VS3AGROHR – Possible Exhaust Leak May cause Fire – 2019 Freightliner Sprinter

February 12, 2020 NHTSA CAMPAIGN NUMBER: 20V078000

Possible Exhaust Leak May cause Fire

If the connecting screws are not properly tightened, hot exhaust gases may leak from the EGR pipe, increasing the risk of a fire.

 

NHTSA Campaign Number: 20V078

Manufacturer Daimler Vans USA, LLC

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 4,424

 

Summary

Daimler Vans USA, LLC (DVUSA) is recalling certain 2019 Mercedes Benz Sprinter and Freightliner Sprinter vehicles. The connecting screws on the exhaust gas recirculation (EGR) pipe may not have been correctly tightened.

 

Remedy

DVUSA will notify owners, and Mercedes-Benz or Freightliner Sprinter dealers will renew the screw connection and the flange seals on the exhaust gas recirculation pipe, free of charge. DVUSA issued owners an interim notification on April 6, 2020. The recall began May 4, 2020. Owners may contact DVUSA customer service at 1-877-762-8267. DVUSA’s number for this recall is VS3AGROHR.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check for Daimler Vans Recalls

 

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TO:  Mercedes-Benz and Freightliner Dealer Principals, General Managers, Sales Managers, Service Managers, Parts Managers	FROM: Anthony Washington, Department Manager, Regulations and Certifications
RE: Initial Recall Campaign Notification Model 907 (Sprinter) Model Years 2019 EGR Screw Connection	DATE:  March 10, 2020

 

IMPORTANT CAMPAIGN INFORMATION

 

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Campaign	Campaign Desc. :		EGR Screw Connection
2020030005	PDGAGROHR
This is to notify you of the upcoming Recall Campaign concerning the screw connections on the exhaust gas recirculation pipe (EGR) on approximately 4,424 MY19 Mercedes-Benz and Freightliner Sprinter vans.  The recall campaign will be visible on the www.safercar.gov website and may generate questions from customers.  All affected VINs will be flagged as “Pending” in VMI.
Background
Issue	Mercedes-Benz AG (“MBAG”), the manufacturer of Mercedes-Benz and Freightliner vans, has determined that on certain Sprinter vehicles from platform 907 (VS30), certain screw connections on the exhaust gas recirculation (EGR) pipe (between the exhaust gas collection pipe and the exhaust gas recirculation controller) may  not have been carried out according to specification. If the connecting screws are not tightened according to specification, the flange surface at the end of the EGR pipe may not be completely sealed. In that case, hot exhaust gas could leak into the engine compartment and cause a potential thermal reaction and/or thermal damage to immediately surrounding components.
What We’re Doing	An authorized Mercedes-Benz or Freightliner Sprinter dealer will renew the affected screw connection and the flange seals on the exhaust gas recirculation pipe.
Parts	Parts are still being verified. An additional notification will be sent when parts are available for repair.
Vehicles Affected
Vehicle Model Year(s)	Model Year 2019
Vehicle Model	Sprinter, VS30 / Platform 907
Vehicle Populations
Total Recall	4,424
Dealer Inventory	123
Given this notice, it is a violation of Federal Law for a dealer to sell or lease any new MY19 Sprinter vehicles in dealer inventory covered by this notification until the vehicle has been repaired. Loaner and demonstrator vehicles may continue to be driven, but must not be retailed until repaired. Additionally, given this notice, it is a violation of Federal Law for rental companies to rent new MY19 Sprinter vehicles covered by this notification until the vehicle has been repaired.
Next Steps/Notes
Customer Notification Timeline	An owner notification letter will be mailed in late March, 2020.
AOMS/SOMS	AOMs – This recall may generate questions from your dealers. Please forward this notice to your dealers ASAP.
Rental Fleet Partners	This recall may affect vehicles in your fleet. Please contact your respective DVUSA fleet representative for further information and next steps. For repairs, please contact your preferred DVUSA dealer.
While we regret any inconvenience this may cause, we are determined to maintain a high level of vehicle quality and customer satisfaction.

 

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TO:  Mercedes-Benz and Freightliner Dealer Principals, General Managers, Sales Managers, Service Managers, Parts Managers	FROM: Anthony Washington, Department Manager, Regulations and Certifications
RE: Recall Campaign Notification Model 907 (Sprinter) Model Years 2019 EGR Screw Connection	DATE:  April 27, 2020

 

IMPORTANT CAMPAIGN INFORMATION

 

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Campaign	Campaign Desc. :		EGR Screw Connection
2020040009	VS3AGROHR
This is to notify you of the Recall Campaign concerning the screw connections on the exhaust gas recirculation pipe (EGR) on approximately 4,333 MY19 Mercedes-Benz and Freightliner Sprinter vans.  The recall campaign will be visible on the www.safercar.gov website and may generate questions from customers.  All affected VINs will be flagged as “Open” in VMI.
Background
Issue	Mercedes-Benz AG (“MBAG”), the manufacturer of Mercedes-Benz and Freightliner vans, has determined that on certain Sprinter vehicles from platform 907 (VS30), certain screw connections on the exhaust gas recirculation (EGR) pipe (between the exhaust gas collection pipe and the exhaust gas recirculation controller) may  not have been carried out according to specification. If the connecting screws are not tightened according to specification, the flange surface at the end of the EGR pipe may not be completely sealed. In that case, hot exhaust gas could leak into the engine compartment and cause a potential thermal reaction and/or thermal damage to immediately surrounding components.
What We’re Doing	An authorized Mercedes-Benz or Freightliner Sprinter dealer will renew the affected screw connection and the flange seals on the exhaust gas recirculation pipe.
Parts	Parts are available.
Vehicles Affected
Vehicle Model Year(s)	Model Year 2019
Vehicle Model	Sprinter, VS30 / Platform 907
Vehicle Populations
Total Recall	4,333
Dealer Inventory	123
Given this notice, it is a violation of Federal Law for a dealer to sell or lease any new MY19 Sprinter vehicles in dealer inventory covered by this notification until the vehicle has been repaired. Loaner and demonstrator vehicles may continue to be driven, but must not be retailed until repaired. Additionally, given this notice, it is a violation of Federal Law for rental companies to rent new MY19 Sprinter vehicles covered by this notification until the vehicle has been repaired.
Next Steps/Notes
Customer Notification Timeline	An owner notification letter will be mailed in early May, 2020.
AOMS/SOMS	AOMs – This recall may generate questions from your dealers. Please forward this notice to your dealers ASAP.
Rental Fleet Partners	This recall may affect vehicles in your fleet. Please contact your respective DVUSA fleet representative for further information and next steps. For repairs, please contact your preferred DVUSA dealer.
While we regret any inconvenience this may cause, we are determined to maintain a high level of vehicle quality and customer satisfaction.

 

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Campaign No. 2020040009, April 2020

TO:	ALL MERCEDES-BENZ CENTERS
SUBJECT:	Model 907 (Sprinter), Model Year 2019 EGR Screw Connection

 

Mercedes-Benz AG (“MBAG”), the manufacturer of Mercedes-Benz and Freightliner vans, has determined that on certain Sprinter vehicles from platform 907 (VS30), certain screw connections on the exhaust gas recirculation (EGR) pipe (between the exhaust gas collection pipe and the exhaust gas recirculation controller) may not have been carried out according to specification. If the connecting screws are not tightened according to specification, the flange surface at the end of the EGR pipe may not be completely sealed. In that case, hot exhaust gas could leak into the engine compartment and cause a potential fire and/or fire damage to immediately surrounding components. An authorized Mercedes-Benz or Freightliner Sprinter dealer will renew the affected screw connection and the flange seals on the exhaust gas recirculation pipe.

 

Prior to performing this Recall Campaign:

• Please check VMI to determine if the vehicle is involved in the Campaign and if it has been previously repaired.
• Please review the entire Recall Campaign bulletin and follow the repair procedure exactly as described.

 

Please note that Recall Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.

 

Approximately 4,333 vehicles are involved.

 

Order No. V-RC-2020040009

 

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Operation no. of the operation texts or standard texts and flat rates

Op. no.	Operation text	Time (hr)	Acc. no.
02 1697	Operations: Replace threaded connection of exhaust gas recirculation line	1.0	14 910 56 7
02 3283	Operations: Remove lower engine compartment lining (when working on vehicle)	0.1	14 910 56 7

 

1	Exhaust gas recirculation line	5
2	Bolts	6	Seal
3	Screw	7	Oil pan
4	Seal	8	Front axle carrier

 

Danger	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
Warning	Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
Warning	Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.	AS49.00-Z-0001-01A
Caution	Risk of injury caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Check
1	Check if vehicle is affected by measure.	For authorized Mercedes‑Benz service partners, only the entry in the “Extended VEGA Application” (EVA) system, in the “Current” tab, is decisive. An additional test of the affected vehicles in the workshop information system (WIS) or vehicle list is thereby not necessary.
	Remove
2	Remove air filter housing.		AR09.10-D-1150TSV
3	Remove engine cover.		AR01.10-D-2405TSV
4	Remove trim of right cylinder head cover.		AR01.20-D-5017TSV
5	Loosen screw (3).	This enables the lower section of the exhaust gas recirculation line (1) to be moved for later replacement of the seal (6). Set of flexible head wrenches	001 589 81 09 00
6	Remove screws (2) from exhaust gas recirculation line (1).	Screws (2) are replaced. Set of flexible head wrenches	001 589 81 09 00
7	Remove seal (4).	Seal (4) is replaced.
	Install
8	Position new seal (4) on exhaust gas recirculation line (1) and fit new screws (2).	Check seal (4) is in correct installation position. Otherwise, leaks can occur in the exhaust system. Use a mirror to help.
9	Tighten new screws (2). Note on calculation of tightening torque when using insertion or socket tools with various effective lengths	Make sure that the seal (4) is correctly aligned with the exhaust gas recirculation line (1). Otherwise, leaks can occur in the exhaust system. n Bolt, exhaust gas recirculation line to exhaust collector pipe Set of flexible head wrenches	AH00.00-P-0015-01CW BA14.20-N-1006-01TSV 001 589 81 09 00
	Remove
10 Topical note	Raise vehicle. Special instructions for lifting and supporting vehicle		AH00.60-N-0100-01TS f AR00.60-D-1000-04TS
11	Remove bottom engine compartment paneling.	Model 907 with code XM1 (Noise abatement measures)	AR61.20-D-1105TS
12	Remove screws (5) from exhaust gas recirculation line (1).	The screws (5) can be reached through the space between the oil pan (7) and the front axle carrier (8). Screws (5) are replaced. n Bolt, exhaust gas recirculation line to exhaust gas recirculation bypass flap	BA14.20-N-1005-01TSV
13	Remove seal (6).	Seal (6) is replaced.
	Install
14	Position new seal (6) on exhaust gas recirculation line (1) and fit new screws (5).	Check seal (6) is in correct installation position. Otherwise, leaks can occur in the exhaust system. Use a mirror to help.
15	Tighten bolts (5). Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
		Make sure that the seal (6) is correctly aligned with the exhaust gas recirculation line (1). Otherwise, leaks can occur in the exhaust system. n Bolt, exhaust gas recirculation line to exhaust gas recirculation bypass flap Set of flexible head wrenches	BA14.20-N-1005-01TSV 001 589 81 09 00
16	Lower vehicle.
17	Tighten screw (3).	Bolt, EGR line to bracket Set of flexible head wrenches	BA14.20-N-1007-01TSV 001 589 81 09 00
18	Install cover of right cylinder head cover.		AR01.20-D-5017TSV
19	Install engine cover.		AR01.10-D-2405TSV
20	Install air filter housing.		AR09.10-D-1150TSV
	Check
Warning	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
21	Check for leak tightness when engine is running.	Visual inspection only.
	Install
22	Install lower engine compartment lining.	Model 907 with code XM1 (Noise abatement measures)	AR61.20-D-1105TS

 

Exhaust gas recirculation

Number	Designation	Engine 642 in model 907
BA14.20-N-1005-01TSV	Bolt, exhaust gas recirculation line to exhaust gas recirculation bypass flap	Nm 12

 

Exhaust gas recirculation

Number	Designation	Engine 642 in model 907
BA14.20-N-1006-01TSV	Bolt, exhaust gas recirculation line to exhaust collector pipe	Stage 1 Nm 10
		Stage 2 ∡° 90

 

Exhaust gas recirculation

Number	Designation	Engine 642 in model 907
BA14.20-N-1007-01TSV	Bolt, EGR line to bracket	Nm 9

 

001 589 81 09 00

Set of flexible head wrenches

 

Parts ordering note

Designation	Quantity	Part no.
Seal	2	A 642 142 18 80
Screw	2	A 000 990 69 03
Screw	2	N 000000 001116

 

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IMPORTANT SAFETY RECALL # 2020040009
This notice applies to your vehicle, VIN:
EGR Screw Connection
NHTSA Recall # 20V078

May, 2020

2020040009

A safety defect exists in your vehicle Schedule an appointment with your authorized Freightliner Sprinter dealer as soon as possible. This repair will be provided free of charge.

 

Dear Freightliner Sprinter Owner or Lessee,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Mercedes-Benz AG (“MBAG”), the manufacturer of Freightliner Sprinter vans, has decided that a defect which relates to motor vehicle safety exists in certain Model Year 2019 Freightliner Sprinter vehicles.  Our records indicate that your vehicle is included in the affected population of vehicles.

What is the CONCERN?

MBAG determined that on certain Freightliner Sprinter vehicles certain screw connections on the exhaust gas recirculation (EGR) pipe (between the exhaust gas collection pipe and the exhaust gas recirculation controller) may not have been carried out according to specification. If the connecting screws are not tightened according to specification, the flange surface at the end of the EGR pipe may not be completely sealed. In that case, hot exhaust gas could leak into the engine compartment and potentially cause a fire and/or fire damage to immediately surrounding components.

What will your DEALER DO?

An authorized Freightliner Sprinter dealer will replace the affected screw connection and the flange seals on the exhaust gas recirculation pipe.  This service will be provided free of charge. While the minimum repair time is approximately 1 hour, your dealer can provide you with a better estimate of the overall time for this service visit.  As a matter of normal service process, an authorized Freightliner dealer will also check for other repair measures which might be applicable to your vehicle and this may increase the required working time.  You will not be charged for other service or repairs unless so requested.

 

Schedule an appointment immediately at your preferred authorized Freightliner Sprinter Dealer. See

www.freightlinersprinterusa.com/freightliner/owners-resources/recall for the Dealer Locator.  Please mention you are scheduling an appointment to replace the affected screw connection and the flange seals on the exhaust gas recirculation pipe under Recall Campaign # 2020040009.  You may be asked for your 17-digit Vehicle Identification Number (VIN) which for your convenience is located above your name at the top of this letter.

We encourage you to sign up for recall alerts at www.nhtsa.gov/alerts.   In the event that you are no longer the vehicle owner, or have had a change of address, please complete the reverse side and return the updated information in the enclosed envelope.

If this is a leased vehicle and the lessor and registered owner receive this notice, please forward this information by first class mail to the lessee within 10 business days to comply with Federal Regulations.

Should you have any questions difficulty regarding this Recall Campaign, please contact an authorized Freightliner Sprinter dealer. If for any reason a dealer is unable to remedy your situation, we are always happy to hear from you. Please contact us at 1-877-762-8267.

If an authorized Freightliner dealer for any reason is unable to remedy the situation without charge, or within a reasonable amount of time, pursuant to law 49 U.S.C. Chapter 301, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, S.E., Washington, D.C. 20590 or call the toll-free Auto Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153); or go to https://www.safercar.gov.

We apologize for any inconvenience this situation may cause you, but your safety is of utmost concern to Freightliner.

Sincerely,

Daimler Vans USA, LLC
One Mercedes-Benz Drive
Sandy Springs, GA 30328
Phone (770) 705-0600

 

IMPORTANT VIN:

If for any reason YOU NO LONGER OWN THIS VEHICLE OR have a CHANGE OF ADDRESS, please COMPLETE THE SECTION BELOW, place in the ENCLOSED ENVELOPE, and DROP IN ANY MAIL BOX. If possible, provide the name and address of the present owner so that we may contact them. 

 

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IMPORTANT SAFETY RECALL INTERIM NOTICE
This notice applies to your vehicle, VIN:
EGR Screw Connection
NHTSA Recall #20V078

April, 2020

 

A safety defect exists in your vehicle. Remedy parts are not yet available for your vehicle. We will contact you again once parts are available.

 

Dear Valued Freightliner Sprinter Owner or Lessee:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Mercedes-Benz AG (“MBAG”), the manufacturer of Sprinter vans, has decided that a defect which relates to motor vehicle safety exists in certain Model Year 2019 Freightliner Sprinter vehicles.  Our records indicate that your vehicle is included in the affected population of vehicles.

MBAG has determined that on certain Freightliner Sprinter vehicles Platform 907 (VS30), certain screw connections on the exhaust gas recirculation (EGR) pipe (between the exhaust gas collection pipe and the exhaust gas recirculation controller) may not have been carried out according to specification. If the connecting screws are not tightened according to specification, the flange surface at the end of the EGR pipe may not be completely sealed. In that case, hot exhaust gas could leak into the engine compartment and cause a potential fire and/or fire damage to immediately surrounding components.

We want to assure you that MBAG is taking all necessary measures to remedy this situation for you.  We are also working closely with the National Highway Traffic Safety Administration (“NHTSA”) and suppliers to provide a remedy as soon as possible. Unfortunately, replacement parts are not yet available for your vehicle, and we will contact you again once parts become available.

As soon as a suitable replacement part is available for your vehicle, we will send another letter notifying you to bring your vehicle to your local authorized Freightliner Sprinter dealer to repair your vehicle free of charge.  In the meantime, please visit

www.freightlinersprinterusa.com/freightliner/owners-resources/recall and enter your 17 digit VIN in the VIN Look-up tool, then enter your most recent contact information.

We also encourage you to sign up for recall alerts at www.nhtsa.gov/alerts.

In the event that you are no longer the vehicle owner, or have had a change of address, please complete the reverse side and return the updated information in the enclosed envelope. If this is a leased vehicle and the lessor and registered owner receive this

notice, please forward this information by first class mail to the lessee within 10 business days to comply with Federal Regulations.

We apologize for any inconvenience this situation may cause you. Sincerely,

Daimler Vans USA, LLC
One Mercedes-Benz Drive
Sandy Springs, GA 30328
Phone (770) 705-0600

 

IMPORTANT VIN:

If for any reason YOU NO LONGER OWN THIS VEHICLE OR have a CHANGE OF ADDRESS, please COMPLETE THE SECTION BELOW, place in the ENCLOSED ENVELOPE, and DROP IN ANY MAIL BOX. If possible, provide the name and address of the present owner so that we may contact them. 

 

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Chronology of Defect (too many characters for the recall portal comment box)

 

Chronology:

MBAG became aware of a potential issue related to the installation of the exhaust gas recirculation pipe in the engine compartment through a notification from its production plant at the end of June 2019.  MBAG conducted a review of all vehicles that remained at the plant and corrected the installation of the screw connections for the EGR pipe as necessary.

 

MBAG launched an investigation and conducted various analyses of the effect of an EGR pipe with screws not tightened to specification.

 

This investigation also included a detailed thermal analysis regarding the effect of potentially leaking exhaust gas on the various surrounding components. MBAG also analyzed the various functions of nearby components and their specific material properties, especially their resistance against high temperatures.

 

During the analysis MBAG also closely considered the potential for the spread of contaminated air in the event the EGR pipe began to leak.  As part of this analysis, MBAG reviewed  the vehicle features that could prevent  exhaust gas intrusion into the passenger compartment’s  fresh air supply as well as whether passengers may be able to detect the presence of exhaust gas during different operating scenarios.  MBAG ultimately was able to rule out the possibility of exhaust gas entering the passenger compartment through the fresh air supply  because the components responsible for the fresh air supply in the passenger compartment are tightly sealed towards the rest of the engine compartment.

 

On February 5, 2020, DAG determined that a safety risk could not be ruled out and decided to initiate a recall campaign.

 

Around the same time the initial investigation of this matter began, MBAG also became aware of a potential issue related to the operation of the flange seal between the exhaust gas turbocharger and the diesel particulate filter.  Since the underlying circumstances between this subject and the flange seal are very similar regarding the location of components and possible affects, both subjects where analyzed simultaneously. To date DAG is not aware of any complaints concerning this matter from the field.

 

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8 Affected Products

Vehicles

MAKE	MODEL	YEAR
FREIGHTLINER	SPRINTER 1500	2019
FREIGHTLINER	SPRINTER 2500	2019
FREIGHTLINER	SPRINTER 3500	2019
FREIGHTLINER	SPRINTER 4500	2019
MERCEDES BENZ	SPRINTER 1500	2019
MERCEDES BENZ	SPRINTER 2500	2019
MERCEDES BENZ	SPRINTER 3500	2019
MERCEDES BENZ	SPRINTER 4500	2019

 

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14 Associated Documents

ISSUED Interim Owner Notification Letter(Part 577)

RIONL-20V078-6941.pdf 93.078KB

 

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Recall 573 Report-Amendment 2

RCLRPT-20V078-5490.PDF 213.83KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V078-4313.pdf 689.292KB

 

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Recall 573 Report- Amendment 4

RCLRPT-20V078-8923.PDF 214.034KB

 

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Recall 573 Report- Amendment 3

RCLRPT-20V078-7003.PDF 214.03KB

 

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Recall Acknowledgement

RCAK-20V078-8605.pdf 245.216KB

 

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Miscellaneous Document- Supplemental Chronology

RMISC-20V078-1924.pdf 419.093KB

 

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Defect Notice 573 Report

RCLRPT-20V078-4307.PDF 213.788KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V078-1922.pdf 1262.797KB

 

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V078-9217.PDF 211.146KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V078-7435.pdf 192.469KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V078-2857.pdf 102.79KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V078-1545.PDF 211.246KB

 

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V078-8755.PDF 211.332KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V078&docType=RCL

 

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