LI09_41-N-079165_2_en

Complaint Low Coolant warning with possible engine misfire caused by a leaking Charge Air Cooler (Intercooler), accompanied by one or more of the following possible fault codes related to the coolant system: P30040B: Component 'Temperature sensor downstream of charge air cooler' has an open circuit or short circuit to positive. P25567B: Sensor 'Coolant level' has a malfunction. The fluid level is too low. Cause The potential causes for this topic are: A. A leak in the Coolant System, other than the Charge Air Cooler. B. An Internal leak of the Charge Air Cooler. C. An unapproved/aftermarket upfit or modification to the coolant system. Remedy A. A leak in the Coolant System, other than the Charge Air Cooler 1. Complete a coolant system pressure test:
•Refer to WIS Doc AR20.00‐D‐1011TS ‐ Check engine cooling system for leak tightness.
•Use Tester Cap 210 589 00 91 and Pressure Pump 124 589 24 21 00.
•Apply test pressure to the engine cooling system. Do not exceed the specified test pressure of 1.5 Bar to prevent damage to the engine cooling system.
•Perform a visual check on the top and bottom of the engine compartment and in the vehicle interior.
•If coolant loss or pressure loss is present, perform suitable repair measures depending on the vehicle equipment.
•If NO signs of coolant loss are found but pressure loss is present, proceed to Step B. B. An Internal leak of the Charge Air Cooler 1. Inspect the Charge Air Cooler for an internal leak:
•Remove either the Throttle Valve or Charge Air Temperature Sensor to inspect for coolant loss. See attachments for the failed Charge Air Cooler.
•If coolant is found inside the Charge Air Cooler:
•Perform a manual compression test to confirm the absence of internal engine failures per WIS Doc AR01.00‐D‐1201TSM ‐ Check compression pressure.
•Remove and clean any coolant present in the Charge Air System, Intake System, and Cylinders.
•Replace the Charge Air Cooler, the glow plugs, and then conduct an oil and filter change. Refer to AR09.41‐D‐6817TSM ‐ Remove/install charge air cooler.
•If coolant is not found inside the Charge Air Cooler, proceed to Step C. C. An unapproved/aftermarket upfit or modification to the coolant system 1. Inspect the Coolant system for any unapproved/aftermarket upfits or modifications:
•See the Attachments for examples of non‐approved upfits or modifications.
•Note: The OM654 cannot have any aftermarket modifications made to the coolant system per the Body and Equipment Guidelines (BEG) under 4.4.3 Engine Cooling, "Do not make modifications to the cooling system (cooler components, air ducting, hose, and other detachable parts that are part of the cooling system)".
•If there are modifications made to the coolant system that violate the BEG, do not complete any repairs on the system under warranty until either your Vans Aftersales Business Development Manager (VABDM) or facing Field Service Engineer (FSE) reviews the vehicle.