SP 2-219-001

SERVICE PROGRAM
August, 2016

ATTENTION:

Service Managers / Parts Managers

SUBJECT:

Charge air cooler (CAC) pipe and static pipe
replacement.

DESCRIPTION OF WORK:

This service program provides information
regarding the replacement of the CAC pipe
and the static pipe on certain 2016 model
year Xpeditor vehicles equipped with ISL
engines.

PROGRAM EXPIRES:
August 31, 2017

VEHICLES AFFECTED:

This Service Program covers 93 vehicles.
Refer to the VIN list beginning on page 6.

SERVICE RESPONSIBILITY:

Service Programs are performed on eligible
vehicles at no charge to the owner until the
expiration date listed above.

SERVICE PROGRAM
INFORMATION:

Service Programs are product modifications
and/or product improvements that Autocar
has determined will enhance the operation of
the truck. In a continuing effort to inform our
customers of potential service issues and
avoid unnecessary down time, Autocar has
identified the following operation as
recommended preventive maintenance.
This Service Program should be added to
your preventive maintenance and service
manuals.
While being committed to continuous product
improvement, Autocar is not liable for
updating existing chassis after they have been
placed in service.
Questions regarding this Service Program
should be directed to Autocar Technical
Support at 888-218-3611.

TO OBTAIN PARTS:

DO NOT submit a Solutions ticket.
Ensure that you have authorization from the
customer to perform this work and send an
e-mail to: [email protected]
Include:
1. VIN(s) (or) (last 6 digits of the VIN(s))
2. Attention To Name
3. Ship To Address.

Autocar, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

Page 1 of 6

SP 2-219-001

SERVICE PROGRAM
August, 2016

REQUIRED PARTS:

S2192000K001 Service kit
(1) A2120448-001 Static fill pipe
(1) A2190234-001 CAC pipe
Cable ties (Obtain locally)

CLAIMS FOR REIMBURSEMENT:
Submit a claim for reimbursement in
accordance with Autocar’s Warranty
Administration Manual.

SAFETY NOTICES:

Allow the vehicle’s engine and cooling
system to cool to ambient temperature
before performing the repair procedure.
A hot engine or cooling assembly may
cause burns or other personal injury.

CLAIM CODING INFORMATION:
Repair
Number
(Op Code)

Time
Allowance
(SRT)

26503-2-01

2.00 HR

Description

Charge Air Cooler (CAC)
Pipe and Static Pipe
Replacement

TOOLS REQUIRED:

3/8” drive ratchet
3/8” drive torque wrench capable of 72 inch
pounds / 6 foot pounds
3/8” drive 1/2” deep socket
Standard pliers
Drain pan, 15-gallon (57-liter)
3/8” drive 3/4” deep socket
3/8” drive 5/16” deep socket
3/8” drive 7/16” deep socket
7/16” combination wrench
1/2” combination wrench

Page 2 of 6

To prevent eye injury, always wear eye
protection when performing vehicle
maintenance, service or inspection.

Before working on a vehicle, set the
parking brake, place the transmission
in neutral and block the wheels. Failure
to do so can result in unexpected
vehicle movement and can cause
serious personal injury or death.

Take proper precautions before working
under the vehicle. Use ramps approved
for the weight of your vehicle, or use
floor jacks and stands. Never work
under a vehicle supported by jacks
alone. Always use jack stands to
support the vehicle.

Autocar, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

SP 2-219-001

SERVICE PROGRAM
August, 2016

LOCKOUT/TAGOUT
PROCEDURES:

Before entering the vehicle or vehicle body,
read and follow OSHA regulations concerning
entry and working in “CONFINED SPACE”
OSHA 1910.146 and “LOCKOUT/TAGOUT”
OSHA 1910.147. Follow OSHA regulations
while performing any work on the vehicle. The
vehicle must be disabled by the following steps
before performing any work on the vehicle:
1. Place the transmission in NEUTRAL.
2. Set the parking brake.
3. Shut the engine OFF.
4. Lock cab doors, keep the key in your
pocket. Block the wheels before entering
the body or performing any work on the
vehicle.
5. Turn the battery disconnect switch OFF, if
equipped.
6. Completely drain the air from the
primary/A system and secondary/B
system by opening the drain valves on
the air tanks themselves or by using the
drain manifold if supplied. When draining
the air tanks, do not look into the area
where air is draining. Dirt or sludge
particles may be expelled in the air
stream and can cause eye injury.
7. Place magnetic “DANGER” signs on both
cab doors before entering the body or
performing any work on the vehicle.
8. Take proper precautions before working
under the vehicle. Use ramps approved
for the weight of your vehicle, or use floor
jacks and stands. Never work under a
vehicle supported by jacks alone. Always
use jack stands to support the vehicle.

Autocar, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

Autocar natural gas powered vehicles
require specific compliance in the service,
storage and refueling procedures.
If you store or dispense Compressed
Natural Gas (CNG) or Liquid Natural
Gas (LNG), or if you work on CNG or
LNG trucks, your location must be
fully compliant with applicable codes,
regulations and standards, including
National Fire Protection Association
(NFPA) codes, Society of Automotive
Engineers (SAE) standards, American
National Standards Institute (ANSI), Natural
Gas Vehicle (NGV) standards, the United
States Code of Federal Regulations (CFR),
and your state and local fire and other
applicable codes (including the California
Code of Regulations and the Texas
Administrative Code, as applicable).
Contact your local fire department for
guidance and additional compliance
information. Technicians working on
Autocar trucks with CNG or LNG engines
must be trained in the proper repair of CNG
and LNG engines and the safe storage and
dispensing of CNG and LNG.

Page 3 of 6

SP 2-219-001

SERVICE PROGRAM
August, 2016

CAC PIPE AND STATIC FILL PIPE
REPLACEMENT:
1.

After turning the key to the “OFF”
position, remove the key and allow
sufficient time for the vehicle to cool
down completely.

2.

Raise the cab in accordance with
the following safety precautions and
procedures.

Due to the danger of sustaining
personal injury and/or damage to the
vehicle, never attempt to raise the
cab outdoors under extremely windy
conditions. Strong wind conditions
could force the cab beyond the normal
limits of its travel. Never rely on the
hydraulic pressure to hold the cab in
an open position. Always use the safety
pin in the cab tilt lock tube to prevent
serious personal injury or death.

Remove or secure all loose articles
and close all doors before raising the
cab. The area above and ahead of the
cab must be clear from obstructions.
Place front wheels in a straight ahead
position.
Remove the pump handle from its
storage on the inside of the cab near the
driver or passenger seat.

Page 4 of 6

Place the selector lever on the hydraulic
pump in the RAISE position. Insert the
pump handle into the pump and operate
the handle in an up and down motion.
The hydraulic cab latches will open,
then the hydraulic cylinders will lift the
cab until the midpoint (top) is reached.
Once the cab has reached its midpoint
the cab will move forward to the fully
open position. The safety pin in the cab
tilt lock device must be installed when
the holes line up in the sliding bar.
Remove the pump handle when not in
use. It may stick out and could cause
injury to passersby.
3.

Remove the cooling system pressure
cap.

Do not remove the pressure cap from
a hot engine. Wait until the coolant
temperature is below 120°F [50°C]
before removing the pressure cap.
Heated coolant spray or steam can
cause personal injury.
4.

Using a 15-gallon (57-liter) drain pan,
drain the cooling system by opening
the drain valve on the radiator and the
drain valve on the bottom of the engine
oil cooler housing. Capture the drained
coolant and set aside for reinstallation.
Autocar, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

SP 2-219-001

SERVICE PROGRAM
August, 2016

Note: Refer to the engine manufacturer’s
instructions for complete cooling
system drain procedure and
information.
CAC Pipe

Static Fill Pipe

Coolant is toxic. Keep away from
children and pets. If not reused,
dispose of in accordance with local
environmental regulations.
5.

After the cooling system is completely
drained, close the drain valves.

6.

Remove and discard the CAC pipe by
first loosening the T-Bolt clamps and
then removing the tension clamp, and set
aside for reinstallation (See Figure 1).

7.

8.

Install the new CAC pipe (A2190234001) and tighten the T-Bolt clamps to
72 in-lb/6 ft-lb of torque. Reinstall the
tension clamp (See Figure 1).
Remove the tension clamps from
the static fill pipe and set aside for
reinstallation (See Figure 1).

Note: It may be necessary to loosen the oil
fill pipe and the dipstick to be able to
extract the static pipe.
9.

Remove and discard the static fill pipe
(See Figure 1).

Figure 1
Note: Tighten the oil fill pipe and the dipstick
if loosened in step 8.
11. Reinstall the previously captured engine
coolant.
Note: Refer to the engine manufacturer’s
instructions for complete cooling
system fill procedure and information.
12. Operate the engine, top off the engine
coolant as necessary, and pressure test
the cooling system to 16 PSI and check
for leaks.
13. Lower the cab.
14. Replacement is complete.

10. Install the new static fill pipe (A2120448001). Reinstall the tension clamps
(See Figure 1).

Autocar, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

Page 5 of 6

SP 2-219-001

SERVICE PROGRAM
August, 2016

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Page 6 of 6

Autocar, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486