Reliability

Driven~

Service Bulletin No. 411
!

DATE

SECTION/GROUP

TYPE

J4500 Series

Field Change Program

I

I June 6, 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 will
reduce the potential of premature fatigue and melting .

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

Correctjye Action:
MCI strongly encourages owners of the J4500 series coaches listed in the table below to implement the steps in
this procedure as soon as possible .

65758

65782 to 65783

65791 to 65792

65801 to 65806

65877

65917 to 65919

65923

65956 to 66007

66009 to 66031

66033 to 66073

66075 to 66077

66079 to 66081

66083 to 66084

66086

66088 to 66131

66134 to 66146

66148 to 66178

66185 to 66186

66189 to 66194

66201

66208

66211 to 66221

66225 to 66238

66241 to 66278

66284 to 66294

66301 to 66304

66308

66311 to 66317

66320 to 66341

66349 to 66381

66383 to 66408

66410 to 66412

66417 to 66428

66440

66443 to 66444

66447

66454 to 66459

66461 to 66502

66510

66524 to 66525

66530

66535 to 66539

66542 to 66578

66580 to 66608

66610 to 66647

66649 to 66697

66704

66725 to 66734

66739 to 66758

66763 to 66785

66789 to 66790

66793 to 66805

66808 to 66815

66823 to 66848

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Service Bulletin No. 411
Date June 6, 2014

Reliability Driven·

Page 2

Parts
Qty.

Old PIN

New PIN

Description

26-08-0024

Kit, Heat Sleeve, J4500 Coach
Kit contents are:

1

08-20-2458

Heat Shield, Reflectsleeve , 1450E

2
1

08-20-2459

Tie Straps, SST

19-1-1072

Caps crew

1

19-2-25

Washer, Lock

19-2-57

Washer, Fender

19-3-19

Nut, Hex

1

6

19-4-47
T08-1281

ai r

Clamp, Line Support
Clip , Spring Clip Connector, DEF Hose

19-11-258

Tyrap

19-04-0440

Clamp, CAC Hose, T Bolt

Service Procedure :

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

G
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. Turn the main battery disconnect switch to the OFF position .
2. Chock both sides of the tires .
3. Open the engine compartment door.

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Service Bulletin No. 411
Date June 6, 2014

Reliability Driven·

Page 3

NOTICE
Positioned in front of the engine compartment, visually inspect the DEF pressure line loom
for signs of melting and/or heat related damage in the area of the turbo heat shield (refer to
Figures 1 and 2 ).
Visually inspect to ensure that the turbo heat shield is in place.

Figure 1. Inspection location.

Description

Item

1

Turbo heat shield

2

Visually inspect this section of the DEF pressure line on both sides of the turbo heat shield.

Figure 2. Damaged loom.

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RellobHi!y Driven·

Service Bulletin No. 411
Date June 6, 2014

Page 4

NOTICE

If the loom has signs of melting and/or heat related damage as shown in Figure 2, or the turbo
heat shield is missing, contact the MCI Fleet Support Technical Center at 1-800-241-2947 for
further information regarding replacement. Close the engine compartment door.

Do not proceed with Steps 4 to 16 as replacement of the DEF pressure line and/or the turbo heat
shield is required.
Procedure complete.

NOTICE
If the loom has no signs of melting and/or heat related damage and the turbo heat shield is in
place as shown in Figures 1 and 2, proceed to Step 4.

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Service Bulletin No. 411
Date June 6, 2014

Reliability Driven·

Page 5

4. In the engine compartment, locate the intake manifold tube . Loosen the t-bolt clamps on the hump
hoses. Remove the intake manifold tube and place aside to be re-installed at a later step in this
procedure ( refer to Figures 3 and 4 ). Cover the two ( 2 ) open exposed ends of the tubing ( refer to
Figure 4 ) to prevent contaminants from entering the system

Figure 3.

Figure 4.

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Reliability Driven·

Service Bulletin No. 411
Date June 6, 2014

Page 6

NOTICE
The dosing module connection, located behind the radiator, is accessed through the engine
compartment.

&CAUTION
To avoid internal damage to the connector, do not pry off the spring-lock connector from the
dosing module.
5. Locate the connection of the DEF pressure line at the dosing module ( refer to Figure 5 ). Cut and remove
any tyraps from the DEF pressure line at the dosing module . Apply pressure to the button on the springlock connector located at the end of the DEF pressure line to release the line from the dosing module.

Figure 5. Reference photo of dosing module located behind the radiator.
6. Cover the open end of the DEF pressure line as well as the doser connector to prevent contaminants
from entering the system .

NOTICE
IF YOUR COACH IS EQUIPPED WITH AN EIGHTEEN ( 18) INCH LENGTH OF HEAT SHIELD AT THE DOSER
CONNECTOR, REMOVE AND DISCARD THE EIGHTEEN ( 18) INCH LENGTH OF HEAT SHIELD. PROCEED
TO STEP 7.

7. Locate the diesel exhaust fluid ( DEF ) pressure line in the rear, roadside section of the engine compartment
( refer to Figure 6 ).

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Service Bulletin No. 411
Date June 6, 2014

Reliability Driven·

Page 7

Figure 6. Reference photo of DEF pressure line routing.
8. 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 line support clamp ( downstream of the turbo heat shield ) shown in
Figure 7. Remove any tyraps, line support clamps and mounting hardware up to the location shown in
Figure 7. Do not remove the line support clamp shown in Figure 7. Retain the hardware and discard the
clamps.

Figure 7.

Description

Item
1

Turbo heat shield

2

Line support clamp. Do not remove clamp at this location.

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Service Bulletin No. 411
Date June 6, 2014

Page 8

NOTICE
To aid in the installation and routing of the heat shield over the DEF pressure line, an
electrician's fish wire can be utilized.
9. 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 past the turbo heat shield
to the line support clamp shown in Figure 7. Cut any excess heat shield that may interfere with the existing
line support clamp shown in Figure 7.

NOTICE
To ensure proper installation, install the tie strap at the ends of the heat shield.
10. Orient and install the tie strap, p/n 08-20-2459, over the heat shield and the DEF pressure line at the dosing
module location. Carefully pull the tie strap to secure, ensuring no damage to the hose body. Cut the
excess tail end. Install another tie strap on the opposite end of the DEF pressure line at the line support
clamp shown in Figure 7.

&CAUTION
Visually check the open end of the DEF pressure line to ensure that no dirt or debris enter the
system.
11 . 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. Positioned close to the dosing module, use a tyrap, p/n 19-11-258, to secure the dosing
module harness to the heat shield.

NOTICE
To prevent damage to the DEF pressure line, do not re-use the existing line support clamps.
12. Secure the DEF pressure line along its routing in the engine compartment using the existing mounting
hardware, new line support clamps, p/n 19-4-47. Tighten to secure.

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Service Bulletin No. 411
Date June 6, 2014

Reliability Driven·

Page 9

13. Remove and discard the self tapping screw mounting the p-clip to the after treatment support frame .( refer
to Figure 8 ).

Figure 8.
14. Using capscrew, p/n 19-1-1072, washers , p/n 19-2-25 and 19-2-57, and nut p/n 19-3-19, mount the clamp
to the after treatment support frame using the existing hole location .
15. Remove the covers from the two ( 2 ) open exposed ends of the tubing . Orient and re-install the intake
manifold tube . Torque the t-bolt clamps on the hump hoses to 90-110 in-lbs.
16. Close the engine compartment door.
Procedure Complete.

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Service Bulletin No. 411
Date June 6, 2014

Reliability Driven·

Page 10

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 this 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 supplied without charge.
A labor allowance of 2.0 hours will be granted for the procedure of installing the specified part(s) in this bulletin on
J4500 Series coaches.
Thi s 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 required 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 th is
change as soon as possible.

Sincerely,

Motor Coach Industries