LI03.10-N-071148
Service Bulletin Details
Public Details for: LI03.10-N-071148
Engine runs irregularly and shakes. Check engine lamp lights up. Information: fault codes for injectors and/or combustion misfires may be stored in the cdi control unit: ? On engine 642 cylinder 6 is affected. ? On engine 651 cylinder 2
- 2020 -
Models from 2020
2020 MERCEDES-BENZ SPRINTER 1500 |
2020 MERCEDES-BENZ SPRINTER 2500 |
2020 MERCEDES-BENZ SPRINTER 3500 |
2020 MERCEDES-BENZ SPRINTER 4500 |
Engine runs irregularly and shakes. Check engine lamp lights up Topic number LI03.10-N-071148 Version 3 Function group 03.10 Connecting rods, pistons Date 06-04-2020 Validity Model 906 with engine OM651 Model 906, 907 with engine OM642 Reason for change Operation Codes Updated Reason for block Complaint: Engine runs irregularly and shakes. Check engine lamp lights up. Information: Fault codes for injectors and/or combustion misfires may be stored in the CDI control unit: • • On engine 642 cylinder 6 is affected. On engine 651 cylinder 2 is affected. Cause: Charge air from the exhaust gas recirculation is condensed after being introduced into the charge air system. Information: Under certain operating conditions, condensation that has collected in the charge air cooler can enter the combustion chamber to a damaging degree causing a mild hydro lock scenario and the connecting rod(s) to bend. Remedy: Perform following testing and diagnosis operations **************************************************************************************************************************** 1. Attach diagnostic system (see AD00.00-D-2000-04SD in model 906 or AD00.00-D-2000-06TS in model 907). 2. -------------------------------------------------------------------------------------------------------------------------------Perform initial quick test and save to paperless (see AD00.00-D-2000-04SD in model 906 or AD00.00D-2000-06TS in model 907). Information: For fault codes (current or stored) on injector and/or combustion misfires in the CDI control unit, continue with operation step 2. Information: If there are no fault codes on the injector or combustion misfires in the CDI control unit, conduct further research on the exact reason for the customer complaint and initiate corresponding repair measures. 3. -------------------------------------------------------------------------------------------------------------------------------Remove charge air hoses from inlet and outlet fittings on charge air cooler (see AR09.41-D-1311-01WE) and check if there is any condensation in them. Information: If any condensation is detected, it must be removed. -------------------------------------------------------------------------------------------------------------------------------- 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 1/9 4. Check air filter and air filter housing for ingressed fluid (see AR09.10-D-1050US and AR09.10-D-1150SF in model 906 with engine 642, AR09.10-D-1050US and AR09.10-D-1150WE in model 906 with engine 651, AR09.10D-1050TS and AR09.10-D-1150TSV in model 907 with engine 642). Information: If any fluid is detected, it must be removed. 5. -------------------------------------------------------------------------------------------------------------------------------Perform compression test using XENTRY Diagnosis. Information: If noticeable problems are found (speed deviations), continue with operation step 6. Information: If no noticeable problems are found, conduct further research on the exact reason for the customer complaint and initiate corresponding repair measures. 6. -------------------------------------------------------------------------------------------------------------------------------Check compression pressure using compression pressure recorder (see AR01.00-D-1200SF in model 906 with engine 642, AR01.00-D-1200WE in model 906 with engine 651, AR01.00-D-1201TSV in model 907 with engine 642). Information: If, when checking the compression pressure using the compression pressure recorder (on engine 651 this affects cylinder 2 and on engine 642 cylinder 6) a pressure difference is detected to the other 3 or 5 cylinders that is greater than 3 bar, you can assume that the connecting rod is damaged or bent. If noticeable problems are found, continue with operation step 7. Information: If no noticeable problems are found, conduct further research on the exact reason for the customer complaint and initiate corresponding repair measures. 7. 8. -------------------------------------------------------------------------------------------------------------------------------Remove fuel injectors (see AR07.16-D-1000SF in model 906 with engine 651, AR07.16-D-1000WE in model 906 with engine 642, AR07.16-D-1020TSV in model 907 with engine 642). -------------------------------------------------------------------------------------------------------------------------------Manually turn cylinders, one after the other, to TDC position (see AR01.00-D-0100SF in model 906 with engine 642, AR01.00-D-0100-01TSV in model 907 with engine 642, AR01.10-D-1000-01WE in model 906 with engine 651) and use welding wire or a vernier caliper through the fuel injector slot to measure the distance to the piston (see Picture 01 and 02). Information: If noticeable problems are found, continue with operation step 9. Information: If no noticeable problems are found, conduct further research on the exact reason for the customer complaint and initiate corresponding repair measures. 9. -------------------------------------------------------------------------------------------------------------------------------Replace engine (see AR01.10-D-2401SF in model 906 with engine 642, AR01.10-D-2401TSV in model 907 with engine 642, AR01.10-D-2401WE in model 906 with engine 651) or repair it (see AR03.10-S-7021SE in model 906 with engine 642, AR03.10-D-7021TSV in model 907 with engine 642, AR03.10-D-7021WE in model 906 with engine 651). Information: - On vehicles covered by warranty: Replace engine. - On vehicles not covered by warranty and with a properly operating crankcase and properly operating cylinder barrel: repair engine or offer replacement engine. - On vehicles not covered by warranty and with defective crankcase and/or defective cylinder barrel: replace engine (offer replacement engine). -------------------------------------------------------------------------------------------------------------------------------- 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 2/9 10. Check as-built configuration of charge air cooler. Information: Perform only on model 906, 907 before production date 02/2019. Information: For an older as-built configuration (fitting in center, see Picture 03), continue with operation step 11. Information: For a current as-built configuration (see Pictures 03, 04(OM651) and 05(OM642)), do not undertake any more repair measures. 11. -------------------------------------------------------------------------------------------------------------------------------Replace charge air cooler (see AR09.41-D-6817SD in model 906 with engine 642, AR09.41-D-6817TS in model 907 with engine 642 or AR09.41-D-6817WE in model 906 with engine 651). Information: Perform only in accordance with result after checking as-built configuration of charge air cooler (see operation step 10) and only in model 906, 907 before production date 02/2019. Information: The new charge air cooler with lowered fitting on the cold side (see AR09.41-D-8619M in model 906 with engine 642, AR09.41-D-8621TSR in model 907 with engine 642 or AR09.41-D-8619WE in model 906 with engine 651) must be installed (see Picture 04 and 05). Cost acceptance to be checked through advance agreement with regard to goodwill (ESKULAB). The modification of the charge air cooler is to be applied for as additional work through an ESKULAB query for engine damage (Note service information bulletin SI01.10-S-0001A hereto). Information: On vehicles in which the charge air cooler and charge air hose were replaced, the following text must be entered in the "Vehicle Documentation" (VeDoc) as FO texts: - Text for engine 651: Charge air cooler and charge air hose modified. New part numbers: Charge air cooler A 907 501 16 00, charge air hose A 907 528 23 00. - Text for engine 642: Charge air cooler and charge air hose modified. New part numbers: Charge air cooler A 907 501 17 00, charge air hose A 907 528 22 00. -------------------------------------------------------------------------------------------------------------------------------- Attachments File Description 01.jpeg Measurement of distance to piston (cylinder 1). 02.jpeg Measurement of distance to piston (cylinder 2). 03.jpeg Old as-built configuration of charge air cooler (fitting in center) (A 906 501 02 01). Standard on model 906. 04.jpeg New as-built configuration of charge air cooler (with lowered fitting on cold side) (A 907 501 16 00). Model 907 with engine 651. 05.jpeg New as-built configuration of charge air cooler (with lowered fitting on cold side) (A 907 501 17 00). Model 907 with engine 642. Symptoms Power generation / Engine management / Engine running / Surges Power generation / Engine management / Engine running / RPM too high/low Power generation / Engine noise / Noise Power generation / Engine management / Engine running / Runs rough/shakes Power generation / Engine management / Engine running / RPM reduces with delay 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 3/9 Power transmission / Function / Vibrates Power generation / Engine management / Indicator lamp / Engine diagnosis / lit Power generation / Engine management / Indicator lamp / Electronic diesel control / lit Power generation / Engine management / Engine performance / No/poor output Power generation / Engine management / Function / Malfunction Control unit/fault code Control unit Fault code Fault text N3/28 - Motor electronics 'CDI61NFZ' for combustion engine 'OM642' (CDI) (CR61NFZ) (Sprinter 907) P3004DA Combustion misfiring of cylinder 6 has been detected. N3/28 - Motor electronics 'CDID3' for combustion engine 'OM651' (CDI) (Code: MA5|MP6|MP8|MA6|MB6) (CRD3NFZ) (Sprinter III) P026685 Teach-in of the operating parameters for cylinder 2 has a malfunction. The correction value for the smooth running control of cylinder 2 is outside the permissible range. N3/28 - Motor electronics 'CDI- P310179 D3S2' for combustion engine 'OM651' (CDI) (CRD3S2NFZ) (Sprinter 907) Teach-in of the operating parameters for cylinder 2 has a malfunction. Calibration is missing. N3/28 - Motor electronics 'CDI- P3100F9 D3S2' for combustion engine 'OM651' (CDI) (CRD3S2NFZ) (Sprinter 907) Teach-in of the operating parameters for cylinder 2 has a malfunction. There is a signal above the permissible limit value. N3/28 - Motor electronics 'CDI61NFZ' for combustion engine 'OM642' (CDI) (CR61NFZ) (Sprinter 907) Combustion misfiring of cylinder 6 has been detected. P3004C6 Parts Part number ES1 ES2 Designation Quantity Note EPC A 907 501 16 00 Charge air cooler 1 Model 907 with engine 651 Information: For old as-built configuration only (fitting in center, see Picture 03, 04 and 05 and operation step 10 of remedy). X A 907 501 17 00 Charge air cooler 1 Model 907 with engine 642 Information: For old as-built configuration only (fitting in center, see Picture 03, 04 and 05 and operation step 10 of remedy). X A 907 528 22 00 Charge air hose 1 Model 907 with engine 642 Information: For old as-built configuration only (fitting in center, see Picture 03, 04 and 05 and operation step 10 of remedy). X A 907 528 23 00 Charge air hose 1 Model 907 with engine 651 X 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 4/9 Information: For old as-built configuration only (fitting in center, see Picture 03, 04 and 05 and operation step 10 of remedy). Additional necessary replacement part scopes, small parts and consumable materials must be replaced according to the information in the repair documents referred to in this document. These are to be determined according to the vehicle identification number (VIN) through the XENTRY Portal Parts Information system. Operation numbers/damage codes Op. no. Operation text Time 54-1011 PERFORM QUICK TEST --- 07-0641 CHECK ENGINE COMPONENTS: ........ --............ ACCORDING TO FAULT CODE 01-1200 CHECK COMPRESSION PRESSURE Damage code Note 03201 A3 Connecting rod – warped The listed damage code is not to be considered as an acceptance of costs. The general guidelines in the Warranty Manual apply. --- WIS-References Document number Title Note Allocation AD00.00-D-2000-04SD Connect STAR DIAGNOSIS, read out fault memory Model 906 Remedy AD00.00-D-2000-06TS Connect/disconnect diagno- Model 907 stic device Remedy AR01.00-D-0100SF Crank engine Model 906 with engine 642 Remedy AR01.00-D-0100-01TSV Crank engine on belt pulley Model 907 with engine 642 of crankshaft Remedy AR01.00-D-1200SF Check compression pressu- Model 906 with engine 642 re Remedy AR01.00-D-1200WE Check compression pressu- Model 906 with engine 651 re Remedy AR01.00-D-1201TSV Check compression pressu- Model 907 with engine 642 re Remedy AR01.10-D-1000-01WE Move engine to TDC positi- Model 906 with engine 651 on Remedy AR01.10-D-2401SF Remove/install engine with transmission Remedy 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG Model 906 with engine 642 BSTRINE Page 5/9 AR01.10-D-2401TSV Remove/install engine with transmission Model 907 with engine 642 Remedy AR01.10-D-2401WE Remove/install engine with transmission Model 906 with engine 651 Remedy AR03.10-D-7021TSV Remove/install piston Model 907 with engine 642 Remedy AR03.10-D-7021WE Remove/install piston Model 906 with engine 651 Remedy AR03.10-S-7021SE Remove/install piston Model 906 with engine 642 Remedy AR07.16-D-1000SF Remove/install fuel injectors Model 906 with engine 651 Remedy AR07.16-D-1000WE Remove/install fuel injectors Model 906 with engine 642 Remedy AR07.16-D-1020TSV Remove/install fuel injectors Model 907 with engine 642 Remedy AR09.10-D-1050TS Remove/install air filter Model 907 with engine 642 Remedy AR09.10-D-1050US Remove/install air filter Model 906 with engine 642, Remedy 651 AR09.10-D-1150SF Remove/install air filter hou- Model 906 with engine 642 sing Remedy AR09.10-D-1150TSV Remove/install air filter hou- Model 907 with engine 642 sing Remedy AR09.10-D-1150WE Remove/install air filter hou- Model 906 with engine 651 sing Remedy AR09.41-D-1311-01WE Open/close connector Remedy AR09.41-D-6817SD Remove/install charge air cooler Model 906 with engine 642 Remedy AR09.41-D-6817TS Remove/install charge air cooler Model 907 with engine 642 Remedy AR09.41-D-6817WE Remove/install charge air cooler Model 906 with engine 651 Remedy AR09.41-D-8619M Remove/install charge air hose Model 906 with engine 642 Remedy AR09.41-D-8619WE Remove/install charge air hose Model 906 with engine 651 Remedy AR09.41-D-8621TSR Remove/install charge air Model 907 with engine 642 hose upstream of charge air cooler Remedy SI01.10-S-0001A Service Information bulletin: Standardized procedure for engine problems Remedy Validity Vehicle Engine Transmission Sprinter 907 642 * Sprinter III 651 * Sprinter III 642 * Attachments 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 6/9 01.jpeg: 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 7/9 02.jpeg: 03.jpeg: 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 8/9 04.jpeg: 05.jpeg: 06-04-2020 3:56 PM © Copyright Mercedes-Benz AG BSTRINE Page 9/9