2020040003 – Modification to the Emissions Control System – 2015 Mercedes-Benz Sprinter

SEOCONTENT-START

Campaign No. 2020040003, March 2021
TO: ALL MERCEDES-BENZ and FREIGHTLINER SPRINTER CENTERS
SUBJECT: Model 906 (Sprinter)
Model Year 2015
Modification to the emissions control system
Daimler Vans USA, LLC (“DVUSA”) and Mercedes-Benz USA, LLC (“MBUSA”) are performing an
emissions campaign on certain 906 Sprinter vehicles in order to modify to the vehicles’ emissions control
system. EPA and CARB have approved this emissions modification for these MY15 Sprinter (Model
906) vehicles. An authorized Mercedes-Benz or Freightliner Sprinter dealer will replace certain
emissions control system components and update certain software in the affected vehicles at no cost to
the owner of the vehicle.
Prior to performing this Emissions Campaign:
• Please check VMI to determine if the vehicle is involved in the emissions modification campaign and
if it has been previously repaired. Always Check VMI for any open campaigns, and perform
accordingly.
• Please review the entire Emissions Campaign bulletin and follow the repair procedure exactly as
described.
Approximately 837 vehicles are involved.
Order No. V-RC-2020040003
This bulletin has been created and maintained in accordance with MBUSA-SLP S423QH001, Document and Data
Control, and MBUSA-SLP S424HH001, Control of Quality Records.
Emissions Campaign 2020040003
o Model: 906 Sprinter
o Model Year: 2015 4×4
o Engine: 6-Cylinder Diesel (OM 642)
Warranty Information
Damage Code Operation No. Time Operation Text
Denial of AEM
49 10N 01 use operations for
labor performed
up to 2 hr Diagnosis time for pre-inspection if client declines
to reverse non-compliant modifications
Perform AEM
07 970 97 02 1212 1.4 hr Perform work package for field measure
Additional: Mobile AEM at customer location
21 812 00 00 9627 +50% Mobile AEM Labor surcharge
sublet $75 travel allowance
Additional: Mobile AEM at customer location requiring overnight accommodation
21 813 00 00 9627 +50% Mobile AEM Labor surcharge
sublet $100 travel allowance
Parts Overview
Reference last page for complete list of parts to perform AEM
NOx sensor upstream of
SCR catalytic converter
NOx sensor downstream
of SCR catalytic converter
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Scope of Work Outline
Read and follow all pages of work instructions completely! Page:
1. Safety Notes 4-18
2. Lifting and Ramps 19-21
3. Initial Quick Test 22-28
a. Upload print-out to paperless pXD
b. Evaluate pre-existing faults (see Pre-Inspection Guide below)
4. Pre-Inspection Special Procedure 29-32
a. Includes visual inspection of Exhaust Aftertreatment system (see Pre-Inspection Guide below)
5. Replacement of AEM parts 33-38
a. NOx Sensor Upstream of SCR Catalytic Converter
b. NOx Sensor Downstream of SCR Catalytic Converter
6. Execution of AEM Special Procedure 39-50
a. Includes guided steps: Software updates of CDI, ETC, IC, and SCR
b. Fill-out and Install AEM Label
c. Result Report to verify successful completion of all AEM steps
i. Upload print-out to paperless pXD
7. Final Quick Test 51-56
a. Upload print-out to paperless pXD
b. Erase stored faults caused by the workshop
8. Parts List 57
Pre-Inspection Guide
1. Pre-existing fault codes causing a Check Engine Light (CEL):
a. If component causing fault will be replaced as part of the AEM:
i. Perform AEM – No additional action is needed
b. If component causing fault will be covered by the AEM Extended Warranty:
i. Perform AEM
ii. Perform repair of pre-existing fault
iii. Submit AEM Extended Warranty claims on a separate Repair Order after AEM claim is submitted
c. If component causing fault will not be replaced as part of AEM and not covered by AEM Extended Warranty:
i. Provide client with repair estimate, advise client AEM will not resolve Check Engine Light (CEL)
ii. Document on Repair Order if client approves or declines repairs
iii. Perform AEM regardless if client approves or declines repairs
d. A list of AEM Extended Warranty covered components is available in: XENTRY / CDI / Special Procedures /
Exhaust Aftertreatment Service Measure / Extended Warranty
2. Non-Compliant Alterations to the Exhaust Aftertreatment system found during the visual Pre-Inspection:
a. Document all non-compliant alterations to the Exhaust Aftertreatment system on the Repair Order
b. If altered component(s) will be replaced as part of the AEM:
i. Perform AEM
c. If altered component(s) inhibit AEM installation or will sustainably affect the operation of the AEM:
i. Provide client with a repair estimate to reverse non-compliant alterations
1. If client approves repairs:
a. Reverse non-compliant alterations
b. Perform AEM
2. If client refuses repairs:
a. Do not perform AEM – Vehicle ineligible
b. Claim ‘Denial of AEM’ damage code and labor ops for diagnosis time performed
3. If technical assistance is needed, create a PTSS case
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AEM installation Videos
Exemplary videos of the AEM installation are available via the following:
o XENTRY Workshop (XiW) / VAN / Emissions Modification Program
o Scan the QR code below with a mobile device and log-in with your XENTRY credentials
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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.
aWarning
Risk of injury
Contact with hot or glowing objects without suitable
protective clothing causes severe burns to skin and eyes.
When glowing objects come into contact with water, they
produce hot steam or cause the water to splash, which can
cause serious burns to skin or eyes.
If hot or glowing objects come into contact with unprotected
skin or eyes, they can cause serious and even permanent
injuries.
i
There is a risk of fire when glowing objects come into
contact with combustible material.
Safety precautions/instructions
• Wear protective clothing, safety glasses and heatresistant
gloves.
• Only transport hot or glowing objects with suitable aids.
• Avoid the formation of sparks and contact with
combustible material when handling glowing objects.
First aid measures
• Treat affected areas of skin with plenty of cold water
and cover with sterile dressings.
• Consult a physician immediately.
Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
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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.
aWarning
Potential risks
Risk of accident
Caused by the vehicle starting off by itself during the
starting procedure
(e.g. during compression test) due to engaged gear or
with the engine running and vehicles with automatic
transmission due to selector lever position “P” or
“N” not being engaged (except for vehicles that do not
have selector lever position “P”).
Risk of injury
Severe injuries can be caused by freely rotating parts in
the area of the running engine.
Because the engine heats up when operating, serious
burns can be caused by touching unshielded parts.
Safety instructions/precautions
• In general, only work on a running engine when it is
absolutely necessary.
• Apply parking brake before starting the engine.
• The vehicle is to be secured against moving forwards or
backwards.
• The person performing tests on a vehicle with the
engine running must sit in the driver’s seat to be able to
prevent the vehicle from moving.
• It is not permitted for persons to be in the danger zone
in front of or behind the vehicle while tests are being
performed.
• Shift the gearshift lever to neutral on vehicles with
manual transmission.
• On vehicles with automatic transmission, move selector
lever into position “P” or “N” (except for vehicles that
do not have selector lever position “P”).
• On vehicles that do not have selector lever position “P”,
the selector lever is to be secured against
unauthorized access.
• Wear closed and snug-fitting work clothes.
• Remove all jewelry such as necklaces, rings, etc.
• Wear suitable head wear to cover long hair.
• Before commencing any work on the running engine,
familiarize yourself with the location of potentially hot
parts.
• When carrying out work when starting the engine or
when the engine is running, do not touch any hot or
rotating parts.
• Use the exhaust extraction system.
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First aid measures in the event of burns
• Do not rub the skin areas affected; rinse with plenty of
cold water and cover skin with sterile dressings.
• Consult a physician immediately.
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.
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Risk of injury. Moving parts
can pinch, crush or, in extreme
cases even sever extremities.
No parts of the body or limbs
should be within the operating
area of mechanical components
when moving components.
aWarning
Risk of injury
When working on components that can be moved either by
hand, by means of electric motors, or hydraulically/
pneumatically via a connecting mechanism, serious injuries
can occur due to body parts being cut, pinched or crushed.
Safety instructions/precautions
• Monitor hazard area.
• Secure the operating area of mechanical components
against interference when parts are in motion.
• Never touch the mechanism of a component while it is
being actuated by electric motors via the diagnosis or by
direct actuation (terminal 30).
• Choose a test cable of sufficient length.
Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.
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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.
aDanger
Risk of accident and injury
Ensure that the vehicle is ideally aligned and secured
against tilting according to the general safety specifications
and regulations.
Non-observance of the safety specifications can cause the
vehicle to slip off the lift system and thereby result in life
threatening or fatal injuries.
i
This list of hazards is not complete.
The safety specifications of the respective country are
always valid. The user is personally responsible for
complying with these.
Risk of death caused by vehicle slipping or toppling off of the lifting platform.
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Risk of burn injuries and
scalding when working at
AdBlue® lines and the
components attached to them.
Risk of injury to skin and eyes
when handling AdBlue®. Risk
of poisoning caused by
swallowing AdBlue®
Pour AdBlue® into suitable
containers only. Wait until the
pressure is released before
starting any work on the
exhaust aftertreatment system.
aWarning
Potential risks
Risk of burn injuries and scalding
The AdBlue® lines and all components attached to them
are under pressure during operation and remain so after
the engine is switched off and may be hot. There is a risk of
burn injuries. There is a risk of scalding caused by
escaping hot AdBlue® when the line system is opened.
Risk of injury
There is a risk of skin irritation and eye damage on contact
with AdBlue®.
Risk of poisoning
There is a risk of poisoning if AdBlue® is swallowed.
Rules of conduct
On vehicles with a compressed air system, individual
lines are flushed with compressed air after the engine is
switched off. The engine must therefore be switched off
for at least 5 minutes before work on the exhaust
aftertreatment system may begin.
• Open connections and plugs on the system components
slowly. Cover the connecting point with rags when
opening.
•
•
Only pour AdBlue® into marked containers specially
designated for the purpose. Do not pour AdBlue® into
drinking containers.
Wipe up any AdBlue® spills immediately as there is a
high risk of someone slipping.
• On vehicles with electrical delivery pump, the AdBlue®
is pumped from the line back into the AdBlue® tank
after the engine is switched off.
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Safety precautions for handling removed parts and
working under the vehicle
• Wear suitable protective gloves
• Wear protective clothing
• Wear safety glasses
First aid measures
Contact with skin: Wash the affected skin areas with plenty
of clean water. Change wetted clothing as quickly as
possible.
Contact with eyes: In the event of contact with eyes,
immediately rinse eyes thoroughly with plenty of clear
water; contact an eye doctor if necessary.
Ingestion: rinse mouth with clean water and drink large
quantities of water. Immediately seek medical assistance.
Firefighting measures
AdBlue® is not combustible. NH3 (ammonia) can be
released in the event of fire, causing a risk of poisoning.
Firefighting measures must therefore be suited to the
surroundings.
Risk of burn injuries and scalding when working at AdBlue® lines and the components attached to them. Risk of injury
to skin and eyes when handling AdBlue®. Risk of poisoning caused by swallowing AdBlue®
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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.
aWarning
Risk of burn injuries
The exhaust system and all components connected to it
are very hot during operation and remain so after the
engine is switched off. Do not touch hot parts.
Risk of suffocation and poisoning
Exhaust gases may also cause cancer.
At higher concentrations, irritation of mucous membranes
and headaches may occur. Carbon monoxide may cause
damage to unborn children.
Avoid inhalation of exhaust gases; wear respiratory
protection.
Use the exhaust extraction system.
Risk of injury
Risk of injury to the eyes, skin, and respiratory paths due to
contact with exhaust residues such as diesel particulates
and diesel soot. To prevent skin contact on hands, wear
nitrile gloves.
First aid measures
In the event of inhalation:
Move victim from the hazard area to fresh air without
endangering yourself and consult a physician immediately.
After contact with skin:
Immediately wash affected areas of the body with plenty of
soap and water. Employees who have experienced skin
contact must consult a physician immediately.
After contact with eyes:
Rinse eyes thoroughly with running water for at least ten
minutes with the eyelids wide open and contact an eye
doctor immediately.
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.
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Risk of explosion from
explosive gas. Risk of
poisoning and caustic burns
from swallowing battery
electrolyte. Risk of injury
through burns to skin and eyes
from battery acid or when
handling damaged lead-acid
batteries
No fires, sparks, open flames or
smoking. Wear acid-resistant
gloves, clothing and glasses.
Only pour battery acid into
suitable and appropriately
marked containers.
aDanger
Potential risks
Risk of explosion
When charging lead batteries with battery electrolyte
containing sulfuric acid, a highly explosive oxyhydrogen
gas mixture is created that ignites by means of fire, sparks,
open flames and smoking.
Risk of injury
The battery electrolyte contains diluted sulfuric acid that
causes caustic burns to the skin, eyes and mucous
membranes in the event of contact. Bonded electrolyte is
just as caustic as liquid electrolyte. Battery electrolyte mist
causes caustic burns to the eyes. If inhaled, this can result
in caustic burns to the mucous membranes and respiratory
paths. In the event of a short circuit from the battery
positive to ground, battery terminals and conductive objects
causing short circuit, e.g. tool or jewelry (watch band or
ring), become hot in seconds and red hot/liquid metal
sprays are released.
Risk of burn injuries
In the event of a short circuit from the battery positive to
ground, battery terminals and conductive objects causing
short circuit, e.g. tool or jewelry (watch band or ring),
become hot in seconds and cause burns.
Risk of poisoning
If battery electrolyte is swallowed, this can result in
symptoms of poisoning such as headache, dizziness,
stomach ache, respiratory paralysis, unconsciousness,
vomiting, caustic burns and cramps. Absorption of lead in
the body through contact with leaded components (battery
terminals, lead plates in damaged batteries) damages the
blood, nerves and kidneys; lead compounds are also toxic
for reproduction.
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Safety precautions/instructions
• Wear acid-resistant gloves and clothing and safety
glasses with side guards.
• Only charge lead batteries in well ventilated rooms with
appropriate voltage and appropriate current with
approved chargers, taking into account the instructions
of the battery and battery charger manufacturers.
• No fire, sparks, open flames and smoking.
• Switch on the battery charger only after connecting to
the terminals; switch off the battery charger before
disconnecting from the terminals.
• Do not place any conductive objects on the battery and
do not wear any conductive jewelry (risk of short circuit).
• Always disconnect the negative terminal first; always
connect the positive terminal first (risk of short circuit
caused by tool).
• Strict caution is required when handling damaged
batteries (removing from vehicle damaged in accident)
because of the sharp edges on the fractured housing
and escaped electrolyte.
• Keep batteries and battery electrolyte away from
unauthorized persons (especially children).
• Only fill liquid battery electrolyte into suitable and
appropriately marked containers.
• Only store, transport and install batteries with liquid
battery electrolyte horizontally, otherwise battery
electrolyte can escape from the degassing holes.
• Ensure that at least one degassing hole at the battery is
not sealed, as otherwise overpressure builds that leads
to bursting of the battery.
• Ensure proper connection of the degassing line to the
degassing hole.
• Ensure the degassing line does not have any kinks and
is not blocked at any point.
• Observe the instructions for use for the respective lead
batteries and the operator’s manual of the vehicle.
• The battery housing may become brittle over time,
therefore do not expose the battery to direct sunlight.
• Discharged batteries may freeze and are thereby
damaged, therefore always store batteries at a location
protected against frost.
Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of
injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
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First aid measures
Contact with eyes
• Rinse eyes immediately with plenty of water.
Contact with skin
• Remove wet clothing.
• Immediately neutralize battery electrolyte on the skin or
clothing with acid neutralizer or soapy water and rinse
off with plenty of water.
• Wash off lead on the skin immediately with water and
soap.
Inhalation of battery electrolyte mist
• Take the affected person out into the fresh air.
Swallowing battery electrolyte
• Have the person affected drink plenty of water with
activated charcoal supplement.
As a general rule, the person affected should consult a
medical service or physician after first aid has been
rendered.
Fire protection measures
Suitable extinguishing agents
• CO2 and dry extinguishing agent
Warning notes for lead batteries with battery electrolyte containing sulfuric acid
1 No fire, sparks, open flames or
smoking
4 Risk of caustic burns 6 Keep away from children
2 Risk of explosion 5 Wear eye protection 7 First aid
3 Observe operating instructions
Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury
through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
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Risk of injury caused by
contact with battery gel when
handling damaged leadgelbatteries
No fires, sparks, open flames or
smoking. Wear acid-resistant
gloves, clothing and glasses.
aWarning
Potential risks
Risk of poisoning
Swallowing battery gel can cause symptoms of poisoning
such as headaches, dizziness, stomach aches, respiratory
paralysis, unconsciousness, vomiting, caustic burns and
cramps.
The absorption of lead in the body can cause damage to
blood, nerves and kidneys; in addition, lead compounds are
considered to represent a reproductive hazard.
Risk of injury
The bonded electrolyte set free is just as caustic as a
liquid electrolyte that can cause heavy caustic burns to skin
and eyes. Strict caution is required when handling
damaged lead-gel batteries (e.g. removing from vehicle
damaged in accident) because of the sharp edges on the
fractured housing and direct contact with the lead plates.
Safety precautions and rules of conduct
• No fires, sparks, open flames or smoking.
• Do not place any tool or other conductive object on the
lead-gel battery (risk of short circuit!).
• Disconnect and remove lead-gel batteries for charging.
• Always disconnect the negative terminal first and
always connect the positive terminal first .
• Only switch on the battery charger after connecting to
the terminals and switch off before disconnecting.
• Keep lead-gel batteries away from unauthorized
persons (especially children).
• Pay attention to instructions for use of the particular
lead-gel battery and the operator’s manual for the
vehicle.
• Wear acid-resistant clothing and safety glasses with
side guards.
• Only pour acid gel into suitable and appropriately
marked containers.
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First aid measures
Contact with eyes
• Rinse out eyes immediately with plenty of water.
Contact with skin
• Remove moistened clothing.
• Immediately neutralize drops of acid or gel on skin or
clothing with acid neutralizer or soapy water and rinse
off with plenty of water.
Swallowing battery gel
• Have the person affected drink plenty of water
supplemented with activated charcoal.
After performing first aid, always consult medical
service or a physician.
Fire protection measures
Suitable extinguishing agents
• CO2 and dry extinguishing agent
Risk of injury caused by contact with battery gel when handling damaged lead-gelbatteries
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Notes on avoiding damage
through contamination and
foreign objects
Topical note
Information on affected component parts
With each maintenance and repair work to the engine as
well as to the ancillary assemblies and detachable parts
comes the danger of property damage caused by
contamination and foreign bodies.
Particularly at risk are:
• Exhaust gas turbocharger
• Hot film mass air flow sensor
• Compressor
• Emission control system
• All components involved in gas exchange
Notes on removal/installation
Openings through which soiling or foreign objects are
introduced into the engine, its ancillaries or detachable
parts, must be sealed immediately.
For this purpose, suitable, clean covers and plugs or clean,
lint-free rags are to be used.
p
Do not forget to remove all covers, plugs or rags when
assembling or when finalizing the work.
This avoids any damage and complaints about engine
running characteristics.
g
Before assembling or finalization work all components
are to be checked for soiling, left-over foreign objects and
any fluids, and if any are found they are to be removed.
Information on cleaning
For cleaning, use only clean tools and clean, lint-free rags.
Residues of cleaning agents and removed contaminants
must be cleared from the engine, ancillary assemblies and
detachable parts.
p
Do not use compressed air for removing any soiling.
Otherwise, components (e.g. the hot-wire element of the
hot film mass air flow sensor) could be damaged or
contamination could enter the engine, ancillary assemblies
and detachable parts without being noticed.
Notes on avoiding damage through contamination and foreign objects
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Notes on use, material
properties and handling of
AdBlue®
Topical note
Tasks of AdBlue®
AdBlue® serves to convert nitrogen oxides into water vapor
and nitrogen.
Chemical characterization and composition of
AdBlue®
The urea content is 32.5%. AdBlue® consists of urea
dissolved in demineralized water. AdBlue® is not an
additive.
Chemical formula: H2N-CO-NH2
Molecular weight (urea): 60.06 g/mol
CAS (Chemical Abstracts Service) no.: 57-13-6
Marking
AdBlue® dispensers are marked with the standard
designation ISO 22241 or with the trade designations
AdBlue® or Diesel Exhaust Fluid (DEF).
Transport
In vehicles with BlueTEC technology, AdBlue® is carried in
a tank.
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Physical and chemical properties of AdBlue®
State: Liquid
Color: Colorless, clear, light-yellow
Odor: Slight ammonia odor
pH value: 10 (aqueous solution, 10 %)
Crystallization temperature: –11 °C / 12 °F
Boiling point: 103 °C / 217 °F
Auto-ignition temperature: Not spontaneously inflammable
Density: approx. 1.09 g/cm3 at 20 °C / 68 °F
Viscosity (dynamic): approx. 1.4 mPa*s at 25 °C / 77 °F
Handling contaminated operating fluids
It is essential that AdBlue® be kept separate from other
operating fluids, fuels and lubricants such as coolant,
engine oil, transmission oil, fuel, hydraulic fluid and brake
fluid and not used in the same containers and collecting
bowls. The smallest amounts of AdBlue® can damage
thermostats or temperature sensors.
Operating fluids which contain traces of AdBlue® must not
be used again.
Handling contaminated AdBlue®
AdBlue® must be checked as per the repair instructions
before every fill. Individual components of the exhaust
aftertreatment system already react very sensitively with
even the smallest traces of contaminants in AdBlue®.
When handling AdBlue® it is important, therefore, to
always use clean containers and collecting bowls which are
only reserved for this purpose. Contaminated AdBlue®
must not be used again.
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Handling contaminated materials
It is essential that AdBlue® does not come into contact with
materials used in the interior of the vehicle. AdBlue®
exposed to air passes within just a few hours from a liquid
state into the crystalline state and can therefore damage
and destroy contaminated surfaces.
Textiles, e.g. the reversible mat in the luggage
compartment, which have been fouled with AdBlue®
should be alternately cleaned and then rinsed with water
several times.
It must be ensured that there are no further traces of
AdBlue® in the textiles.
Handling contaminated tools
All tools coming into contact with AdBlue® must be
thoroughly cleaned with water immediately after use!
Only fully dried measuring instruments and filling tools
should be used so as not to dilute the AdBlue®
concentration.
Protecting components when working with AdBlue®
AdBlue® leads to corrosion on electronic components and
strong fouling on all other materials. It is therefore
necessary to cover up all components in the vicinity over
the whole surface with plastic foil when working in
circumstances where AdBlue® could leak out.
Storage and packaging
Storage at temperatures between 0°C/32°F and 25°C/77°F
should be ensured in order to avoid crystallization occurring
Notes on use, material properties and handling of AdBlue®
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in AdBlue®. To avoid deterioration in quality due to
contamination, AdBlue® must only be handled in storage
and filling systems intended exclusively for AdBlue®.
Suitable container materials are alloyed steel, various
plastics and plastic coatings in metal containers.
Not to be used are unalloyed steel, aluminum, copper,
copper-containing alloys and zinc-dipped steel.
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Service life and durability
AdBlue® breaks downs during storage into ammonium
hydroxide and carbon dioxide and then no longer fulfills the
requirements of standard ISO 22241.
If the recommended storage temperature of a maximum of
25°C/77°F is maintained, the AdBlue® will fulfill the
requirements of this standard for at least 18 months after
manufacture. If this recommended storage temperature is
exceeded then this period is reduced. Duration of storage
and the temperatures to be used are given as guideline
values at the end of the document. At temperatures below
-11°C/12 °F, the AdBlue® freezes and becomes solid.
On warming up again the frozen AdBlue® becomes liquid
again and can be reused without any loss of quality.
The maximum permissible service life of AdBlue® can be
taken from the MB Specifications for Operating Fluids.
Disposal and degradability
Disposal of AdBlue®:
When disposing of AdBlue® the legal requirements of the
country in which the AdBlue® is used must be observed.
Contaminated packaging/materials:
Packaging which contains residues of AdBlue® is to be
handled like the substance itself. Packaging should
emptied as well as possible; it can then be reused after
appropriate cleaning with water.
– – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –
Constant ambient conditions
Storage temperature in °C/°F – Durability in months
≤10 / 50 – 36
≤25 / 77 – 18
≤30 / 86 – 12
≤35 / 95 – 6
>35 / 95 – —
Notes on use, material properties and handling of AdBlue®
a Emissions Campaign 2020040003
15
Information on preventing
damage to electronic
components due to electrostatic
discharge
Topical note
Electrostatic charge
Every contact and every physical separation of materials or
every movement of solids, liquids or charged particlecontaining
gases can generate electrostatic charge.
Plastics generally produce the highest electrostatic charge.
We come across electrostatic charge or discharge in lots of
everyday situations, e.g. with:
• Combs
• Walking on carpets or plastic floors
• Putting on and taking off textiles with synthetic fiber
content
• Disembarking from the vehicle
• Contact between various electrostatically chargeable
packaging materials in shelves or in the transport
container
The resulting electrostatic discharge (Electrostatic
Discharge (ESD)) can be so strong that a small electric
shock is detected. Even the smallest discharges which
people cannot detect can cause lasting damage to
electronic components and control units.
Effects and consequences of ESD
Electronic components and control units are very sensitive
to ESD. The damage is often not immediately obvious, but
becomes apparent some time later. In order to avoid
failures and damage due to ESD in vehicle electronics,
various procedures and safety precautions must be taken
into account and followed.
Risk of damage arises during the transportation, handling,
testing, removal and installation of electronic components
during production and repair work.
– – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –
The following electronic components listed as an example
can be damaged by ESD:
• Airbag components
• Control units, in particular their bus connections
Controller Area Network (data bus/CAN bus) (CAN),
Local Interconnect Network (LIN) etc.
• Sensors
• Mechatronic component parts (actuators etc.)
• Antenna amplifier
• Receivers and displays (Radio, TV, GPS, telephone
etc.)
Modes of behavior and safety precautions
• Electrostatic discharge of the technician (e.g. by briefly
touching the vehicle body).
• Suitable clothing, e.g. made of cotton.
• Wear ESD safety shoes with conductive soles.
• Keep workplace clean and clear away unnecessary
objects such as conventional plastics.
• Special antistatic seat cushion protectors should be
used when performing repair work inside a vehicle.
• Leave replacement parts in the original packing for as
long as possible, do not tear open seals but cut them
open carefully.
• The ESD workplace must conform to the ESD
guidelines.
• The operation-specific documentation in the WIS must
be observed and the specified special tools and/or
workshop equipment must be used in each case.
• Before unpacking, discharge ESD protective packaging
at the ESD workplace.
• Avoid any contact with electrostatic chargeable
materials such as, e.g. polyethylene, PVC, styrofoam.
• Use only original packaging or specially labeled and
defined packaging and transport materials.
• Electronic components which have been removed must
be put down on an ESD workplace.
• Electrical connectors on electronic component parts and
in the wiring harness should be touched by their
housing only. Do not touch pins or contacts!
• Electronic components must be installed before they are
connected so that potential equalization with the body
can take place.
• Shelves and worktables must stand directly on the floor,
there must not be any insulating materials between the
base of the shelves/feet and the floor. If the above
mentioned insulators cannot be removed, the shelves
and work tables must be grounded (e.g. low-resistance
electrical connection/line from metal shelf to a coolant
pipe).
• Do not put down conductive containers/crates when
insulated,
(e.g. on a wooden pallet), as otherwise potential
equalization will not take place.
Information on preventing damage to electronic components due to electrostatic discharge
a Emissions Campaign 2020040003
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• Do not place control units and electronic components
removed from the vehicle on electrostatically
chargeable materials, such as PE, PVC, styrofoam. The
electrostatic charge is transferred to the control unit or
electronic component. An ESD service kit or a
connected ESD table mat must be used.
– – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –
Training
It is strongly recommended that every company has an
ESD officer trained in accordance with DIN EN 61340-5-1.
The ESD officer can carry out staff training courses.
The aim of the training measures is to communicate the
main problems and effects of ESD to staff:
• Discharge generation
• Reasoning for safety precautions
• Effects and consequences of ESD
• ESD rules of conduct and safety precautions
Return of electronic components in warranty and
goodwill cases
When returning electronic components it is absolutely
essential to observe the procedure and safety precautions
listed. The original fault may be falsified or hidden by
electrostatic charge/discharge.
This can lead to distorted fault symptoms in the case of the
fault analysis of the component concerned.
Information on preventing damage to electronic components due to electrostatic discharge
a Emissions Campaign 2020040003
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Notes on carrying out repair
work in the vehicle interior
Topical note
In order to prevent soiling or damage, the following
information must be observed:
• Before starting repairs in the vehicle interior, the
corresponding protective covers must be provided in the
repair area for the floor coverings, seats, steering
wheel, etc. to prevent them from becoming dirty.
• Persons performing work in the vehicle interior should
ensure they have clean work clothes, clean shows and
clean hands.
• When removing bulky or difficult to handle parts (e.g.
bench seat, roof lining, instrument panel etc.), always
work with aid of at least a second person.
• Do not use dirty or unapproved tools. This prevents any,
e.g. scratching or crazing of interior parts etc.
• Always place removed interior parts on a clean and soft
surface.
– – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –
Further information:
• Repair or replace damaged interior parts (particularly
mounts such as retaining clips, Velcro fasteners etc.).
• When installing interior parts at the intended locations,
install insulation material and/or protective foils, or,
replace insulation material/protective foils as required in
order to dampen vibrations and noise.
• Many equipment parts in the area of the vehicle interior
have been installed or made specifically to the
customer’s request, and cannot be replaced easily if
damaged or soiled; for this reason, utmost care must be
ensured when carrying out operations in the vehicle
interior.
• Remove any dirt present with cleaners approved by
Daimler and suitable for corresponding surfaces. When
doing so, where possible, the compatibility of the
cleaning agent should be tested at a concealed area of
the part to be cleaned.
Notes on carrying out repair work in the vehicle interior
a Emissions Campaign 2020040003
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Lift mounting points on the vehicle
in the area of the front axle
01 spring clamp plate
02 longitudinal member
08 bracket
011 arm of hydraulic lift
012 support plate
013 long support plate
017 support drift
Lift mounting points on the vehicle in the area of the rear axle
07 014
011 016
v-block
prop
03
04
06
front rear spring bracket
longitudinal member
front rear spring bracket 013
crossmember
arm of hydraulic lift
long support plate
Lift point locations
i
When performing procedure on a vehicle lift
i
Vehicle must be in a ready to lift position
before procedure is started.
i
Read the operating instructions for
the vehicle lift.
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Picture reference Pick-up point
Information
03 Support at rear to front rear spring
bracket.
04 Rear support at longitudinal member. ‑ If possible, always support at rear
Install at longitudinal member (4).
06 Install on front rear spring bracket.
012 Support plate. ‑ For front support to spring clamp plate
(1). Unscrew support plate (012) at right
and left an equal distance.
‑ In vehicles with vehicle lift support
point at integral carrier (5).
013 Long support plate. ‑ For front support at longitudinal
member (2) and support at front rear
spring bracket (6). Can be used
alternatively to front support to spring
clamp plate (1). Pull out long support
plates (013) at right and left an equal
distance.
‑ In vehicles without a vehicle lift
support point at the integral carrier (5)
in the vicinity of the inner mounts of the
semi-trailing arms.
014 V-block ‑ For rear support at front rear spring
bracket (3) and rear support at
longitudinal member (4). Pull v-block
(014) at right and left rear out an equal
distance.
016 Ram ‑ Vehicles with heavy bodies and panel
vans/crewbuses with a long wheelbase
at the crossmember (7) should be
supported with a prop (016).
017 Support drift ‑ With soundproofing Ensure that
support drift (017) does not make
contact with bracket (8) of rear
soundproofing. If necessary, loosen
bracket (8), push towards the front as
far as possible and retighten it.
Otherwise the brackets (8) of the rear
soundproofing and the longitudinal
members may be damaged.
‑ For front support to longitudinal
member (2). Unscrew support drift
(017) at right and left an equal distance.
Secure vehicle on lift.
p
Heavily loaded vehicles, vehicles with a heavy body and
vehicles with unfavorable load distribution must be
secured.
Otherwise these may fall.
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Instructions for driving onto ramps
Read the operating instructions provided by the manufacturer
of the ramps. Since these are ramps that have not been built
or tested by Mercedes Benz, no information can be given on
safety. Mercedes Benz excludes all liability when using these
ramps.
1
2
Place the vehicle on a clean, firm and
level surface.
i
Make sure that there is enough space to
the front.
Place ramps in the middle (arrows A) of
the front wheels.
i
The ramps must be aligned parallel to
each other.
3
4
Drive the vehicle onto the ramps until it is
positioned in the end position specified by
the manufacturer of the ramps.
p
Drive the vehicle slowly and at a constant
speed onto the ramps.
Otherwise the vehicle may be damaged.
i
If necessary, include a helper to instruct
you.
Secure the vehicle against rolling away.
i
For example, by applying the parking
brake and by placing a wheel chock
(arrow B) on the rear wheels.
i
Vehicle must be driven onto ramps
before procedure is started, and
may remain on ramps for the
entire procedure.
i
Race Ramps are available for
order from MBUSA Standard
Service Equipment Program
(SSEP): www.mbusassep.com
Part number:
784-RR-HTVR-RC-KIT
i
i
When performing procedure on
ramps.
a Emissions Campaign 2020040003
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Initial Quick Test
1
2
3
Switch off the ignition.
Disconnect Geotab, Omni Track, Navigation
or any aftermarket devices that are connected
to the X11/4 diagnostic socket.
Open the hood.
a
4 Connect the battery charger to the
vehicle’s jump posts as indicated.
(arrows)
p
A sufficient power supply to the
vehicle on-board system must be
ensured throughout the entire work
procedure.
Otherwise any undervoltage that
occurs may damage the control
units.
i
Do not connect the battery charger to
the auxiliary battery in the engine
compartment.
i
Follow the operating instructions for
the battery charger.
i
Use a Mercedes-Benz recommended
battery charger to ensure an
adequate voltage supply (min. 12.5 V)
is provided for the on-board electrical
system battery.
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5
6
7
Ensure XENTRY is fully updated with the
latest release and all available add-ons.
Connect the diagnostic system. Make sure
that the OBD2 connection cable is
connected directly to the factory X11 / 4
diagnostic socket and not via an adapter
cable.
Switch on the ignition.
i
The diagnostic system remains connected to
the vehicle throughout the work procedure!
Do not disconnect the diagnostic system’s
online connection.
Start the diagnostic system.
9
10
Run XENTRY and perform Quick Test.
Upload Initial Quick Test print-out to
paperless pXD.
i
Pre-existing faults causing a Check Engine
Light must be evaluated. Reference Pre-
Inspection Notes on page 2.
i
The procedure via the diagnostic system
is shown on the following pages.
Perform Emissions Modification Pre-
Inspection.
8
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First
Second
Third
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wait
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wait
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First
Fourth
Name file:
QT 1
Third
Second
a
i
Pre-existing faults causing a Check Engine Light must be
evaluated. Reference Pre-Inspection Guide on page 2.
Emissions Campaign 2020040003
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First
Second
a
Pre-Inspection Special Procedure
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a
i
If ????on-Compliant alterations are found???? reference the
Pre-Inspection Guide on page 2 for next steps.
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11 End the XENTRY session.
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a
12
13
14
Switch off the ignition.
Disconnect the diagnostic system.
Disconnect battery charger.
Emissions Campaign 2020040003
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16 Spray penetrating oil
on the threads of the
NOx sensor upstream
(3) and downstream
(5) of SCR catalytic
converter, as shown.
p
Exhaust system
should be cold in
order to carry out
the next steps.
This avoids injuries.
i
Observe the wait
period and details
provided by the
manufacturer of the
penetrating oil!
Replacement of AEM Parts
a
15 Lift:
Raise the vehicle.
i
A description of the lift points is
available on pages 19-20.
Ramps:
Vehicle may remain on ramps.
Emissions Campaign 2020040003
33
a
17
18
19
20
21
22
23
i
This is done by bending up the individual locking
fins with a screwdriver and unscrew the clamping
nut (48) in a counter-clockwise direction with a
screwdriver.
i
To do this, unlock the gray retaining tab by moving
in the direction of the arrow.
i
To do this, remove and dispose nuts (46)
i
Observe state-specific regulations for disposal.
Loosen the heat shield (47).
Bend the heat shield (47) down until the NOx
sensor control unit upstream of the SCR catalytic
converter (23) is accessible.
Disconnect the electrical plug connection (24)
NOx sensor control unit upstream of the SCR
catalytic converter (23).
Remove the NOx sensor control unit upstream of
the SCR catalytic converter (23) from the frame.
Remove and dispose the cable ties and retaining
clips (arrows) from harness (22) of the NOx
sensor control unit upstream of the SCR catalytic
converter (23).
Remove NOx sensor upstream (3) of the SCR
catalytic converter.
i
The control unit and the NOx sensor upstream
(3) of the SCR catalytic converter are a single
unit.
i
Return the NOx sensor upstream of SCR catalytic
converter (3) to the originating parts department.
Clean the threads and the contact surfaces on the
exhaust pipe.
Removal of Upstream NOx Sensor
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a
27
25
26
24 Remove and dispose mounting tab
(34) from harness (32).
i
Observe state-specific regulations
for disposal.
Remove and dispose of the
clamping nuts (26).
i
This is done by bending up the
individual locking fins with a
screwdriver and unscrew the
clamping nuts (26) in a counterclockwise
direction with a
screwdriver.
Remove the heat shield (25).
28
Disconnect the electrical plug connection (30) at the NOx
sensor control unit downstream of the SCR catalytic
converter (27).
Remove the NOx sensor control unit downstream of the
SCR catalytic converter (27).
Remove the NOx sensor downstream of the SCR catalytic
converter (5).
i
The control unit and the NOx sensor downstream of the
SCR catalytic converter (5) are a single unit.
i
Return the NOx sensor downstream of the SCR catalytic
converter (5) to the originating parts department.
i
To do this unlock the gray locking device (29)
by moving in the direction of the arrow.
i
To do this, remove and dispose the nuts (28)
and cable tie (31).
i
Observe state-specific regulations for disposal.
29
Removal of Downstream NOx Sensor
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30
31
32
33
Installation of Upstream NOx Sensor
34 Bend the heat shield (47) back into
old position and install a new clamping nut
(48).
A 000 994 32 11
i
To do this, place the clamping nut (48)
centrally on the pin, as shown, and slide up
to the stop using a socket wrench.
Install new NOx sensor
upstream of SCR catalytic
converter (3).
i
A 000 905 85 11 80
(included in package
A 642 905 19 00 85)
NOx sensor upstream of SCR
catalytic converter: Torque to
60 Nm / 44.3 ft·lb
Install the NOx sensor control
unit upstream of the SCR
catalytic converter (23) on the
frame.
i
Use new nut fasteners (46):
N 000000 003477
NOx sensor control unit:
Torque to 9 Nm / 6.6 ft·lb
Connect the electrical plug
connection (24).
i
Push the gray retaining tab
(24.1) in the direction of the
arrow to lock.
Secure the harness (22) with
a cable tie.
i
A 007 997 56 90 (1x)
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35
37
36
Install new NOx sensor control unit
downstream of the SCR catalytic
converter (27).
i
A 000 905 84 11 80 (included in
package A 642 905 19 00 85)
Use new nut fasteners:
N 000000 003477
NOx sensor control unit: Torque to
9 Nm / 6.6 ft·lb
Install the new NOx sensor
downstream of the SCR catalytic
converter (5) on the new SCR catalytic
converter.
i
NOx sensor downstream of catalytic
converter: Torque to 60 Nm / 44.3 ft·lb
38
Connect and lock the electrical plug
connection (30).
i
Push the gray locking piece (29) in the
direction of the arrow to lock.
Secure harness (32) with cable tie (31).
i
A 007 997 56 90 (1x)
a
p
Do not route the harness (32) under tension.
Otherwise damage could occur.
Installation of Downstream NOx Sensor
Emissions Campaign 2020040003
37
39 Install the heat shield (25).
i
To do this, place the new
clamping nuts (26) centrally
on the pin, as shown, and
slide up to the stop using a
socket wrench.
i
A 000 994 32 11
40
41
Install the new mounting tab (34) on the heat shield (25).
i
A 220 546 18 43
Clip the harness (32) into the mounting tab (34).
p
Do not kink the harness (32) and make sure it is not routed
so as to be abraded.
This prevents damage.
p
The harness (32) must not touch heat shield (25).
This prevents damage.
i
The layout schematic of the harness (32) has changed on
account of the changed position of the NOx sensor
downstream of the SCR catalytic converter (4).
Lift:
Lower the vehicle.
Ramps:
Vehicle may remain on ramps
42
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38
Execution of the AEM Special Procedure
43
a
Connect the battery charger to the
vehicle’s jump posts as indicated.
(arrows)
p
A sufficient power supply to the
vehicle on-board system must be
ensured throughout the entire work
procedure.
Otherwise any undervoltage that
occurs may damage the control
units.
i
Do not connect the battery charger to
the auxiliary battery in the engine
compartment.
i
Follow the operating instructions for
the battery charger.
i
Use a Mercedes-Benz recommended
battery charger to ensure an
adequate voltage supply (min. 12.5 V)
is provided for the on-board electrical
system battery.
Emissions Campaign 2020040003
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a
Connect the diagnostic system.
i
The diagnostic system remains connected to the vehicle
throughout the work procedure!
Do not disconnect the diagnostic system’s online connection.
Switch on the ignition.
Start the diagnostic system.
44
46
45
47
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40
Run XENTRY and start special procedure of
customer service measure.
i
To do this, select the following menu items: N3/35 –
Motor electronics ‘CDI60’ for combustion engine
‘OM642’ (CDI) (Code: MH3|MH5|MH7) → Special
procedures → Service measure “Exhaust gas aftertreatment”
i
The process starts automatically after starting the
special procedure. The operation steps must be
performed exactly as per the diagnostic system.
If a fault arises during the special procedure,
repeat the procedure. If the fault persists, create a
PTSS case or XSF-ticket including the following:
A result report is displayed at the end of the
special procedure. Upload this report to
paperless pXD. The report must indicate “OK” for
all items. Otherwise, the procedure must be
repeated. The vehicle can only be returned to the
customer after successfully completing the
special procedure.
i
Parts of the procedure via the diagnostic system
are shown on the following pages.
•Initial Quick test
•Current Quick test
•Control unit log
•AEM Result Report
•Support Packag
i
i
First
Second
Third
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wait
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wait
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44
First
Second
First
Third
Second
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45
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Make sure it’s unchecked
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48 Complete the information on the
APPROVED EMISSION
MODIFICATION LABEL and attach it to
the hood near the hood lock.
p
The attachment areas must be entirely
free from dust and grease.
Otherwise, adequate adhesion cannot
be ensured.
i
Fill in Emission Modification Program
No., your dealer code, the date of the
repair and mark the components that
have been installed or modified. Use a
black ultra fine point permanent marker.
i
A 000 584 93 13
Failure to comply may result in dealer
debit and/or possible fines.
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48
Verify completed
successfully
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First
Second
Fourth
Third
Fifth
a
Name file:
AEM Results
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50
a
49 Perform a final quick test and upload to paperless pXD.
i
Faults stored in the memory????must be deleted from the
fault memory after completing the work.
i
If faults are current and stored in the updated control
modules they need to be addressed. If technical
hardships occur create a PTSS ca????????????
The procedure via the diagnostic system is shown on
the following pages.
Final Quick Test
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wait
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53
First
Fourth
Name file: QT 2
Third
Second
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54
50 End the XENTRY session
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a
Switch off the ignition.
????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????
51
52
54
55
56
Close the hood.
Connect any aftermarket devices that
were connected to the X11/4 diagnostic
socket before.
Ramps:
Remove wheel chocks, release parking
brake, and drive the vehicle off the
ramps.
p
Drive the vehicle slowly and at a
constant speed off the ramps.
Otherwise the vehicle may be
damaged.
53 ????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????
Emissions Campaign 2020040003
56
Replacement parts 2020040003
Part No. Designation Quantity
A 642 905 19 00 85 NOx Sensor package 1
A 220 546 18 43 Mounting Tab 1
A 000 994 32 11 Lock Pin 4
A 007 997 56 90 Cable Tie (with holding clip) 2
N 000000 003477 Nut Fastener 4
A 000 584 93 13 APPROVED EMISSION MODIFICATION LABEL 1
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SEOCONTENT-END