2020 Mercedes-Benz
SPRINTER 2500Problems & recalls

Complaint While driving through muddy / sandy/ off road terrain "4Matic Currently Unavailable" message on the dash Cause This vehicle is not equipped with a fixed force distribution AWD, rather force is only applied to the front axle according to ESP calculations. As per GF28.00‑D‑ 9900A: "vehicles with 4MATIC all‑wheel system and variable force distribution, an electronically regulated multiplate clutch integrated into the transfer case provides for the torque distribution. If the multiplate clutch is open during normal driving operation, only the rear axle drives the vehicle. If the clutch is closed, the front axle comes into play." The message "All‑wheel drive temporarily unavailable" is not indicative of a malfunction but rather informs the driver that all‑wheel drive is currently not available due to the transfer case clutch overheating. This occurs when the vehicle is driven in such a way that maximum front axle torque is needed for an extended period, causing the clutch to get excessively hot. If the vehicle is being driven under heavy load conditions, like in deep sand or snow, the rear axle may slip while the front axle does not deliver power. The transfer case then attempts to distribute torque to correct the slip, but it is limited to a maximum of 1150 Nm to protect the front axle transmission. In extended heavy‑load scenarios, the multidisk clutch in the transfer case slips, increasing the temperature. If the temperature model detects a critical temperature of 240°C, the system protects itself by disconnecting until it cools down to around 160°C, after which the all‑wheel drive becomes available again and the warning message disappears.Vehicles can handle flat terrain easily, but steep slopes or situations where wheels slip might cause additional resistance, leading to the described protection events and message in the dash. Remedy Recommendation is to release the vehicle back to the client with an explanation that the vehicle is operating as designed. Please advise the client to limit vehicle acceleration in limited traction situations to avoid disabling of the 4Matic system ‑ please see "Notes on all‑wheel drive" provided in the operators manual.

Components: POWER TRAIN. Confirm detailed applicability in the original document.

Model 907 with all-wheel drive (A4M) – All-wheel drive inoperative Complaint The customer may report one or more of the following: • All-wheel drive is unavailable or inoperative. • Rear wheel slip during acceleration on low-traction surfaces. • Noise from the front axle area while driving. • Message in the instrument cluster indicating all-wheel drive is unavailable due to overheating. • Fault code P27874B - The temperature of the clutch is too high. There is a fault due to overtemperature may be stored in control unit N15 (Transfer Case). Cause An internal failure of the front axle differential may result in loss of torque transfer to the front wheels. In some cases, a fracture of the weld between the crown gear and differential housing may be present. Remedy Replace the front axle differential in accordance with: AR33.30-D-0525TSY – Replace Front Axle Differential.

Components: POWER TRAIN. Confirm detailed applicability in the original document.

ASSYST PLUS service reminder appears earlier than expected due to vehicle operating conditions Complaint The ASSYST PLUS service reminder appears earlier than expected. The customer or dealer may report that the vehicle did not reach the starting maintenance interval shown in vehicle documentation, option coding, sales literature, or the Owner's Manual. The service reminder may appear significantly earlier than anticipated even though no faults are stored and no malfunction is present in the vehicle. The remaining distance and remaining time continue to decrease normally until the service reminder is displayed. Cause This condition is not caused by a malfunction of ASSYST PLUS. ASSYST PLUS is a dynamic maintenance management system that continuously evaluates vehicle usage and opera-ting conditions to determine maintenance requirements. The starting maintenance interval specified by variant coding represents a maximum interval that may only be achieved under favorable operating conditions. Actual maintenance intervals may be significantly shorter depending on vehicle use. Vehicle operating conditions such as driving conditions, engine load, engine operating conditions, idling, short-trip operation, environmental influences, oil aging, and Diesel Particulate Filter (DPF) regeneration activity may reduce the maintenance interval from its starting value. These conditions may accelerate engine oil aging through increased soot loading, fuel dilution, moisture accumulation, and additional engine operating stress. As a result, the remaining distance and remaining time until the next service may be reduced from the starting maintenance interval. Remedy Do not replace any parts. A due service must be assumed if the maintenance data calculated by ASSYST PLUS indicates that service is required.

Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.

Complaint Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. NOTE: This LI supersedes LI14.20-N-073813, which is no longer valid. Cause Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the de-sired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function. Remedy Remedy for Complaint A: Perform the following steps: 1. Disable the EGR Valve (Y27/17) by disconnecting the electrical connector. 2. Perform a test drive to check if the jolting/bucking issue resolves. 3. If the jolting/bucking is resolved, proceed to Remedy for Complaint B. 4. If jolting/bucking is still present, proceed with diagnosis to determine the root cause. Consider checking the follo-wing, but not limited to: •EGR system including the EGR Cooler, EGR Bypass Flap, EGR Temperature Sensor, and pipes for proper operati-on, excessive sooting and/or clogging, as well as EGR Bypass Flap vacuum element, switchover valve, and vacuum system. •Visually check the leak oil line or T-piece; reference LI07.00-N-059118.

Components: POWER TRAIN. Confirm detailed applicability in the original document.

The check engine light is illuminated, or the AdBlue warning is active, with recorded faults related to AdBlue quality or concentration. Complaint Customer reports an illuminated check engine light and or an AdBlue system warning indicating AdBlue quality out of specification. The vehicle may enter reduced performance mode. One or more of the following fault codes related to the AdBlue tank may be stored: P206B31: Malfunction of the concentration sensor for AdBlue; the signal is absent. P203B31: Malfunction of the AdBlue fill level sensor; the signal is absent. P300494: The quality of the AdBlue is insufficient. Background AdBlue must meet ISO 22241 quality requirements. ISO 22241 urea content limits for AdBlue are 31.8 percent to 33.2 percent by mass. AdBlue begins to crystallize and freeze at approximately 12 degrees F. Freeze-thaw does not degrade the product when uncontaminated, and the bulk concentration returns to normal after complete thaw and mixing. Cause In cold soak conditions and during freeze thaw exposure, the tank contents may not be uniform at the time of sampling or system checks. During freezing and partial thaw, ice formation can temporarily create concentration gradients in the tank. As a result, urea percent readings can vary based on sample location and the state of thaw and mixing, which can produce apparent out of range readings even though the bulk fluid returns to normal after mixing. Remedy Testing Do not use a single urea percent reading taken from frozen, partially frozen, or not fully mixed AdBlue to make a repair or responsibility decision. Confirm full thaw and ensure tank contents are mixed before sampling. 1. Confirm full thaw - Confirm the AdBlue tank and associated components are fully thawed before sampling. - Do not sample slushy or partially frozen fluid. 2. Mix tank contents - Perform a road drive intended to mix the tank contents before sampling. - Idle time alone is not a reliable substitute for mixing. 3. Sample and measure - Take the sample and measure with the MB refractometer per the MB tool instructions. - Record the urea percent value. 4. Interpret the result against ISO 22241 limits - Within specification is 31.8 percent to 33.2 percent urea by mass. 5. Repeat if out of specification - If out of specification, repeat after an additional mixing drive to reduce sampling variation. - If still out of specification after full thaw, mixing, and repeat measurement, treat as a true out of specification result and proceed with further diagnosis per applicable MB guidance. Acceptance criteria AdBlue is within the ISO 22241 specification when the urea percent is between 31.8 percent and 33.2 percent by mass. Values outside this range are out of specification and require further diagnosis after completing the full thaw and mi-xing procedure above. Cross reference For vehicles with fault codes P206B31, P203B31, or P300494, refer to LI49.20-N-078838 for the detailed diagnostic and repair procedure. If a SCR or AdBlue warning reset is required after correction, refer to LI49.20-N-075995. Complete the diagnostic and corrective steps first. Perform the warning reset only after the underlying fault condition has been corrected. Warranty information and claim handling

Components: FUEL/PROPULSION SYSTEM. Confirm detailed applicability in the original document.

Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset with fault code P13DF00 or P300685 Complaint Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset. Information: All fault codes in the AdBlue® (SCR) control unit have been processed and corrected; however, fault codes P13DF00 and P300685 remain active and stored in the AdBlue® (SCR) control unit. Cause The procedure for resetting the SCR/AdBlue® warning message with XENTRY Diagnosis has not been carried out. Information: Before resetting the SCR/AdBlue® warning message for SCR Generation 4, the AdBlue® system must be in proper working condition and tested.

Components: ENGINE. Confirm detailed applicability in the original document.

EGR Valve Diagnosis & Cleaning (and EGR Cooler Cleaning) – OM642, Sprinter 906/907 Complaint A: The engine is jolting/bucking between 1700 and 1900 rpm. Complaint B: One or more mechanical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of mechanical fault codes in table below. NOTE: If one or more electrical related fault codes for EGR Valve are also present in CDI, utilize Complaint C. Review list of electrical fault codes PDF document in attachments. Complaint C: One or more electrical related fault codes for EGR Valve stored in CDI control unit, with possible Check Engine Light. Review list of electrical fault codes PDF document attached. Cause of Complaint A: Increased friction between the EGR Valve blade and seat due to soot deposits causing a delay of the EGR Valve being able to reach the target value of the EGR Valve position controller. NOTE: This causes the EGR Valve blade and potentially the boost pressure controller to oscillate. Cause of Complaint B: Soot deposits between the EGR Valve blade and seat leading to the EGR Valve no longer being able to meet the desired target of the EGR Valve position controller. Cause of Complaint C: Internal EGR Valve or other electrical faults related to the EGR Valve function.

Components: ENGINE. Confirm detailed applicability in the original document.

Complaint Vehicles with SCR Generation 4: SCR/AdBlue® warning message cannot be reset. Information: All fault codes in the AdBlue® (SCR) control unit have been processed and corrected; however, fault codes P13DF00 and P300685 remain active and stored in the AdBlue® (SCR) control unit. Cause The procedure for resetting the SCR/AdBlue® warning message with XENTRY Diagnosis has not been carried out. Information: Before resetting the SCR/AdBlue® warning message for SCR Generation 4, the AdBlue® system must be in proper working condition and tested.

Components: ENGINE. Confirm detailed applicability in the original document.

The software for the communication module does not correspond to the latest series production configuration. For this reason, a remote software update to update the software for the communication module is planned for the affected vehicles. This update includes quality-enhancing optimizations for the communication module to improve the system stability and accessibility of connected services. MBUSA is conducting a service campaign. The update is downloaded and installed in the background. This process takes approximately 10 minutes. During installation, the system can be used without restrictions. The new software will become active after the vehicle's ignition cycle.

Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.

Engine Oil Level Cannot Be Checked via Instrument Cluster Service Menu Complaint Sometimes the engine oil level cannot be determined using the instrument cluster's service menu. The following mes- sages may be displayed: •Engine oil level currently inoperative. See Attachment: Message "Engine oil level currently inoperative" (shown in German on model 907 with code C6L (Multifunction steering wheel)). •Engine oil level measurement is running. Repeat the query after a maximum of 30 minutes of driving time. Information: It is still possible to determine the engine oil level via the workshop menu or XENTRY Diagnostics. Cause No current value for the saved oil volume has been stored in the drivetrain control unit (CPC, N127). Remedy 1. Connect diagnostic device (see AD00.00-D-2000-06TS for model 907). •Always use the latest XENTRY Diagnostics software release with all available add-ons. •Follow all operation steps in XENTRY Diagnosis precisely. 2. Perform initial quick test (see AD00.00-D-2000-06TS for model 907). •Print out the initial quick test as a PDF file and attach it to the order in a tamperproof manner. 3. Create and save the control unit log for drivetrain control unit (CPC, N127). •Print out the control unit log as a PDF file and attach it to the order in a tamperproof manner. •Check the saved oil volume in the "Maintenance data" tab of the control unit log. See Attachment: Saved oil volume in "Maintenance data" tab of the control unit log (shown in German). •If the saved oil volume in the "Maintenance data" tab is more than 0.0 liters and it is not possible to determine the en- gine oil level via the service menu, conduct further research on the exact reason for the customer complaint and initia- te corresponding repair measures. •If the saved oil volume is 0.0 liters, proceed with operation step 4. 4. Check actual values for engine oil level in the engine control unit and observe any relevant information and descrip- tions in XENTRY Diagnosis. •Quick test view → Engine control unit → Actual values → Oil circuit → Oil level gauge 5. Clear fault memory (see AD00.00-D-2000-06TS for model 907). 6. Disconnect diagnostic device (see AD00.00-D-2000-06TS for model 907). 7. Carry out a test drive of more than 30 minutes, run the vehicle in idle for approximately 3 minutes on a level sur- face, switch the ignition off and on again, and then record the engine oil level again using the instrument cluster's ser- vice menu. •Only carry this out if the saved oil volume in the "Maintenance data" tab is 0.0 liters. •When checking the engine oil level via the service menu, refer to the operator's manual. Inform the customer accor- dingly about these circumstances. See Attachment: Message "Engine oil level OK" (shown in German on model 907 with code C6L (Multifunction steering wheel)). 8. If the customer complaint occurs again, create a TIPS case directed to the Powertrain inbox, including all required information from this LI.

Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.

Complaint Transmission control unit Y3/8n4 (fully integrated transmission control unit (VGS)) not listed in quick test and/or no communication possible with VGS. Cause Transmission control unit Y3/8n4 Remedy For vehicles with 722.9 transmission: Ensure LI54.15-P-057373 is performed before replacing any component parts. After processing and complying with the above document(s): 1. Perform an ignition reset on Y3/8n4 (VGS) 2. Inspect transmission connector for loose connections, damaged wiring or pins and any other concerns. If communication with the VGS cannot be established, the complete valve body ('electrohydraulic controller unit (EHS)') must be replaced. Installation of a VGS repair kit is not permitted in this case as it is not possible to transfer the necessary valve characteristics without communication with the original control unit.

Components: POWER TRAIN. Confirm detailed applicability in the original document.

MBAG has determined the software of the control unit for the anti-theft warning system does not correspond to the current production configuration. There is a possibility that the alarm system (EDW) could be triggered while the vehicle is parked and locked. MBUSA is conducting a service campaign. An authorized Mercedes-Benz Sprinter dealer will update the anti-theft system software on the affected vehicles.

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.