VS3FLABIND – Exhaust may Leak From Exhaust Flange Connection – 2019 Freightliner Sprinter

February 12, 2020 NHTSA CAMPAIGN NUMBER: 20V079000

Exhaust may Leak From Exhaust Flange Connection

An exhaust gas leak in the engine compartment increases the risk of a fire.

 

NHTSA Campaign Number: 20V079

Manufacturer Daimler Vans USA, LLC

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 4,385

 

Summary

Daimler Vans USA, LLC (DVUSA) is recalling certain 2019 Mercedes Benz Sprinter and Freightliner Sprinter vehicles. The flange connection between the exhaust gas turbocharger and the exit to the diesel particulate filter may not be attached properly, potentially causing an exhaust gas leak.

 

Remedy

DVUSA will notify owners, and Mercedes-Benz or Freightliner Sprinter dealers will replace the flange seals and properly tighten the connection, free of charge. The recall began April 10, 2020. Owners may contact DVUSA customer service at 1-877-762-8267. DVUSA’s number for this recall is VS3FLABIND.

 

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 Flange Connection	DATE:  March 10, 2020

 

IMPORTANT CAMPAIGN INFORMATION

 

 

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Campaign	Campaign Desc. :		Flange Connection
2020030006	PDGFLABIND
This is to notify you of the upcoming Recall Campaign concerning the flange connection between the exhaust gas turbocharger and the diesel particulate filter on approximately 4,385 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), the flange connection between the exhaust gas turbocharger and the exit to the diesel particulate filter may not have been attached properly. If the flange connection is not attached properly, high-temperature exhaust gas could potentially leak into the engine compartment, increasing the risk of a potential thermal reaction as well as thermal damage to the immediately surrounding components.
What We’re Doing	An authorized Mercedes-Benz or Freightliner Sprinter dealer will replace the flange seals and will apply the correct torque to the screw connection.
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	4,385
Dealer Inventory	207
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: Launch Recall Campaign Notification Model 907 (Sprinter) Model Years 2019 Flange Connection	DATE:  April 7, 2020

 

IMPORTANT CAMPAIGN INFORMATION

 

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Campaign	Campaign Desc. :	Flange Connection
202003 0012	VS3FLABIND
This is to notify you of the upcoming Recall Campaign concerning the flange connection between the exhaust gas turbocharger and the diesel particulate filter on approximately 4,337 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), the flange connection between the exhaust gas turbocharger and the exit to the diesel particulate filter may not have been attached properly. If the flange connection is not attached properly, high-temperature exhaust gas could potentially leak into the engine compartment, increasing the risk of a potential thermal reaction as well as thermal damage to the immediately surrounding components.
What We’re Doing	An authorized Mercedes-Benz or Freightliner Sprinter dealer will replace the flange seals and will apply the correct torque to the screw connection.
Parts	Parts are available.
Vehicles Affected
Vehicle Model Year(s)	Model Year 2019
Vehicle Model	Sprinter, VS30 / Platform 907
Vehicle Populations
Total Recall	4,337
Dealer Inventory	190
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 April 10, 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. 2020030012, April 2020

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

 

Mercedes-Benz AG (“MBAG”), the manufacturer of Mercedes-Benz and Freightliner vans, has determined that on certain Sprinter vehicles from platform 907 (VS30), the flange connection between the exhaust gas turbocharger and the exit to the diesel particulate filter may not have been attached properly. If the flange connection is not attached properly, high-temperature exhaust gas could potentially leak into the engine compartment, increasing the risk of a potential thermal reaction as well as thermal damage to the immediately surrounding components.An authorized Mercedes-Benz or Freightliner Sprinter dealer will replace the flange seals and will apply the correct torque to the screw connection.

 

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

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

 

Approximately 4,337 vehicles are involved.

 

Order No. V-RC-2020030012

 

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

Operation Number	Operation text	Time	Damage Code
02 1698	Operations: Replace 3 screws/bolts on exhaust gas turbocharger	0.8 h	14 910 57 7

 

1	Heat shield	4	Exhaust pipe
2	Bolts	5	Bolts
3	Turbocharger	6	Seal

 

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
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 heat shield (1).	To do this, remove screws (2).
5	Remove bolts (5).	Screws (5) are replaced.
6	Remove seal (6) between exhaust gas turbocharger (3) and exhaust pipe (4).	Seal (6) is replaced.
	Install
7	Position new seal (6) between exhaust gas turbocharger (3) and exhaust pipe (4) then fit new screws (5).	Check seal (6) is in correct installation position. Otherwise, leaks can occur in the exhaust system.
8	Tighten bolts (5).	Bolt, exhaust pipe to turbocharger	BA09.40-N-1008-02TSV
	Replace threaded connection between exhaust gas turbocharger and diesel particulate filter (code: VS …		SM09.40-D-0021SG
9	Install heat shield (1).	To do so, screw in and tighten screws (2). Bolt, heat shield to bracket Bolt, heat shield to exhaust collector pipe	BA09.40-N-1009-02TSV BA09.40-N-1010-02TSV
10	Install engine cover.		AR01.10-D-2405TSV
11	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
12	Check for leak tightness when engine is running.	Visual inspection only.

 

Turbocharger

Number	Designation	Engine 642 in model 907
BA09.40-N-1008-02TSV	Bolt, exhaust pipe to turbocharger	Nm 20

 

Turbocharger

Number	Designation	Engine 642 in model 907
BA09.40-N-1009-02TSV	Bolt, heat shield to bracket	Nm 8

 

Turbocharger

Number	Designation	Engine 642 in model 907
BA09.40-N-1010-02TSV	Bolt, heat shield to exhaust collector pipe	Nm 12

 

Parts ordering note

Designation	Quantity	Part no.
Seal	1	A 219 492 00 80
Screw	3	A 000 990 67 03

 

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IMPORTANT SAFETY RECALL 2020030012
This notice applies to your vehicle, VIN:
Flange Connections
NHTSA Recall #20V079

 

April, 2020

2020030012

• 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 (platform 907 (VS30)), the flange connection between the exhaust gas turbocharger and the exit to the diesel particulate filter may not have been attached properly. If the flange connection is not attached properly, high-temperature exhaust gas could potentially leak into the engine compartment, increasing the risk of a fire as well as fire damage to the immediately surrounding components.

What will your DEALER DO?

An authorized Freightliner Sprinter dealer will replace the flange seals and will apply the correct torque to the screw connection.  This service will be provided free of charge. While the minimum repair time is approximately approximately 1 hour and 20 minutes, 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 flange seals of the exhaust gas turbocharger under Recall Campaign #2020030012.

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

 

Chronology:

MBAG initially became aware of a potential issue related to the flange connection on the turbo charger in the engine compartment by a notification from the Mercedes-Benz market organization in Canada in mid -June 2019 after the smell of exhaust was noticed during pre-delivery-inspection.  MBAG conducted a review of all vehicles that remained at the plant and corrected the installation of the flange connection.

 

MBAG launched an investigation and conducted various analyses of the effect of a leak in the flange connection.

 

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 flange connection began to leak. As part of the 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, MBAG 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 screw connection for the exhaust gas recirculation pipe.  Since the underlying circumstances between this subject and the EGR screw connection are very similar regarding the location of components and possible affects, both subjects where analyzed simultaneously.

 

To date MBAG 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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12 Associated Documents

Miscellaneous Document- Supplemental Chronology

RMISC-20V079-0136.pdf 419.914KB

 

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Defect Notice 573 Report

RCLRPT-20V079-1650.PDF 213.769KB

 

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Recall Acknowledgement

RCAK-20V079-4426.pdf 245.167KB

 

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V079-1761.PDF 211.149KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V079-4444.pdf 99.723KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V079-0795.pdf 1498.804KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V079-3858.pdf 194.132KB

 

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Recall 573 Report- Amendment 1

RCLRPT-20V079-5826.PDF 213.809KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V079-6021.pdf 675.416KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V079-1127.PDF 211.251KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V079-1580.PDF 211.248KB

 

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V079-5655.PDF 211.335KB

 

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V079-1761.PDF 211.149KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V079&docType=RCL

 

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