Reliability Driven-

Service Bulletin No. 410
TYPE

D Series

I

SECTION/GROUP

Field Change Program

I

OATE

I June 4, 2014

8-Engine

SUBJECT

DIESEL EXHAUST FLUID PRESSURE LINE HEAT SHIELD
CONDITIONS

Customer Complaint:
Motor Coach Industries {"MCI") has become aware that the diesel exhaust fluid ( DEF ) pressure line may
exhibit signs of fatigue and melting . The addition of a heat shield installed over the DEF pressure line routed
from the dosing module to the pump will reduce the potential of premature fatigue and melting .

Cayse:
The failure is due to elevated heat from the exhaust system.

Correctjye Actjon:
MCI strongly encourages owners of the D series coaches listed in the table below to implement the steps in this
procedure as soon as possible .

59742

59764 to 59789

59829 to 59845

59861 to 59894

59896 to 59906

59923

59989 to 59992

12604 to 12741

12743 to 12755

12757 to 12847

12901 to 12962

Qty.

New P/N

Description

26-08-0023

Kit, Heat Sleeve, D Coach
Kit contents are:

2

08-20-2458

Heat Shield, Reflectsleeve, 1450E

08-20-2459

Tie Straps, SST

10

19-4-47

ai r

T08-1281

Clamp ( utilized quantity to vary per coach installation )
Clip, Spring Clip Connector, DEF Hose

•

Service Bulletin No. 410

Reliability Driven·

Date June 4, 2014

Page 2

Service Procedure:

Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.

To avoid personal injury, never enter or perform work in the engine compartment prior to
positioning the ENGINE RUN and ENGINE START switches on the engine compartment remote
control box to the OFF position. Allow enough time for components to cool down prior to
working in the engine compartment.

1. Position coach to utilize a lift to access the diesel exhaust fluid ( DEF ) pressure line mounting hardware.
2. Turn the main battery disconnect switch to the OFF position.

&w
Before lifting the coach, exhaust the tag axle air springs. The tag axle must not hang
unsupported on the shock absorbers.
Raise coach to the desired height. Position jackstands at the front and rear frame support
points, according to Figure 1, to ensure that the coach is securely supported before attempting
work underneath the coach.
Position additional jackstands under the tag axle for support.

A

REFER TO MANUAL

Refer to Section 3F I Lifting and Towing, in the D Series Maintenance Manual for the basic rules,
procedures and safety precautions that must be followed before a coach is lifted.

II
Reliability Driven·

Service Bulletin No. 410
Date June 4, 2014

Page 3

Figure 1. Underframe jackstand support points ( Section 3G I Maintenance Manual )

3. Enter the coach cabin and locate the engine compartment access hatch cover at the rear of the cab in.
Remove and retain the hardware. Carefully lift the hatch cover and place aside to be re-installed at a later
step in this procedure.
4. Open the engine compartment doors as well as the curbside , rear side service compartment door.
5. Locate the diesel exhaust fluid (DEF) pressure line in the rear, roadside section of the engine compartment
( refer to Figures 2 and 3 ).

II

Service Bulletin No. 410
Date June 4, 2014

Reliability Driven·

Page4

Figure 2.

&CAUTION
To avoid internal damage to the connector, do not pry off the spring-Jock connector from the
dosing module.
6. Follow the routing of the DEF pressure line to locate the connection at the dosing module ( refer to
Figure 3 ). Apply pressure to the button on the spring-lock connector located at the end of the DEF
pressure line to release the line from the dosing module .
7. Cover the open end of the DEF pressure line as well as the doser connector to prevent contaminants
from entering the system .

Figure 3.

II

Service Bulletin No. 410
Date June 4, 2014

Reliability Driven·

Page 5

8. Follow the routing of the DEF pressure line in the engine compartment and locate the line support clamps
mounted to the engine rail ( refer to Figure 4 and 5 ). Remove and retain the two ( 2 ) line support clamps
and mounting hardware shown in Figures 4 and 5.

Figure 4.

Figure 5.
9. Follow the routing of the DEF pressure line in the engine compartment and locate the line support clamps
utilized from the dosing module to the rear bulkhead. Remove the remaining line support clamps and
mounting hardware. Retain the hardware and discard the clamps .

II

Reliability Driven·

Service Bulletin No. 410
Date June 4, 2014

Page 6

1O. Enter the coach cabin and locate the DEF pressure line routing and line support clamps below the engine
compartment access hatch . Remove the line support clamps mounting hardware. Retain the hardware and
discard the clamps.
11 . Orient one end of the heat shield , p/n 08-20-2458, over the disconnected end of the DEF pressure line ( at
the dosing module). Carefully route the heat shield over the line all the way back to the rear bulkhead.

Figure 6. View of the DEF pressure line at the rear bulkhead from the curbside,
rear side service compartment

&CAUTION
Visually check the open end of the DEF pressure line to ensure that no dirt or debris enter the
system.
12. Remove the cover from the disconnected end of the DEF pressure line and the doser connector. Visually
inspect the spring-lock connector located at the end of the DEF pressure line. If the clip on the spring-lock
connector is damaged , replace damaged clip with p/n T08-1281 . Orient and install the DEF pressure line on
the dosing module .

•

Service Bulletin No. 410
Date June 4, 2014

Reliability Driven·

Page 7

NOTICE
To ensure proper installation, install the tie strap at the ends of the heat shield.
13. Orient and install the tie strap, p/n 08-20-2459, over the heat shield at the dosing module ( refer to
Figure 7 ). Carefully pull the tie strap to secure, ensuring no damage to the hose body. Cut the excess
tai l. Install another tie strap on the opposite end of the DEF pressure line at the rear bulkhead.

Figure 7. Reference photo.
14. Using the existing mounting hardware removed in Step 8 of this procedure, re-install the engine cradle line
support clamp . Tighten to secure .

NOTICE
To prevent damage to the DEF pressure line, do not re-use the existing line support clamps
(other than the engine rail location).
15. Secure the DEF pressure line along its routing in the engine compartment using the existing mounting
hardware and the new line support clamp , p/n 19-4-47. Tighten to secure.
16. Re-install the engine compartment access hatch cover.
17. Close the engine compartment doors and the curbside , rear side service compartment doors.
Procedure Complete.

!

II

Service Bulletin No. 410
Date June 4, 2014

Reliability Driven·

Page 8

Mail or fax the completed limited warranty claim form and verification form to MCI's warranty department, or photocopy and mail to :
MCI Fleet Support
Attn : Warranty Department
7001 Universal Coach Drive
Louisville, KY 40258
Fax Number 1-800-360-8886

to receive credit for the hours used to complete th is task. Contact the MCI Fleet Support Technical Center at
1-800-241-2947 for any further information .

Field Change Program Conditions:
The parts required for this change will be suppl ied without charge .
A labor allowance of 1.2 hours will be granted for the procedure of installing the specified part(s) in this bulletin on
D Series coaches .
Th is labor allowance will be credited to your MCI Fleet Support Parts Account on receipt of the attached
"MCI Field Change Program Verification Form" and a "Warranty Claim Form" as detailed in your Owner Warranty
manual to MCI's Warranty department. A "MCI Field Change Program Verification Form" needs to be submitted for
each VIN affected . Photocopy the attached "MCI Field Change Program Verification Form" as requ ired for the
number of affected coaches in your fleet.
This program will end on Dec. 19, 2014 .
Motor Coach apologizes for any inconvenience resulting from this campaign , but urges you to implement this
change as soon as possible.

Sincerely,
Motor Coach Industries