Service bulletins for the 2025 Mercedes-Benz 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.
39 on file from NHTSA, as of 2026-10-19.
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Only bulletins with topic: maintenance are shown. Show all
| LI18_40-N-080867_1_en | 2026-09-03. Service bulletin. POWER TRAIN. OM654 Engine Oil Consumption Complaint The customer may report repeated low engine oil level warnings in the instrument cluster. The customer may also state that engine oil must be added between scheduled maintenance intervals. During diagnosis, oil residue may be observed at the oil filler neck, cylinder head cover, crankcase ventilation connection, charge air pipes, charge air cooler, intake tract, or turbocharger area. In some cases, the complaint may be accompanied by increased diesel particulate filter (DPF) regeneration frequency or aftertreatment‑related fault entries. Cause Increased engine oil consumption may be caused by external oil leakage, crankcase ventilation system concerns, reduced oil separation efficiency in the cylinder head cover, turbocharger oil leakage, charge air system oil accumulation, fuel dilution, vehicle operating profile, oil level sensor plausibility concerns, or internal engine mechanical damage. A measured engine oil consumption test is required before a repair direction is determined. Customer‑reported oil additions or instrument cluster oil level messages alone are not sufficient to determine the repair. Remedy 1. Perform the engine oil consumption measurement according to AR18.00‑D‑ 0025TSM. 2. If the measured oil consumption is within specification, no repair related to engine oil consumption is required. • Verify the correct engine oil specification and review the vehicle operating profile, maintenance history, idle time, and regeneration frequency. If the complaint is based mainly on an oil level message and measured oil consumption is not confirmed, verify oil level sensor plausibility before continuing with engine oil consumption diagnosis. 3. If the measured oil consumption exceeds specification, inspect the engine for external oil leaks. • Pay close attention to the oil filler neck, oil filler neck seal, cylinder head cover area, oil filter housing, crankcase ventilation connections, turbocharger oil supply and return areas, and other visible sealing points. 4. If an external oil leak is identified, repair the leak according to the applicable repair instructions. • Correct the engine oil level and repeat the oil consumption measurement if necessary. 5. Inspect the crankcase ventilation connection, turbocharger inlet and outlet, charge air pipes, and charge air cooler for oil accumulation. • A light oil film alone does not confirm a turbocharger or engine failure. Oil pooling, heavy oil accumulation, debris, or oil migration into the intake tract requires further inspection. 6. If there is no clear external oil leak, no severe charge air system oil contamination, and no obvious turbocharger damage, inspect the crankcase ventilation system first. 7. Perform the crankcase ventilation shutoff valve leak‑tightness test according to AR01.40‑D‑0050TSM. 8. If the crankcase ventilation shutoff valve fails the leak‑tightness test, replace the shutoff valve and the cylinder head cover with integrated oil separator. Replace all required seals and hardware. 9. If the crankcase ventilation shutoff valve passes the leak‑tightness test, no external oil leak is identified, no abnormal turbocharger oil entry is found, and the engine mechanical condition is not suspect, replace the cylinder head cover with integrated oil separator. • Fill the engine with oil meeting MB 229.52 SAE 5W‑30 and repeat the engine oil consumption measurement according to AR18.00‑D‑0025TSM. |
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| LI54_30-N-080701 | 2026-08-03. Service bulletin. UNKNOWN OR OTHER. ASSYST PLUS service reminder appears earlier than expected due to vehicle operating conditions Complaint The ASSYST PLUS service reminder appears earlier than expected. The customer or dealer may report that the vehicle did not reach the starting maintenance interval shown in vehicle documentation, option coding, sales literature, or the Owner's Manual. The service reminder may appear significantly earlier than anticipated even though no faults are stored and no malfunction is present in the vehicle. The remaining distance and remaining time continue to decrease normally until the service reminder is displayed. Cause This condition is not caused by a malfunction of ASSYST PLUS. ASSYST PLUS is a dynamic maintenance management system that continuously evaluates vehicle usage and opera-ting conditions to determine maintenance requirements. The starting maintenance interval specified by variant coding represents a maximum interval that may only be achieved under favorable operating conditions. Actual maintenance intervals may be significantly shorter depending on vehicle use. Vehicle operating conditions such as driving conditions, engine load, engine operating conditions, idling, short-trip operation, environmental influences, oil aging, and Diesel Particulate Filter (DPF) regeneration activity may reduce the maintenance interval from its starting value. These conditions may accelerate engine oil aging through increased soot loading, fuel dilution, moisture accumulation, and additional engine operating stress. As a result, the remaining distance and remaining time until the next service may be reduced from the starting maintenance interval. Remedy Do not replace any parts. A due service must be assumed if the maintenance data calculated by ASSYST PLUS indicates that service is required. |
| LI09.41-N-080666 | 2026-07-02. Service bulletin. ENGINE. Check engine light with reduced power –P300A6D due to charge air system contamination Complaint The check engine light is activated, accompanied by fault code 'P300A6D The boost pressure is too low', indicating reduced boost pressure. Cause Charge air system restriction due to contamination: • Oil mist from the crankcase ventilation system can enter the intake tract and deposit within the charge air system • Under high thermal load and with soot-laden or aged engine oil, these deposits may carbonize • Carbonized deposits can loosen and accumulate in the charge air cooler and related components • This can result in partial or complete restriction of the charge air cooler, leading to underboost conditions and fault codes such as P300A6D Contributing factors may include: • High engine load operating profiles • Extended oil service intervals or degraded engine oil condition Remedy Prerequisite: Complete all guided diagnostic test steps for fault code P300A6D in Xentry Diagnostics and follow LI09.40-N-079144 before performing the repairs below. If carbonized oil deposits or restriction are identified within the charge air system: 1. Replace the following components as a set: • Charge air cooler • Exhaust turbocharger • Charge air pipe upstream of the charge air cooler 2. After completing repairs: • Perform engine oil and filter replacement using an approved specification oil. Approved oil specifications: • MB 229.52 SAE 5W-30 - BB00.40-P-0229-52A • MB 229.51 SAE 5W-30 - BB00.40-P-0229-51A 3. Perform control unit adaptations: • Reset intake air system adaptation values • Reset low-pressure exhaust gas recirculation (EGR) adaptation values 4. After repair completion: • Perform a test drive • Verify that the fault code does not return 5. If the vehicle is within warranty and the charge air cooler is determined to be obstructed by debris, use damage code 50301 B2 when submitting the warranty claim. Notes: • Additional component replacement is not required unless supported by further diagnostic results. • Do not replace the charge air distributor pipe or Clean Air Line unless additional faults (for example, air mass-related faults) are present. • After replacement of components, ensure proper initialization and learning procedures are completed in the control unit. • Creation of an XENTRY TIPS case is not required for this condition. • Please review the attached photos for previously identified causes of these fault codes. |
The summaries are NHTSA's. Each bulletin's page links NHTSA's copy of the manufacturer's document.