Engine May Overheat and Shutdown – 2017-2020 Prevost X3-45 Coach, Commuter, VIP, & VIP Entertainer Buses, & H3-45 Coach & VIP Buses

July 31, 2019 NHTSA CAMPAIGN NUMBER: 19V565000

Engine May Overheat and Shutdown

If the engine unexpectedly shuts down, passengers may have to be transferred to another vehicle on the side of the road, increasing the risk of an injury. If the engine unexpectedly shuts down while the vehicle is in motion, there is an increased risk of crash.

 

NHTSA Campaign Number: 19V565

Manufacturer Prevost Cars, Inc.

Components ENGINE

Potential Number of Units Affected 1,440

 

Summary

Prevost Cars, Inc. (Prevost) is recalling certain 2017-2020 X3-45 Coach, Commuter, VIP, and VIP Entertainer buses, and H3-45 Coach and VIP buses. Under certain conditions, such as high altitude and heavy climbing, the engine may overheat and shutdown.

 

Remedy

Prevost will notify owners and will update the engine software, free of charge. The Prevost issued owners an interim notification on September 27, 2019. The recall began December 19, 2019. Owners may contact Prevost customer service at 1-866-870-2046.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Prevost Technical Publications

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SAFETY RECALL

SR19-31

DATE: December 2019	SECTION: 01  ENGINE
SUBJECT:	ENGINE CONTROL MODULE (ECM) SOFTWARE UPDATE – Engine Cooling Strategy in High Altitude Operation

 

First Release 12-13-20

 

APPLICATION

IMPORTANT NOTICE TO SERVICE CENTERS Verify vehicle eligibility by checking warranty bulletin status with SAP or via ONLINE WARRANTY SYSTEM available on Parts and Service / Warranty tab of Prevost’s website.
Model	VIN
X3-45 VIP motorhomes  Model Year: 2017 & 2019	2PCBS349XHC7                                2PCBS3499KC7
X3-45 VIP commercial use  Model Year: 2017 – 2020	Specific vehicles within the following range From 2PCCS3498HC73 up to 2PCCS3492LC7   incl.
X3-45 coaches  Model Year: 2017 – 2020	Specific vehicles within the following range From 2PCG33491HC7 incl. From 4RKG33494J97 incl. and 2PCS33496JC7
X3-45 Commuter  Model Year: 2019	2PCJ33491KC7
H3-41, H3-45 coaches  Model Year: 2018 – 2020	Specific vehicles within the following range From 2PCH33493JC7  up to 2PCH33494LC7  incl.
H3-45 VIP motorhomes  Model Year: 2019 – 2020	2PCVS3498KC 2PCVS3494KC 2PCVS3491KC7 2PCVS3497LC 2PCVS349XKC
This Safety Recall does not necessarily apply to all the above-mentioned vehicles, some vehicles may have been modified before delivery. The owners of the vehicles affected by this recall will be advised by a letter indicating the Vehicle Identification Number (VIN) of each vehicle concerned.

 

PART 1 – ENGINE SOFTWARE UPDATE

DESCRIPTION – PART 1

Part 1 of this safety recall applies to all the vehicles listed in the application table of the front page on which a notification identified SR19-31: PART 1- ENGINE SOFTWARE UPDATE exists.

On determined vehicles equipped with Green House Gas 17 (GHG17) or OBD18 Volvo D13 engine, perform the latest software update of the Engine Control Module.

Please contact your nearest Prevost Service Center or Prevost service manager and schedule an appointment to have the required software update applied.

 

SOFTWARE TOOL NEEDED

Description

Latest version of Premium Tech Tool (PTT) with appropriate communication interface equipment

 

PROCEDURE

DANGER

Park vehicle safely, apply parking brake, stop the engine.

Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to your local procedure for detailed information regarding the control of hazardous energy.

1. Connect the vehicle’s battery charger to a 120-Volt outlet.
2. Connect Premium Tech Tool (PTT) to the vehicle On-Board Diagnostics connector (OBD). Connect the PC to a functional LAN or Wi-Fi connection and a power source.
3. Turn the ignition switch to “ON”. Activate the hazard warning flashers to prevent the vehicle from entering sleep mode.
4. Log in to PTT.
5. On Product tab (item A), identify the vehicle (item B).
6. Select Program tab and then 1700-08-03-39 Program Electronic Control Unit. Click Start.

7. Select ENGINE CONTROL MODULE (EMS).
8. Select the following programming option ‘’Update Electronic Control Unit with latest software’’.
9. Click Program
10. Certain conditions must be met to allow programing:
    1. battery voltage above 10 Volts;
    2. parking brake applied;
    3. ignition key in ON position and the engine is not running.

When all conditions have been met, click Continue to proceed with programming.

11. Wait until all Programming Steps check turn to green color (Programming completed).
12. When the programing is complete, click Exit button.
13. Clear any diagnostic trouble codes (DTC).
14. Enter the Work Order Number information and then click Start Work.

 

WARRANTY – PART 1

Part 1 of this safety recall is covered by Prevost’s normal warranty. We will reimburse 1/2 hour (0.5) of labor upon receipt of a warranty claim. Please submit claims via our Online Warranty System, available at www.prevostcar.com (under Service \ Warranty section). Use Claim Type:  “Bulletin/Recall” and select ‘’Warranty Bulletin SR19-31”.

 

OTHER

VBC Bulletin	N/A
Fail Code	01.00-2
Defect Code	49
Syst. Cond	R
Causal Part	3092091

 

Access all our Service Bulletins on https://techpub.prevostcar.com/en/ or scan the QR-Code with your smart phone.

Are you a vehicle owner? E-mail us at technicalpublications_prev@volvo.com and type “ADD” in the subject to receive warranty bulletins applicable to your vehicle(s) by e-mail.

 

PART 2 – CYLINDER LINER AND PISTON REPLACEMENT

DESCRIPTION – PART 2

PART 2 of this safety recall applies only to the vehicles listed in the application table of the front page on which a notification identified SR19-312*: PART 2- LINERS & PISTONS REPLAC exists. These vehicle mileage equals or exceeds 100 000 miles (160 000 km) at the launch of this campaign.

* SR19-312 stands for SR19-31Part2

 

IMPORTANT NOTICE TO SERVICE CENTERS

Verify vehicle eligibility by checking warranty bulletin status with SAP or via ONLINE WARRANTY SYSTEM available on Parts and Service / Warranty tab of Prevost’s website.

 

On determined vehicles equipped with Green House Gas 17 (GHG17) or OBD18 Volvo D13 engine, perform the replacement of the liner and piston of all six (6) cylinders.

Refer to Impact for the procedures, torque and good practice guidelines.

 

Suggested procedures:

ID 2171-03-02-01 Oil Pan, Replacement

ID 2131-03-03-01 Cylinder Liners and Pistons, Replacement (All)

ID 2111-03-03-03 Cylinder Head, Replacement

 

Other procedures found on Impact that may be useful:

2515-03-03-02 Exhaust Manifold, Replacement

2115-03-03-01 Sealing Strip, Valve Cover, Replacement

2373-08-03-04 Common Rail, Fuel Leak Test

 

Kit SR19-31 includes the following parts:

#	STEP	DESCRIPTION	PART NO	QTY
OIL PAN		Use the following Impact procedure for reference: 2171-03-02-01 Oil Pan, Replacement
1	3	oil pan seal	21293367	1
2		gasket, magnetic plug	20579690	1
LINERS &  PISTONS		Use the following Impact procedure for reference: 2131-03-03-01 Cylinder Liners and Pistons, Replacement (All)
3	6	cylinder liner kit (for 6 cylinders)	22724238 or 23775630	1
		or cylinder liner kit (for 1 cylinder)	22565407	6
4	23	bolt, piston jet	994445	6
5	25	fastener, stiffening frame	969445	24
6	25	gasket, oil pickup tube	22275838	2
7	25	fastener, oil pickup tube	994451	3
8	25	sealing ring, oil circuit, pipe on stiffening frame	21092243	4
CYLINDER  HEAD		Use the following Impact procedure for reference: 2111-03-03-03 Cylinder Head, Replacement
9	187	gasket, cylinder head	21510072	1
10	196	screw, cylinder head	21345131	38
11	209	seal, engine brake control valve	20526428	1
12	227	screw, sensor wheel	8192804	8
13	236	O-ring, injector kit (upper grove O-ring violet)	276948	6
14	241	screw, injector	21344774	6
15	268	pressure pipe, common rail	23000880	1
16	270	pressure pipe, common rail right	23000879	3
17	268	pressure pipe, common rail left	23000870	3
18	281	gasket, timing gear cover	21447682	1
19	295	O-ring, impulse sensor cam speed sensor	20966752	1
20	301	pipe, Volvo engine brake	22782247	1
21	339	gasket, valve cover & spacer	22777560	2
22	350	seal, thermostat	21503575	1
23	350	seal, thermostat I-Shift	975675	2
24	356	gasket, water manifold	21298915	1
25		sealing ring, water manifold	1547254	2

 

#	STEP	DESCRIPTION	PART NO	QTY
26	365	plane gasket, starter element, mixing camber	3979639	2
27	381	gasket, EGR valve	20850815	1
28	381	sealing ring, EGR valve	20841816	2
29	383	screw & sleeve, EGR valve	21528673	4
30	385	O-ring, EGR valve oil return hose	976014	1
31	385	seal/gasket, EGR valve oil supply hose	976014	1
32		O-ring, EGR coolant return pipe	1547253	2
33	389	V-clamp, EGR valve	20755169	2
34	392	seal, oil return pipe	21940615	1
35	395	turbocharger installation kit	85137676	1
36		seal, banjo coolant turbo act supply	947281	2
37		sealing ring,  rubber (use as required)	1547252	1
38		sealing ring, banjo fitting (use as required)	20852765	2
39		V-clamp EGR crossover hot side	20504408	2
40		O-ring EGR crossover hot side	967343	2
41		V-clamp turbo to CAC pipe interface	20592787	1
42		O-ring, V-clamp turbo to CAC pipe interface	21096684	1
43		seal, transmission dipstick	571662	1
44		straight coupling, EGR crossover pipe	22889034	1

 

OTHER PARTS

#	STEP	DESCRIPTION	PART NO	QTY
45		V-clamp, on Prevost exhaust pipe at flexible & at DPF	21021850	3
46		seal ring, on Prevost exhaust pipe at flexible & at DPF	21095726	3
47		oil filter, bypass	21707132	1
48		oil filter, long life	21707133	2
49		cable tie, nylon BLK (STD)	504637	30
50		cable tie, nylon (50 POUNDS)DOUBLE LOOP	507664	20
51		cable tie, nylon	G5007996	40
52		V-clamp, turbo outlet diffuser interface with Prevost pipe	21060426	1
53		gasket, turbo outlet diffuser interface with Prevost pipe	21095721	1
54		gasket, inlet elbow interface with mixing box	1675066	1
55		V-clamp inlet elbow interface with mixing box	20592783	1

 

NOTE

Material can be obtained through regular channels.

 

PART DISPOSITION

DO NOT RETURN THE REPLACED PARTS. Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

 

WARRANTY – PART 2

This modification is covered by Prevost’s normal warranty.  We will reimburse you the parts and up to 50 hours of labor upon receipt of a completed A.F.A. Please submit claim via our Online Warranty System, available at www.prevostcar.com (under service \ warranty section). Use Claim Type:  “Bulletin/Recall” and select ‘’Safety Recall SR19-31 “.

Should you only wish to close the safety recall (without reimbursement), fill-in the ‘’Safety Recall Certification Sheet’’ provided with this bulletin and return it to our warranty department by email at prevost.onlinewarranty@volvo.com or by fax at 418-831-9301.

 

OTHER 

VBC Bulletin	N/A
Fail Code	01.00-2
Defect Code	09
Syst.Cond	R
Causal Part	22724238

 

Access all our Service Bulletins on https://techpub.prevostcar.com/en/ or scan the QR-Code with your smart phone.

E-mail us at technicalpublications_prev@volvo.com and type “ADD” in the subject to receive our warranty bulletins by e-mail.

 

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IMPORTANT SAFETY RECALL
NHTSA RECALL #19V-565
December 2019

CUSTOMER
ADD
CITY, ST  ZIP
US

 

SAFETY DEFECT / NONCOMPLIANCE NOTICE

PREVOST SAFETY RECALL SR19-31

 

Dear Customer,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act and 49 CFR Part 573.

Prevost Car US Inc. has decided that a defect which relates to motor vehicle safety exists on certain Prevost vehicles as listed below.

• H3-45, model years 2018 through 2020;
• H3-45 VIP model year 2019 & 2020;
• X3-45, model years 2018 through 2020;
• X3-45 VIP Commercial Use, model years 2017 through 2020;  X3-45 VIP Private Use, model years 2017 & 2019.

According to our records, you are the registered owner of the following vehicles involved in safety recall SR19-31 PART 1 “Engine Control Module (ECM) Software Update”:

VIN

DEFECT DESCRIPTION

Under certain high-altitude and heavy load conditions, the engine could overheat.

 

FAILURE CONSEQUENCE

This could cause a disabled vehicle. Disabled vehicle may lead to transferring passengers on the side of the road, which may increase the risk of a passenger death or injury. Prevost has not received report of death or injury associated with this defect. Therefore, we consider this as a proactive measure to protect the public from the potential risk associated with this defect.

 

WHAT YOU NEED TO DO

Please make an appointment to your nearest Prevost Service Center and refer to PART 1 of SR19-31 to receive an engine software update that will improve the cooling system strategy. This update is available and can already be uploaded into your vehicle.

Optionally, you may have the work performed by qualified personnel of your choice, following PART 1 of Safety Recall SR19-31 available on Prevost Technical Publications web site at this address: https://techpub.prevostcar.com/en/

Prevost will reimburse you the labor as described in the SR19-31 procedure. Please file an online warranty claim following normal campaign procedures if you are a registered customer, otherwise, contact the Prevost Warranty Department at 1-866870-2046 for reimbursement instructions.

The time required to perform the software update on your vehicle is ½ hour (0.5 h).

 

OTHER REPAIR – PART 2 OF SAFETY RECALL SR19-31

PART 2 of safety recall SR19-31 applies to the vehicles having a mileage greater than 100 000 miles (160 000 km) at the launch of this campaign. In addition to the engine software update covered by PART 1 of SR19-31, the replacement of the cylinder liners and pistons will be carried out on these vehicles, free of charge.

If applicable, you will find the list of vehicles involved in SR19-31 PART 2 “Cylinder Liners & Pistons Replacement” appended to this notice letter.

The estimated time required to perform PART 2 of this campaign is 50 hours.

 

The parts required to perform SR19-31 PART 2 will be available from mid-February 2020. Please make an appointment to your nearest Prevost Service Center from midFebruary to have the hardware replacement performed on your vehicle.

 

NOTICE REGARDING LEASED VEHICLES

If you are a vehicle lessor, Federal Law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten working days.

 

CHANGE OF ADDRESS OR OWNERSHIP

If your address has changed, or you no longer own the vehicle(s), please help us update our records. Accessing the Prevost Warranty Support web page https://www.prevostcar.com/parts-and-services/warranty , fill-in the form ‘Change of address or ownership’, and email it to prevost.onlinewarranty@volvo.com.

 

ASSISTANCE

If you need assistance, please contact your nearest Prevost Service Center. You will find the Prevost Parts & Service Centers location at this address: https://www.prevostcar.com/contact-us/prevost-service-centers

 

COMPLAINTS

If you believe that Prevost Car US has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll-free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1800-424-9153), or go to https://www.safercar.gov.

We regret any inconvenience this may cause to your operation, but hope you will appreciate our sincere efforts to demonstrate Prevost’s commitment to provide our customers with the best possible product.

Truly yours,

Prevost Service Team

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CUSTOMER
ADDRESS BLOCK

 

APPENDIX

List of vehicles involved in SR19-31 PART 2 “Cylinder Liners & Pistons Replacement”

 

PART 2 of safety recall SR19-31 applies to the vehicles having a mileage greater than 100 000 miles (160 000 km) at the launch of this campaign.

According to our records, you are the registered owner of the following vehicles involved in PART 2 of safety recall SR19-31:

VIN  XXXXXX Miles

 

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IMPORTANT SAFETY RECALL

NHTSA RECALL #19V-565 September 2019

 

INTERIM NOTICE

We are currently preparing the remedy. We will notify you again when the remedy is ready.

 

«customer»
«add» «po»
«city», «st»  «zip»
«pays»

 

SAFETY DEFECT / NONCOMPLIANCE INTERIM NOTICE

PREVOST SAFETY RECALL SR19-31

 

Dear Customer,

This interim notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act and 49 CFR Part 573.

Prevost Car US Inc. has decided that a defect which relates to motor vehicle safety exists on certain Prevost vehicles as listed below.

• H3-45, model years 2018 through 2020;
• H3-45 VIP model year 2019;
• X3-45, model years 2018 through 2020;
• X3-45 VIP Commercial Use, model years 2017 through 2019;
• X3-45 VIP Private Use, model years 2017 & 2019.

According to our records, you are the registered owner of the following vehicles involved in safety recall SR19-31:

 

DEFECT DESCRIPTION

Under certain high-altitude and heavy load conditions, the engine could overheat.

 

FAILURE CONSEQUENCE

This could cause a disabled vehicle.  Disabled vehicle may lead to transferring passengers on the side of the road, which may increase the risk of a passenger death or injury. Prevost has not received report of death or injury associated with this defect. Therefore, we consider this as a proactive measure to protect the public from the potential risk associated with this defect.

 

WHAT YOU NEED TO DO

We appreciate your patience while we are preparing the remedy. You will receive a second owner notification when the solution is available. There may be warnings or indicators that this condition exists. These warnings will typically be due to fault codes triggered for engine coolant over temperature condition or engine coolant level low.

 

NOTICE REGARDING LEASED VEHICLES

If you are a vehicle lessor, Federal Law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 

CHANGE OF ADDRESS OR OWNERSHIP

If your address has changed, or you no longer own the vehicle(s), please help us update our records. Accessing the Prevost Warranty Support web page https://www.prevostcar.com/parts-and-services/warranty , fill-in the form ‘Change of address or ownership’, and email it to prevost.onlinewarranty@volvo.com.

 

ASSISTANCE

If you need assistance, please contact your nearest Prevost Service Center. You will find the Prevost Parts & Service Centers location at this address: https://www.prevostcar.com/contact-us/prevost-service-centers

 

COMPLAINTS

If you believe that Prevost Car US has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll-free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1800-424-9153), or go to https://www.safercar.gov.

We regret any inconvenience this may cause to your operation, but hope you will appreciate our sincere efforts to demonstrate Prevost’s commitment to provide our customers with the best possible product.

Truly yours,

Prevost Service Team

 

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8 Affected Products

Vehicles

MAKE	MODEL	YEAR
PREVOST	H3-45	2017-2020
PREVOST	X3-45	2017-2020

 

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8 Associated Documents

Recall Quarterly Report #1, 2019-4

RCLQRT-19V565-7928.PDF 211.127KB

 

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Recall Quarterly Report #2, 2020-1

RCLQRT-19V565-2824.PDF 211.232KB

 

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Recall Acknowledgement

RCAK-19V565-2178.pdf 244.928KB

 

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Defect Notice 573 Report

RCLRPT-19V565-5391.PDF 213.645KB

 

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-19V565-4672.pdf 207.882KB

 

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Recall 573 Report- Amendment 4

RCLRPT-19V565-1359.PDF 213.655KB

 

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Remedy Instructions and TSB

RCRIT-19V565-8812.pdf 616.566KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V565-3443.pdf 749.285KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V565&docType=RCL

 

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Heavy Duty Truck Reprogramming

Description:

Designed for flexibility, the USB-Link 3 Wired Edition connects to your PC, tablet, or smartphone with a USB cable, allowing techs to directly connect to a device when working in the field or during signal interruptions.

Built to support the latest protocols (CAN FD, DoIP) and compatible with a wide range of OEM diagnostics software, the USB-Link 3 is our most advanced VCI to date, with the performance and technology you can rely on well into the future.

 

The USB-Link™ 3 comes with the following:

• Latching USB Cable (PN 404032)

• 9-Pin Deutsch Adapter, 1 Meter (PN 493128)

• J1962 Adapter (16-Pin OBD II, 1 Meter (PN 491113)

The USB-Link™ 3: Wireless is also available (PN 121052).

 

Specifications
Vehicle Network Protocol Support
CAN FD / J1939 FD / ISO15765 FD - 250K, 500K, 1M b/s with auto baud detection
Single wire CAN (SWCAN)
ISO 11898-3 Fault Tolerant CAN (FTCAN)
Diagnostics Over Internet Protocol (DoIP)
J1708
J1850 VPW (Class 2)
ISO PWM (SCP)
ISO 9141 / KWP2000 (ISO 14230) K/L line
ALDL 9600 and 8192 baud
ATEC 160 baud

Windows® Vehicle Communication API
Windows® Vehicle Communication API
RP1210 a/b/c
J2534 (2004 draft)
J2534-1 partial implementation (commercial vehicle focused)

Operating System Compatibility
iOS
Android™
Windows® 10, 11

Interfaces to Computing Platforms
USB 2.0 (vehicle-to-PC connectivity)
Bluetooth® 2.1 + EDR
Wi-Fi (dual band)

Compatible Software
Detroit Diesel Diagnostic Link
CAT Electronic Technician (On-Highway only)
Cummins Insite
International - ServiceMAXX Fleet Pro
Hino eXplorer
Volvo PTT
VCAD Elite Mack/Volvo
V-MAC Service Tools
Allison DOC® For PC-Service Tool - Protocols Supported: J1939, J1708/J1587, and J1850
Allison DOC® For Fleets (1000/2000) - Protocols Supported: J1939, J1850
Allison DOC® For Fleets (3000/4000) - Protocols Supported: J1939, J1708/J1587
Eaton ServiceRanger
Bendix ACom
WABCO Toolbox
Freightliner ServiceLink
International ABS
International DLB
International Intune
International IPC v2.02
PACCAR DAVIE4

 

121052

121054

 

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Daimler Truck

DiagnosticLink Order Site:

DiagnosticLink Direct Link:

https://diagnosticlink.nexiq.com/DTNA/Default.aspx

 

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