TRAIN. Clunking noise on load change or gear engagement Complaint Clunking noise can be heard on some load changes or when changing from N->R or N->D Cause Movement of transfer case splines Remedy Apply bearing retainer (green) Loctite to both output shaft splines of the transfer case. Loctite 648, 609 and 603 are acceptable for this repair. Note: Do not apply Loctite to input shaft (connection with transmission) splines of the transfer case else possible damage could occur. |
| LI88.30-N-078036_2 | 2025-12-03. Service bulletin. STRUCTURE:BODY. Electric Step will not extend/inoperative Complaint T57 Electric step inop with warning on cluster. Cause Possible damage to end position sensors. Remedy Please remove lower panel on step and inspect for damage to end position sensors. If no damage is found to end position sensors, please continue diagnosis of concern as normal. If damage to end position sensors are found, please check the serial number on step (see attached image of serial number location) If the serial number is below 126050: 1. Please check that the drive motor is secured to the step properly. 2. Replace the end position sensor/sensors and install them in an adjusted position that allows proper clearance between drive and sensor/sensors. (see attached image of sensor position example.) 3. Function test the step at least 5 times to check for proper clearance. If the serial number is 126050 or higher: 1. Please open a TIPS case including images of the damaged sensor/sensors and serial number of step. |
| LI54.21-N-069524_7 | 2025-12-03. 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-080010 | 2025-12-03. 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-078466 | 2025-11-04. 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). |
| LI54.30-N-079757 | 2025-10-07. Service bulletin. UNKNOWN OR OTHER. Engine Oil Level Cannot Be Checked via Instrument Cluster Service Menu Complaint Sometimes the engine oil level cannot be determined using the instrument cluster's service menu. The following mes- sages may be displayed: •Engine oil level currently inoperative. See Attachment: Message "Engine oil level currently inoperative" (shown in German on model 907 with code C6L (Multifunction steering wheel)). •Engine oil level measurement is running. Repeat the query after a maximum of 30 minutes of driving time. Information: It is still possible to determine the engine oil level via the workshop menu or XENTRY Diagnostics. Cause No current value for the saved oil volume has been stored in the drivetrain control unit (CPC, N127). Remedy 1. Connect diagnostic device (see AD00.00-D-2000-06TS for model 907). •Always use the latest XENTRY Diagnostics software release with all available add-ons. •Follow all operation steps in XENTRY Diagnosis precisely. 2. Perform initial quick test (see AD00.00-D-2000-06TS for model 907). •Print out the initial quick test as a PDF file and attach it to the order in a tamperproof manner. 3. Create and save the control unit log for drivetrain control unit (CPC, N127). •Print out the control unit log as a PDF file and attach it to the order in a tamperproof manner. •Check the saved oil volume in the "Maintenance data" tab of the control unit log. See Attachment: Saved oil volume in "Maintenance data" tab of the control unit log (shown in German). •If the saved oil volume in the "Maintenance data" tab is more than 0.0 liters and it is not possible to determine the en- gine oil level via the service menu, conduct further research on the exact reason for the customer complaint and initia- te corresponding repair measures. •If the saved oil volume is 0.0 liters, proceed with operation step 4. 4. Check actual values for engine oil level in the engine control unit and observe any relevant information and descrip- tions in XENTRY Diagnosis. •Quick test view → Engine control unit → Actual values → Oil circuit → Oil level gauge 5. Clear fault memory (see AD00.00-D-2000-06TS for model 907). 6. Disconnect diagnostic device (see AD00.00-D-2000-06TS for model 907). 7. Carry out a test drive of more than 30 minutes, run the vehicle in idle for approximately 3 minutes on a level sur- face, switch the ignition off and on again, and then record the engine oil level again using the instrument cluster's ser- vice menu. •Only carry this out if the saved oil volume in the "Maintenance data" tab is 0.0 liters. •When checking the engine oil level via the service menu, refer to the operator's manual. Inform the customer accor- dingly about these circumstances. See Attachment: Message "Engine oil level OK" (shown in German on model 907 with code C6L (Multifunction steering wheel)). 8. If the customer complaint occurs again, create a TIPS case directed to the Powertrain inbox, including all required information from this LI. |
| LI27.19-N-079793 | 2025-10-07. Service bulletin. POWER TRAIN. Complaint Transmission control unit Y3/8n4 (fully integrated transmission control unit (VGS)) not listed in quick test and/or no communication possible with VGS. Cause Transmission control unit Y3/8n4 Remedy For vehicles with 722.9 transmission: Ensure LI54.15-P-057373 is performed before replacing any component parts. After processing and complying with the above document(s): 1. Perform an ignition reset on Y3/8n4 (VGS) 2. Inspect transmission connector for loose connections, damaged wiring or pins and any other concerns. If communication with the VGS cannot be established, the complete valve body ('electrohydraulic controller unit (EHS)') must be replaced. Installation of a VGS repair kit is not permitted in this case as it is not possible to transfer the necessary valve characteristics without communication with the original control unit. |
| LI01.40-N-077649 | 2025-10-07. 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-079275 | 2025-10-07. 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-079573 | 2025-08-01. 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. |
| LI49.20-N-079157_6 | 2025-07-01. Service bulletin. ELECTRICAL SYSTEM. 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 Vehicles Produced Before August 1, 2024 (Code XY4 = MY24) A. Leak in the AdBlue System 1. Complete the Guided Tests for DTC P20F409 or P202E84: •Inspect the AdBlue tank, pump, line, and both injectors for leaks. •Ensure the AdBlue line is properly routed, securely fastened, and not in contact with the exhaust system. •Remove both AdBlue injection valves, perform 2–3 pressure build-ups, and check for AdBlue leaks. •If a leak is detected, repair it and retest. B. Internal Fault with AdBlue Injection Valve #1 (Motor Side) 1. Process All Other Related DTCs First: •Address any other fault codes relating to AdBlue injection valves before proceeding. •If AdBlue Injection Valve #1 (engine side) fails the guided tests, replace it and retest. C. Air Pocket Forming in the AdBlue Line (Motor Side) 1. If Guided Tests Pass and No Leaks are Found: --Do not replace any components.-- •The MY23-24 (Code XY4 = MY24, OM654) AdBlue line (A907 470 01 01) has a known design issue that can cause air pockets and DTC P20F409. This may also result in DTC P202E84, depending on the air pocket size. •The guided tests for P20F409 now include resetting the learned values for the AdBlue delivery pump (A103m1). After this, the vehicle can be released to the customer. NOTE: Replacing the AdBlue tank or line will NOT resolve this air pocket issue. TIPS cases are no longer required for MY23–24 vehicles. Steps to Perform (MY23–24, Code XY4): 1. Complete the guided tests for DTC P20F409 and/or P202E84. 2. Perform an initial start-up of: •The SCR control unit •AdBlue tank components •Both AdBlue injectors 3. Conduct a 20-mile test drive. If no faults occur, the vehicle can be released. 4. Inform the customer that frequent starting/stopping increases the likelihood of this fault due to repeated cycling of AdBlue in/out of the line each ignition cycle. Vehicles Produced After August 1, 2024 (Code XY5 = MY25) A. Leak in the AdBlue System 1. Complete the Guided Tests for DTC P20F409 or P202E84: •Inspect the AdBlue tank, pump, line, and both injectors for leaks. •Ensure the AdBlue line is properly routed, securely fastened, and not in contact with the exhaust system. •Remove both AdBlue injection valves, perform 2–3 pressure build-ups, and check for AdBlue leaks. •If a leak is detected, repair it and retest. B. Internal Fault with AdBlue Injection Valve #1 (Motor Side) 1. Process All Other Related DTCs First: •Address any other fault codes relating to AdBlue injection valves before proceeding. •If AdBlue Injection Valve #1 (engine side) fails the guided tests, replace it and retest. C. Incorrect AdBlue Injection Line Installed 1. Verify the Updated Line is Installed: •Confirm that part number A907 470 33 02 is present. •If the AdBlue line is incorrect (e.g., A907 470 01 01), replace it with the updated line. TIPS Case Instructions for All MY25 and Newer Vehicles If you encounter any of the issues above on any MY25 or newer vehicle, including finding an incorrect AdBlue line in- stalled: •Open a TIPS case addressed to the Powertrain inbox. •Reference this LI document. •Include the following information: •Description of the issue encountered (e.g., fault code, check engine light, or incorrect AdBlue injection line) •Current Quick Test, SCR N118/5 Control Unit Log, and Guided Test results. •Photo of AdBlue line part number label. •Photos documenting any issues, leaks, or melting observed |
| LI47.70-N-079422_1 | 2025-07-01. Service bulletin. ELECTRICAL SYSTEM. HV battery is not charging to its full capacity with restricted maximum SoC Complaint The vehicle's HV battery is not charging to its full capacity, with the maximum State of Charge (SoC) being restricted to a specific percentage. Cause The State of Charge (SoC) percentage limitation might be influenced by the Onboard Logic Unit (OLU), MBUX Headunit, or the Powertrain Control Unit (PTCU). Remedy If the Onboard Logic Unit (OLU) and MBUX Headunit do not impose a SoC percentage limitation, then proceed with the SCN coding of the Powertrain Control Unit (PTCU). |
| LI14.30-N-075882_6 | 2025-07-01. 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_3 | 2025-07-01. 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_1 | 2025-07-01. 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. |
The summaries are NHTSA's. Each bulletin's page links NHTSA's copy of the manufacturer's document.