SCR (AdBlue) and NOx sensors bypass module for Mercedes BlueTec

cars and vans (v1.71.xx dual mode Dec-15, 2015)

New features v1.71.xx
- with new bypass version, StarDiagnose dealer
equipment is not needed to make initial start-up
anymore. Reset limited starts count, sensors teach-in
and reset NOx adaptations now possible with bypass
internal software. Driver can do those procedures any
time with ignition key and accelerator pedal.

- now SCR control unit totally simulated with

bypass. When bypass connected and real SCR module
disconnected, during diagnostics with StarDiagnose
you will see, that your SCR module present and pass
all possible tests. Dealers can check heaters, pump, valves and even make SCN coding and flash new
firmware to "simulated" SCR module - bypass will look exactly like real SCR. You do not need to
explain to mechanic that you have bypass - nobody will realise that SCR is not real but simulated.

Purpose

Our SCR Emulator purpose and goal - is to give opportunity to lower cost of a repair to owner of a
Mercedes BlueTec car, equipped with modern SCR system with AdBlue injection, when SCR system
has a permanent fault.
On Mercedes cars any permanent fault in SCR system makes car limited mileage or number of
possible motor starts. After that mileage of motor starts owner will be NOT able to start motor
anymore. This makes all BlueTec owners very angry, especially when owners located far from nearest
Daimler service garage.
Very often even owners of a warranty cars ask to remove SCR/AdBlue due to frequent SCR
problems, making them go to dealer garage several times a months.

Our SCR emulator car replace SCR module as well as NOx sensors when one or more system
components are faulty and SCR module limiting car operation (see picture)

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 Advantages

- Bypass installation keeps your emission inspection related monitors located at CDI control module
fully working. So after EMU installation your car will pass emission inspection no problem. CDI
module think, that AdBlue system works as expected.
- price of car repair. Even few components can significantly hit on a owner's pocket. When you will
consider labor cost - it become even more pricy.

1. SERVICE KIT (RS PREHEATER) - $959

2. SERVICE KIT (RS ADBLUE PUMP MODULE.) - $899
3. NOX-SENSOR FRONT - $599
4. NOX-SENSOR BACK - $599

Installation of our SCR Emu takes 30 minutes. All you need to do is disconnect SCR plug and splice 4
wires (or 6 wires) to SCR wiring loom close to plug. SCR module is easy accessible on all cars from a
trunk space.
Device assembled on very small PCB with size of 12x24mm (about SIM card size - see picture)
with automotive-grade electronic components. Operating range is -40 + 85 degrees Celsius. Power
consumption is 0.275W. Voltage range is 5.0 - 18.0V. In a sleep mode electrical current consumption
is 0.0003A. Device is really tiny and can be invisibly interweaved to original car wiring looms. All
devices passed two 12 hours reliability tests (80 on/off cycles) under full load at vibration bench at -
20C (-4F) and +60C (140F)
Operation
SCR Emu starts to operate right after you will turn ignition on (same as SCR module) and provides all
necessary signals to engine control module. ECM think, that SCR is present and operates normally.
Under client wish it is possible to make SCR Emu connected on 6-wire socket - this will make possible
to switch between EMU and normal (real) SCR operation. You can activate and deactivate real SCR as
many times as you wish - no settings and tuning necessary in that case.

Bypass emulates both SCR module as well as two NOx sensors. SCR EMU automatically detects NOx
sensors on a Can-bus and in case, that NOx are present will emulate only SCR. In case, that EMU
detects, that NOx sensors are not present - starts to emulate both SCR and two NOx sensors.

IMPORTANT: EMU can not emulate only NOx sensors without SCR. SCR module have to be
disconnected from a car to use EMU.

Compatibility with Mercedes cars

EMU is compatible with all Mercedes BLUETEC cars and vans (but not trucks) with SCRCM
module (datacard code U42)
E-Class W212 as of 03.2009 R251 W251 07/2008 - EOL
GLK X204 as of S221 all
ML164 W164 07/2008 - 09/2011 G463 W463 as of 06/12
GL164 X164 07/2008 - 09/2011 W906 till 07.2013
ML166 W166 as of 09.2011 W906 as of 07.2013
GL166 X166 as of 09.2011

SCRCM3 module (datacard code U77 on chassis W205/W222) is under test and currently not supported (MY2015
cars). These cars is under Daimler's warranty in any case.

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 Before installation

Since module version v71.XX (6 wire connection) it is not necessary to make any steps before you
start to install. You do not need Star Diagnose dealer equipment to make initial start, nevertheless if
you decide to connect only 4-wires (less problematic with connection but also possible) you will
need Star Diagnose to make initial start-up.

Installation
1. take off ignition key from ignition lock, wait till car electronics will go to sleep (on W166 this
can take to 90 seconds).

2. Locate SCR unit (see pictures, on different cars location is slightly different) but it is mostly in a
trunk area under covers.

3. Disconnect SCR unit main connector from unit. After you

will finish connection - please DO NOT CONNECT it again,
this is not necessary. this connector will remain disconnected
when EMU will work

4. Look to wire harness near SCR connector and locate 4 target

wires (2xSensor-Can-bus wires and 2xpower wires) (see
wiring pictures and table lower on this manual to find a target
wires). Can-bus wires is always twisted each-other - so it is
easy to find right ones at wiring loom.

4a. IMPORTANT: on most cars/vans Chassis-Can-bus wires nearest location is very far from SCR
module and you will need additional wires to make interface wire much longer. See additional
pictures lower manual (section 6-wire connection locations) to locate Chassis can wires at your
car/van. In case of 6-wire connection (the best idea) most probably you will connect 5 wires (4 can
bus wires and ground wire) at one place, but power wire you have to connect either according to 4-
wire connection near SCR module or you have to find nearest Terminal 15 wire near your module
location - in most cases you will need long additional wire for power.

5. As soon as you will successfully detect all 6 target wires - stripe isolation of that wires for 3-
7mm long on a point located 7-10 cm from connector (but do not cut wires), then splice them with
interface wires (see table as well as wiring diagrams lower on that manual). Soldering splicing
points will give you more reliability. IMPORTANT: start splicing with GND (Black) wire

6. isolate your connection with tape. Then it is better to attach EMU module to wire harness with
isolation tape as well. (REMINDER: do NOT connect SCR connector back to SCR module)

7. As soon as NOx sensors emulation necessary as well, please disconnect NOx sensors power fuse
(W164/W166/W212) or NOX sensors Can-bus connectors (W906/W221) - see pictures below. or
better check with WIS software.

IMPORTANT: On US-spec W166/906 cars (datacard code 494) produced after 08/2012 there is a
separate soot sensor N74 or B163 present. That sensor powered from the same fuse with NOx
sensors. On that cars please do not take NOx fuse sensor OFF (this will unpower N74 sensor as
well). Please disconnect can-lines from NOx sensors on X30/38 connector OR take off connectors
from NOx sensors under car.

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 Car wire colors near SCR module big black connector (except Chassis-Can wires - they are
usually very far from SCR module - see pictures lower this document)
INTERFACE
W463 W164/W251 W166 W212 W221 W906
WIRES
GND - black Brown Brown Brown Brown Brown Brown
Power (+12V) - red Black/blue Black/blue Black/blue Pink/Red Black/blue Black/white
Sensor Can-L - green Solid pink Solid pink Solid pink Solid pink Solid yellow Solid violet
Sensor Can-H -
Pink/red Pink/white Pink/white Pink/white Yellow/blue Violet/white
orange
Chassis Can-L -
Solid green Solid green Solid green Solid green Solid green Solid green
green
Chassis Can-H -
Green/white Green/white Green/white Green/white Green/white Green/white
orange

Important note about Chassis-Can-bus connection: it is not necessary to connect Chassis-Can to

make bypass to work. It will operate normally with no chassis-can-bus connected (Sensor Can is
absolutely necessary btw) on all cars except Sprinter 906 MY2013 and later. In case, that you do
not like to connect Chassis-Can - you will loose possibility to reset limited starts count and make
initial start-up without diagnostic equipment, Bypass operation will be limited to certain modes but
still possible.

Common mistakes made by customers on installation

1. wrong ground wire connection. On some cars there more then one brown wire in a loom. Please
make sure, that brown wire you have found at wiring harness near SCR plug goes to pin 7 of SCR
plug - this is real ground. Use multimeter tool to make sure.
2. wrong can-lines connection. Make sure, that wires you have found for can-lines connection are
twisted each-other - these are right ones
3. bad splicing quality. Make sure, that your spliced your wires well, especially ground wire. better
you will solder splicing points - this will give you best reliability.

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 Start-up

1. After you have finished installation - check all connections one more time - this is really
important. All information below related to 6-wire bypass connection. 4-wire connection initial
start-up can be done only with StarDiagnose dealer equipment

2. Teach bypass to your real SCR-module. In order to do that step you have to
- temporary connect BACK big main SCR plug (now bypass and SCR plug both connected)
- turn your ignition ON for 10 seconds (do not start engine)
- turn ignition OFF and remove key
- wait 60 seconds till SCR will pump AdBlue back to tank
- disconnect big main SCR plug again - and hold it disconnected with tape (this is final
position).
During this step bypass reads some important data from SCR module in order to simulate
diagnostics over StarDiagnose. This step is not necessary for bypass operation - this is only for
SCR diagnostics simulation. You can do that step again any time in future.

3. Reset adaptation values, teach-in new NOx sensors and reset starts count
- make sure that bypass connected and SCR module big black plug disconnected
- turn ignition ON (do not start motor) - now you have 20 seconds to finish
- press accelerator pedal to 100% and release it to 0% - ONES
- wait 10 seconds
- turn ignition OFF, remove key and open drivers door (on cars with KeylessGO)
- wait 30 seconds
now adaptations values cleared and NOx sensors teached in.
Now reset starts count:
- turn ignition ON (do not start motor) - now you have 20 seconds to finish
- in a 5 seconds TWICE press accelerator pedal to 100% and release it to 0%
- wait 10 seconds
- turn ignition OFF, remove key and open drivers door (on cars with KeylessGO)
- wait 30 seconds

you can do step 3 again and again any time in future. In case, that for some unknown reason
ocassionally you will have DEF message or check-engine light for AdBlue system- just do step 3
one more time at your next car stop and it will work again.

IMPORTANT: on very old (2012 and older) CDI control unit firmware AdBlue message reset is
not supported by CDI control unit. You can't reset it even with StartDiagnose online. Nevertheless
when your starts count will down to 0 (or to 0 km on EU cars) and motor start is not possible
anymore - step 3 will let you to make 5 more starts (800more km for EU cars).

normally after bypass installation on cars/vans with old firmware it become possible to reset after
50-200 miles driving, but we strongly recommend you to update CDI control unit to new firmware
at dealer site or MB garage people.

IMPORTANT2: in case, that you decide not to connect bypass Chassis-Can-bus wires - all above
statrt-up procedures are not possible. In order to make initial startup with only Sensor-Can
connected - you have to reset starts count as well as adblue and NOx adaptations using
StarDiagnose equipment at MB garage.

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 Settings
by delivery module has following default settings:

- NOx algo => number 1

- AdBlue injection simulation => OFF
- Dosing algorithm => CR60 CDI
(Dosing algorithm will work only when you turn AdBlue injection simulation to ON)

default settings tested on hundreds of Bluetec cars and works very good. AdBlue injection
simulation ON is only necessary to let CDI module to pass OBDII NOx I/M monitor for emission
test - then you can turn if OFF permanently. OBDII NOx I/M monitor = Ready is only necessary at
countries where emission test is done by OBDII algorithm - no other benefits. Ones passed NOx
monitor will stay Ready till next DTC clear by diagnostics.

you only can try to change NOx algo to number 2 or 0 if you have problems with simulated NOx
sensors - no other reasons.

How to change settings

IMPORTANT: changing setting is only possible within first 20 seconds after ignition set to ON

1. turn ignition key off for 10 seconds

2. turn ignition ON - now you have 20 seconds to finish settings
3. within 5 seconds, several times (see table) fully press then release accelerator pedal after that
please wait 10 seconds (10 seconds is important)

1x time: reset CDI control unit NOx and AdBlue adaptation values and clear stored DTC
2 times: reset AdBlue/DEF limited mileage/starts count and clear all stored DTC
5 times: permanently turn AdBlue injection simulation ON
6 times: permanently turn AdBlue injection simulation OFF - default settings
7 times: permanently change NOx algo to number 1 - default settings
8 times: permanently change NOx algo to number 2 -
9 times: permanently change NOx algo to number 0
3 times: Dosing algorithm CR6 CDI control unit (only when AdBlue sim is ON)
4 times: Dosing algorithm CR60 CDI control unit (only when AdBlue sim is ON)
10 times: linear Dosing algorithm (only when AdBlue sim is ON)

4. do not forget to wait 10 seconds after you finished to pressing/releasing pedal

5. turn ignition OFF

if you are not sure - start again with step 1, all permanent setting will be stored at device permanent
memory

note: for professionals it is possible to make very fine tuning of about 25 more settings, but this is
only possible from UDS-type diagnostics (Vediamo software with StarDiagnose mux or any UDS-
protocol capable software and hardware)

End of a manual (see additional information below)

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SCR module location W164/X164/X166

SCR module location W166

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 SCR module location W212/W221

SCR module location W906 (Sprinter w/AdBlue)

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SCR module location W463 (G-class MY2013->)

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 6-wire (both Chassis and Sensor Can bus) bypass
connection location at W166

6-wire (both Chassis and Sensor Can bus) the best

location for bypass connection at Sprinter W906

on W906 connect Sensor-Can and power wires near

SCR module harness, then connect Chassis-can
wires to harness on picture above

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 6-wire (both Chassis and Sensor Can bus) bypass
connection location number 1 at Sprinter W906

Connection schematics of 4- wire connection at

W164/X166/W251
164124/164125/164824/164825/251124/251125/166024/166824 with code U42

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Schematics of 4- wire connection W212/W204
chassis 212024/204997 with code U42

Schematics of 4- wire connection at W906

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Schematics of 4- wire connection at Chassis 221183

Schematics of 4- wire connection at

W463

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NOx sensors fuse location W164/X164/W215 box F58

NOx sensors fuse location W166/X166 box F58

(except USA-spec cars as of 08/2012)

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 NOx sensors fuse location W212 box N10/1

NOx sensors fuse location W463 box F58

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NOx sensors can-connectors location W906 (no fuse on that chassis - you have to
remove two can-connectors from X30/41)

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NOx sensors can-connectors location W221 (no separate fuse on that chassis -
you have to remove two can-connectors from X30/38)

NOx sensors can-connectors location W/X166 (you can remove two can-
connectors from X30/38 on US-spec cars as of 08/2012)

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 StarDiagnose Xentry settings
1. before installation: SCR module Resetting calculated AdBlue tank level

2. before installation: CDI60 module Reset Starts limit

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3. after installation: CDI60 module NOx sensors teach-in

4. after installation: CDI60 module Start DPF regen cycle (it will actually starts next driving cycle)

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5. Make SCN coding of CDI module. This will store new SCN/CVN numbers to modern ECU
this step is not necessary in most cases on cars produced before MY2014

StarDiagnose DAS software settings

1. before installation: SCR module Resetting calculated AdBlue tank level

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2. before installation: CDI60 module Reset Starts limit

3. after installation: CDI60 module NOx sensors teach-in

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4. after installation: CDI60 module Start DPF regen cycle (it will actually starts next driving cycle)

5. Make SCN coding of CDI module. This will store new SCN/CVN numbers to modern ECU
this step is not necessary in most cases on cars produced before MY2014

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