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11. Disconnect the intake air temperature/ pressure sensor
(fig.9). Remove all nylon cable ties and P-clamps.

FIGURE 9

12. Disconnect the following cold side middle harness
connections (fig.10). Remove P-clamps.
a) Crankcase Pressure Sensor
b) Oil Pressure Sensor
c) Aftertreatment Hydrocarbon Dosing Module
d) Aftertreatment Fuel Pressure Sensor

FIGURE 10
1) Aftertreatment Hydrocarbon Dosing Module
2) Aftertreatment Fuel Pressure Sensor
3) Oil Pressure Sensor
4) Crankcase Pressure Sensor

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13. Disconnect the harness from the engine oil
level/temperature sensor and water separator
connector on the cold side of the engine (fig.11).
Remove all nylon cable ties and P-clamps.

FIGURE 11
1) Fuel/Water Separator
2) Engine Oil Level/Temperature Sensor
3) Fuel Pressure Sensor

14. Disconnect the ECM and vehicle harness connections (fig.
12). Remove all nylon cable ties and P-clamps.

FIGURE 12
1) Vehicle Harness Connector
2) Engine Control Module (ECM) Connectors

15. Disconnect the ground connection from the block, fuel
pressure sensor connection (fig.11, item 3), and the
harness ground wire ring terminal from the block behind the
alternator. Remove all nylon cable ties and P-clamps.
16. Disconnect the harness from the data link connector. If
equipped, disconnect the preheater control wires. Remove
all nylon cable ties and P-clamps.
17. Remove the valve cover fasteners and remove the valve
cover from the engine.
18. Cover the valve mechanism and gear train as required, to

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prevent dirt and debris from entering the engine.

19. If equipped, cut the nylon cable tie securing the wiring
harness to the engine compression brake actuator (fig.
13).

FIGURE 13

20. Disconnect the harness from the engine injectors (fig. 14).

FIGURE 14

21. Disconnect the cylinder head pass through fastener.
Carefully remove the harness from the pass through (fig.
15).

FIGURE 15
1) Pass Through

22. Unscrew harness box fasteners. Remove the engine
harness from the engine.

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INSTALLATION
1. Install and secure the harness box and fasteners.
2. Carefully guide the harness into the pass through and
position it on the cylinder head. Route the connectors to
each of the unit injectors.
3. Connect the harness to the unit injectors (fig. 16). Push the
connector until a distinct “click” is heard to ensure the
connector is fully engaged.
4. Use high temperature cable ties #983472 to secure the
harness to the retainers #8131393 on the cylinder head.
Note: It is extremely important that the head of the
cable ties face downward to prevent contact with the
valve cover.

FIGURE 16

5. Clean the gasket sealing surface of the cylinder head. The
surfaces should be clear of any dirt or debris and free of
any oil.
Note: Remove any sealant from the joint between the
cylinder head and upper timing gear cover.
6. Remove the old rubber gasket from the valve cover
channel. Carefully place the new gasket #20538793 into
the channel, making sure that it’s properly seated and
follows the contour of the channel.
7. Apply a 2 mm (0.079 in) bead of sealant at the joint of the
timing cover and the cylinder head on both sides.

FIGURE 17

Note: The valve cover must be installed within 20
minutes of the application of the sealant.
8. Carefully position the valve cover on the cylinder head and
ensure that the seal remains properly seated.
9. Install the spring-loaded bolts in the valve cover.
Torque-tighten the valve cover bolts to 24 ± 4 Nm (18
± 3 ft-lb) in the sequence shown (fig. 18).

FIGURE 18

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10. Install the pass through fastener (fig. 19). Tighten the cap
screw to 24 Nm (18 ft-lb).

FIGURE 19
1) Pass Through

11. Connect the harness to the intake manifold air
temperature/pressure sensor on the intake manifold
(fig. 20). Install nylon cable ties and P-clamps as
necessary.

FIGURE 20

12. Connect the harness to the data link connection. If
equipped, connect the preheater control wires. Install
nylon cable ties and P-clamps as necessary.
13. Connect the harness to the fuel pressure sensor
(fig.22, item 3), ground connection to the block, and
the harness ground wire ring terminal to the block
behind the alternator. Install nylon cable ties and Pclamps as necessary.
14. Connect the harness to the ECM and vehicle harness
connections on the cold side of the engine (fig. 21).
Install nylon cable ties and P-clamps as necessary.
FIGURE 21
1) Vehicle Harness Connector
2) Engine Control Module (ECM) Connectors

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15. Connect
the
harness
to
the
engine
oil
level/temperature sensor and water separator
connector on the cold side of the engine (fig. 22).
Install nylon cable ties and P-clamps.

FIGURE 22
1) Fuel/Water Separator
2) Engine Oil Level/Temperature Sensor
3) Fuel Pressure Sensor

16. Connect the harness connections (fig. 23). When
applicable, secure harness with existing P-clamps.
a) Crankcase Pressure Sensor
b) Oil Pressure Sensor
c) Aftertreatment Hydrocarbon Dosing Module
d) Aftertreatment Fuel Pressure Sensor

FIGURE 23
1) Aftertreatment Hydrocarbon Dosing Module.
2) Aftertreatment Fuel Pressure Sensor.
3) Oil Pressure Sensor.
4) Crankcase Pressure Sensor.

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Put the rear section of the engine harness in place.
Connect the following rear engine harness connections
(fig. 24). Start to attach P-clamps.
a)
b)
c)

Exhaust Gas Recirculation (EGR) Valve
Camshaft Speed Sensor
Crankshaft Speed Sensor

FIGURE 24
1) Exhaust Gas Recirculation (EGR) Valve
2) Camshaft Position Sensor
3) Crankshaft Position Sensor

18.

In the rear junction box, connect the starter wires to
the starter relay solenoid terminals. Install nylon cable
ties as necessary.

FIGURE 25

19.

Connect the engine harness connections on the hot
side of the engine. Install nylon cable ties and Pclamps as necessary (fig. 26).
a)
b)
c)
d)
e)
f)
g)
h)

Turbine Shaft Speed Sensor
Engine Variable Geometry Turbocharger Actuator
EGR Temperature Sensor
Engine Coolant Temperature Sensor
Comp. Discharge Temperature Sensor
Oil Cooling Sensor
Oil Level & Temperature Sensor
Oil piston cooling jet
FIGURE 26
1) Engine Variable Geometry Turbocharger
Actuator

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2) Turbine Shaft Speed Sensor

20.

Install the crankcase ventilation tube with new O-ring
#21532258. Install the fasteners securing crankcase
ventilation tube and bracket to valve cover and intake
manifold (fig. 27). Torque-tighten fasteners to 24 ± 4 Nm
(18 ± 3 ft-lb).

FIGURE 27

21.

Install the air intake pipe assembly. Install the hose
clamps at the air filter housing and the turbocharger
inlet (fig.28). Position the clamps and tighten to
secure.

22.

Install the air compressor inlet hose and clamp. Tighten
to secure.
FIGURE 28

23.

Position the crossover pipe with new O-ring #967343.
Make sure the O-ring is in place and install the V-band
clamp (fig.29). Torque-tighten fasteners to specification.
V-band clamp: 7±1 lbf-ft
Other clamps (2): 62±9 lbf-in

FIGURE 29

24.

Install the floor access panel.

25.

Connect the power and ground cables to the
batteries. Install the battery cover and close the
battery compartment door.

26.

Check Operation: Start Engine. Check for leaks. Check
Operation using Tech Tool, check for Codes.

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PARTS / WASTE DISPOSAL
Return replaced parts to Prevost with A.F.A. for full reimbursement.

ESTIMATED TIME
The time required to perform this special bulletin is approximately 10 hour.
OTHER
S6882
VBC Bulletin

Fail Code

01.00-2

Defect Code

09

System Condition

B

Causal Part

21570897

Prevost engages in a continuous program of testing and evaluating to provide the best possible product. Prevost, however, is not
committed to, or liable for updating existing products.