Campaign - Repl. Diesel Exhaust Fluid (DEF) System Line: Overview
FILE:SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER
Campaign No. 2010090006, October 2010
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
Model 906.6, Model Year 2010
Replace Diesel Exhaust After-treatment Fluid (AdBlue) System Line
Daimler AG (DAG), the manufacturer of Freightliner and Mercedes-Benz Sprinter vehicles, has determined that the metering line at the diesel exhaust after-treatment fluid (AdBlue) tank may leak in
the area of the connector due to production quality issues at the supplier. Through capillary action the reducing agent contained in the AdBlue tank may travel through the connector and into the wiring
harness, and possibly into the AdBlue control module This may lead to electrical signal distortions in the diesel exhaust after-treatment system.
Daimler Vans USA, LLC (DVUSA) and Mercedes-Benz USA, LLC (MBUSA) therefore has initiated a campaign of all potentially affected vehicles described above. The service campaign will be conducted to replace the AdBlue Exhaust After Treatment System Lines. In addition the AdBlue wiring harness and AdBlue control module will be checked for the presence of AdBlue and if found will be replaced.
Attached is a sample copy of a letter which owners of the affected vehicles will receive.
Prior to performing this Service 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 Service Campaign bulletin and follow the repair procedure exactly as described.
Please note that Recall and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.
Approximately 1882 vehicles are affected.
Procedure
A. Inspect AdBlue Control Module Connectors, Wiring Harness and Install AdBlue Fluid Line
Caution!
For information on preventing damage to electronic components due to electrostatic discharge; refer to: WIS: AH54.00-P-0001-01A
1. Disconnect electrical connector at AdBlue control module (4, Figure 1) refer to WIS: AR14.40-D-2020S.
Note (regarding above WIS instructions):
Perform steps 1-5 only.
WARNING!
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. Refer to WIS document: AS14.40-Z-0001-01A.
Note:
For notes on use, material properties and handling of AdBlue; refer to WIS document: AH14.40-N-0001-01AB.
2. Remove AdBlue tank: Refer to WIS: AR14.40-D-2014S.
3. Disconnect electrical connector of wiring harness for AdBlue container (3, Figure 1) from frame/AdBlue control module wiring harness.
Note:
Drying time of 4 hours must be allowed to determine if AdBlue crystal formations appear on the electrical connectors (disconnected in steps 1 and 3). During this time proceed to step 4 of this procedure.
4. Replace AdBlue fluid line (1, Figure 1); refer to WIS document: AR14.40-D-2001S then continue with Procedure.
Note (regarding WIS AR14.40-D-2001S):
^ For AdBlue line connector (arrow, Figure 1) removal from AdBlue pump fitting: Slightly twist/rotate the AdBlue line connector (arrow, Figure 1) on the AdBlue pump fitting before removing (refer also to above WIS instructions for complete information). Be careful not to break the fuel pump fitting
^ 2 AdBlue fluid line mounting clips (arrow, Figure 2) are located above storage box (A, Figure 3) below right seat. Remove these clips by prying them off from the mounting studs (do not remove storage box [A}).
^ Ensure that frame mounting clips (arrow, Figure 2) are transferred from old AdBlue fluid line to new fluid line in the same position on the line. The new fluid line will have white paint marks indicating the mounting clips location.
^ Do not remove AdBlue injection valve (A, Figure 4) from exhaust pipe. Pull back insulation (B) near end of AdBlue line and remove retaining clip (arrow) to disconnect line. Installation is in reverse order. Be sure to roll back insulation over Adblue line when installing new AdBlue line.
Note:
Perform service work on other vehicles during the 4 hour AdBlue drying time on the connectors.
5. Replace harness for AdBlue tank (3, Figure 1 and arrows, Figure 5); refer to WIS document: SM14.40-D-0002-11S.
Note:
Install a new cable tie (A) to secure harness (arrows) to AdBlue tank.
6. Check for crystal formation on AdBlue control module (4, Figure 1) connectors after 4 hours of drying time:
^ If crystal formation can be seen on the electrical connectors:
Replace AdBlue control module; refer to WIS document: AR14.40-D-2020S then proceed to step 7.
Note:
Anticipated replacement rate for control module is very low; ensure replacement criteria is met.
^ If no crystal formation can be seen on connectors: Proceed to Step 7.
7. Check for crystal formation on electrical connectors of frame/AdBlue control module wiring harness to AdBlue container wiring harness (3, Figure 1).
^ If crystal formation can be seen on electrical connectors:
Replace AdBlue control module wiring harness; refer to Subject B then continue with procedure.
Note:
Anticipated replacement rate for Adblue control module wiring harness is very low; ensure replacement criteria is met.
^ If no crystal formation can be seen on electrical connectors: Continue with procedure.
8. Reassemble in reverse order.
9. Perform SCN coding of instrument cluster, refer to WIS: AR54.21-P-0013-02X
Note:
Ensure that AdBlue tank is completely filled with new AdBlue fluid.
10. Read out fault memory; refer to WIS document: AD00.00-D-2000-04SD.
B. Replace Wiring Harness of AdBlue Control Module (only if AdBlue crystals are seen on AdBlue control module harness connector pins)
Note
This new Adblue control module harness does not completely replace the original AdBlue control module harness. This new harness will be routed along the existing harness. Some of the existing harness components will be removed and their functionality will be replaced by this new harness.
Components that will be removed from the original harness include:
^ 2 harness connectors and 3" of wiring harness that connect to the AdBlue tank harness connectors.
^ Wire harness pin connectors inside the AdBlue control module connector and a section of harness.
The cable ends of the harness that were connected to the original AdBlue wiring harness connectors and pin connectors that were removed will no longer be functional and will be sealed-off with Z-splice connectors. The original AdBlue wiring harness also consists of sub-harnesses that are still functional and thereby will not be replaced. The complete procedure is described in the following steps.
1. Disconnect negative battery cable; refer to WIS: AR54.10-D-0003SD.
2. Cut-off connectors from AdBlue control module harness using cutting pliers
CAUTION!
DO NOT cut-off connectors from AdBlue tank harness.
^ Cut harness approx. 3" above AdBlue control module harness connectors (arrows, Figure 6).
^ Install "Z" spice connector (arrow, Figure 7) on wiring harness end (where harness was cut) then heat "Z" splice connector (arrow) using heat gun (to secure splice connector to wire harness end).
3. Connect new AdBlue control module wiring harness connectors (arrows, Figure 8) to AdBlue tank wiring harness connectors then secure connectors to vehicles body.
4. Route new AdBlue control module harness along original AdBlue control module harness, secure to original harness with cable ties (minimum 11 cable ties)
Note:
Do not remove original AdBlue control module harness from vehicles frame. New harness will be routed along original harness.
5. Route new AdBlue control module harness through harness boot (arrow, Figure 9) underneath vehicle (below drivers seat) up to AdBlue control module.
6. Remove AdBlue control module harness connector cover:
^ Remove cable tie (A, Figure 10) from AdBlue harness connector cover then push tab (B) in direction of arrow (Figure 10).
^ Push cover (A, Figure 11) in direction of arrow (Figure 11) then remove cover (A).
7. Remove approx. 4" of tape from harness near AdBlue control module harness connector.
8. Unpin AdBlue control module connector pins from harness connector and install harness connector pins from new AdBlue harness into connector:
^ Slide purple harness connector locking clips/"combs" (arrow, Figure 12) out from harness connector (A).
^ Unpin harness connector pins (listed below) from connector sockets/cells with harness pin removal tool (B) (locally sourced tool).
^ Install harness pins from new harness into harness connector sockets/cells as indicated below:
9. Re-assemble harness connector (A, Figure 12) in reverse order and connect to AdBlue control module (C).
10. Tape AdBlue control module harness (D, Figure 12) near connector using electrical tape (shop supply) and install new cable tie (E) on end of AdBlue control module cover (F).
Note:
Electrical tape part no. (e.g.): A 006 989 84 85 10 (or equivalent).
11. Install "Z"-splice connector on existing AdBlue control module wiring harness ends:
^ Cut-off harness section attached to 14 connector pins from original wiring harness (3, Figure 13) (removed from original AdBlue control module connector) using cutting pliers.
^ Install "Z" splice connector (G, Figure 12) to original AdBlue control module harness end using heat gun (to secure connector to harness).
12. Connect new AdBlue control module harness ground connector (2, Figure 13) to body lug (I, Figure 12).
13. Connect AdBlue control module connector (A, Figure 12) to AdBlue control module (C).
14. Reconnect battery; refer to WIS: AR54.10-D-0003SD.
15. Continue with procedure, proceed to: Subject A, step: 8
Locally Sourced Tool
Primary Parts Information