23. Insert wire 140EN46#2 (red) into supplied 2-pin Deutsch tower p/n 130029 from Kit p/n 166949 at cavity 1 (SIG).
24. Insert wire 140EN46#2 (black) into supplied 2-pin Deutsch tower p/n 130029 from Kit p/n 166949 at cavity 2 (GND).
25. Once the tower has been pinned insert the wedge lock p/n 130030 from Kit p/n 166949.
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26. Connect the newly terminated low coolant harness from Steps 22 thru 25 to the newly installed surge tank low
coolant derate sensor from Step 14c. See Figure 3 for correct rework wiring schematic.
Existing Derate Low Coolant Sensor Circuit

Reworked Derate Low Coolant Sensor Circuit

Figure 3: Surge Tank Derate Low Coolant Sensor Circuit
27. Secure the sensor harnesses to existing structure and/or existing harnesses where possible for support using
tyrap p/n 5958112 (x4). Harness routing should have not have any sharp bends or undue stress applied to the
harness.
28. Re-install the surge tank drop tube, connections and clamps removed in Step 12. Reference Figure 7.
29. Re-install the HVAC coolant lines, clamps and connectors that run underneath the surge tank removed in Step
11. Reference Figure 6.
30. Re-install the existing drain line removed in Step 8 to the new surge tank filler neck using clamp p/n 8410272,
torque to 6 in*lbs. Ref Figure 4.
31. As per Step 19 re-install the surge tank coolant lines removed in Step10. Reference Figure 5.
32. Close side surge tank access door.
33. Turn the main battery disconnect switch to the “ON” position.

NOTE: It will be necessary to perform a cooling system deaeration procedure prior to starting the engine
if any other maintenance activity was performed on the heating system that could have introduced
a significant amount of air into the cooling system. Refer to Section 2.3.4. “Fill & Deaeration” in
the New Flyer Service Manual.

34. Start the engine and inspect for leaks. Top up fluid as required.
35. Close the engine compartment door.
36. Close the interior engine access door.
37. Close the radiator access door.
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LABOUR ESTIMATE
Operation
1

Replace surge tank steel fittings with brass

Men

Hours

1

3.0

Labour Time
M X HR
3.0

PARTS REQUIRED
Description

Qty.
per
Coach
2

Units

Item

Part Number

1

216632

Barb-Hose ¼ x 3/8 ID

2

376677

Hose-EH225-06 Silicone

1.08

FT

3

131322

Clamp-Breeze .44 x .78

2

EA

4

14S00008

Screw-Machine #10 x ½”

1

EA

5

092585

Clamp-P 0.625

1

EA

6

10W04000

Washer-Flat ¼”

2

EA

7

40N04000

Locknut-Hex ¼”

1

EA

8

10B04012

Bolt-Hex ¼”unc x 3/4

1

EA

9

634511

Assembly-Surge Tank, Welded

1

EA

10

8110442

Loctite 567 - Thread Sealant

.01

EA

11

634366

Adapter-M20-1/4” FPT

1

EA

12

411110

Gauge-4.53” viewable Artic

1

EA

13

470238

Cap-Radiator 16 PSIG Lev-R-Vent

1

EA

14

610634

Sensor-Coolant Level Float

1

EA

15

460722

Sensor-Low Fluid Level

1

EA

16

498573

Assy-Brkt Sight Glass Clamp

1

EA

17

5952466

Bushing-1/2 FPT x ¾” MPT

1

EA

18

5955052

Elbow-45°

1

EA

19

5956167

Shrader Valve

1

EA

20

5959829

Bushing-.25 MPT x .13 FPT

1

EA

21

G127951

Plug-Brass ¼” MPT

1

EA

22

G127952

Plug-3/4” MPT

1

EA

23

494795

Adapter-1/2” NPT x-6 JIC Brass

3

EA

24

166949

Kit-2 Circuit Tower, Deutsch

1

EA

25

5958112

Tyrap-7” Black

4

EA

26

198432

Terminal-20 GA #16 Socket

2

EA

27

8410272

Clamp-Hose

1

EA

Notes

EA

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