L784

43

43

L82U9D3001057

L82U9D3001057

1

Whitehorse - Yukon

LA04

—

—

L82J2G3750390

L82J4G3750391

2

Windsor - Ontario

L886

570

577

L82J8F3001818

L82J5F3001825

8

Woodstock - Ontario

L778

—

—

L82U2D3001014

L82U2D3001014

1

Woodstock - Ontario

L832

—

—

L82J9E3001342

L82J9E3001342

1

Woodstock - Ontario

L923

15-16

15-16

L82J9F3001746

L82J9F3001746

1

Woodstock - Ontario

LA08

17-08

17-08

L82J3H3750514

L82J3H3750514

1

York Regional Transit - Ontario

L896

1501

1517

L82J2F3001619

L82JXF3001741

17

York Regional Transit - Ontario

L936

1518

1518

L82J3G3750012

L82J3G3750012

1

York Regional Transit - Ontario

L964

1770

1774

S92J6G3750420

S92J3G3750424

5

York Regional Transit - Ontario

L967

1601

1621

L82J2G9775414

L82J8G9775627

21

York Regional Transit - Ontario

LA07

1701

1715

L82J9G3750340

L82JXG3750363

15

PAGE 6 OF 18

INFORMATION LETTER

SAV.1F.2012MA

LI4263E

WARNING

Follow your internal safety procedures.
Disconnect the batteries before starting any work on the vehicle. See the section 16: BATTERIES of the
maintenance manual.
NOTE

Nova Bus has been advised by its engine supplier that the Cummins engine code 3568 might be sensitive
to the variations in DEF level. An adjustment of the coolant hoses and the angle of the dosage module is
necessary before considering the occurence of the code 3568 as a defect.

PROCEDURE
1.1.

Park the vehicle on an even surface with transmission in neutral (N).

1.2.

Set the Master control switch in the STOP position (see Figure 1).
Master control switch in
STOP position

Figure 1 - Master Control Switch in STOP Position

WARNING

Before starting any work on the vehicle, make sure the vehicle is completely and securely stationary. Set
the battery disconnect switch in the battery compartment to the OFF position.

PAGE 7 OF 18

INFORMATION LETTER
1.3.

SAV.1F.2012MA

LI4263E

Deactivate the bus from the rear engine control box (see Figure 2).

Rear engine control box

Figure 2 - Typical Location of Rear Engine Control Box

1.4.

Open the street side rear engine access panel (can vary as per the configuration) (see Figure 3).

Rear road side engine access door

Figure 3 - Open the street side engine access panel
PAGE 8 OF 18

INFORMATION LETTER
1.5.

SAV.1F.2012MA

LI4263E

Verify that the angle of the dosage module is between 45° and 85° w.r.t. its vertical axis. The ideal angle is
54° (see Figure 4).

Dosing module orientation
Between + 45º and + 85º
or
Between - 45º and - 85º

Figure 4 - Verify the angle of the dosage module

PAGE 9 OF 18

INFORMATION LETTER
1.6.

SAV.1F.2012MA

LI4263E

Adjust the dosage module angle using the jig NT08134 as shown (see Figure 5) to obtain an angle specified
(see Figure 4).

JIG NT08134

Reference line

JIG NT08134

Figure 5 - Adjust the angle of the dosage module

PAGE 10 OF 18

INFORMATION LETTER
1.7.

SAV.1F.2012MA

LI4263E

If the dosage module angle requires adjustment, loose the clamp screws and turn the decomposition tube
to obtain an angle of approximately 54° using the jig NT08134 (see Figure 6).
Loosen the clamp screws

Turn the tube

JIG NT08134

Reference line
Figure 6 - Adjust the angle of the dosage module
PAGE 11 OF 18

SAV.1F.2012MA

INFORMATION LETTER
1.8.

LI4263E

Tighten the clamps by applying the torque value of 14 ± 1 N•m (see Figure 7).

Torque clamp screws

Figure 7 - Tighten the clamps

1.9.

Locate the decomposition coolant lines (see Figure 8).

1.10.

Locate all the positions (A, B, C, D and E) shown (see Figure 8), where new brackets have to be installed.

D

E

DEF Line
Upper Coolant Line

C

B

Lower Coolant Line
A

Figure 8 - Typical View of Coolant Lines

1.11.

Drain the coolant circuit.

PAGE 12 OF 18

INFORMATION LETTER
1.12.

SAV.1F.2012MA

LI4263E

Remove and discard the tie wraps holding the electrical harness and lower coolant line (see Figure 9).
Lower Coolant Line

Electrical Harness

Figure 9 - Removal of Tie Wraps

1.13.

Remove and retain the existing plastic bracket and hardware from its original position shown (see Figure 10).

Lower Coolant Line

Electrical Harness

Plastic Bracket and
hardware to be removed

Figure 10 - Removal of Plastic Bracket and Hardware

PAGE 13 OF 18

INFORMATION LETTER
1.14.

SAV.1F.2012MA

LI4263E

Install the bracket (N87984) and the retained plastic bracket in the inverse position from its original position
as shown (see Figure 11) with the hardware provided.

Bracket: N87984

Retained
Hardware

Plastic Bracket

Figure 11 - Installation of New Bracket

1.15.

Secure the electrical harness to plastic plug using tie wrap N56339.

1.16.

Reposition the lower coolant line at the lowest point as shown (see Figure 12).

1.17.

Install the p-clamp N31320-04 on the bracket to secure the lower coolant line (see Figure 12).

P-Clamp: N31320-04
Nut: N38593
Tie Wrap: N56339

Figure 12 - Installation of P-Clamp and Tie Wrap
PAGE 14 OF 18

INFORMATION LETTER

SAV.1F.2012MA

LI4263E

1.18.

Remove the existing bracket and p-clamp securing the upper coolant line. Retain the bracket hardware.

1.19.

Install the new bracket N87985 with the retained hardware (see Figure 13).

1.20.

Install new p-clamp N31320-04 with the new bolt N40492 and nut N38593 provided to secure the upper
coolant line as shown (see Figure 13).

Bracket: N87985

Bracket and P-clamp to
be Removed

Bracket: N87985
P-Clamp: N31320-04
Bolt: N40493
Nut: N38593

Figure 13 - Installation of Bracket and P-Clamp

1.21.

Remove and discard the existing bracket and p-clamp holding the DEF coolant line at the location shown
(see Figure 13). Retain the bracket hardware.

1.22.

Install the new bracket N90007 with the retained hardware and fix the mount fire N57807 (see Figure 14).

Bracket: N90007
Mount Fire: N57807
Existing Bracket and P-Clamp
to be removed
DEF Coolant Line

Figure 14 - Typical View of Bracket and Mount Fire

PAGE 15 OF 18

INFORMATION LETTER

SAV.1F.2012MA

LI4263E

1.23.

Remove and discard the hardware at the location shown (see Figure 15).

1.24.

Install the new bracket N90018 with new nut N38593 and fix the mount fire tree N57807 to bracket (see
Figure 15).

Hardware to be
Removed

Bracket: N90018
Nut: N38593

Figure 15 - Typical View of New Bracket Installed

1.25.

Remove and retain the hardware at location shown (see Figure 16).

1.26.

Install the new bracket N90007 with the retained hardware and fix the mount fire tree to bracket (see Figure 16).

Bracket: N90007
Mount Fire Tree:

Hardware to be
Removed

Figure 16 - Installation of New Bracket and Mount Fire

1.27.

Cut the existing DEF coolant hose as shown and discard the other portion of hose connected to dosing module.

1.28.

Insert one end of the fitting N75961 in new hose N95827-35 and other end in the retained cut hose (see
Figure 17).

1.29.

Install stepless crimp N57634-01 as shown (see Figure 17).
Fitting to be Inserted

Cut Hose

New Hose:
N95827-35
Fitting
Fitting: N75961
Stepless Crimps:
N57634-01

Figure 17 - Preparation of DEF Hose

PAGE 16 OF 18

SAV.1F.2012MA

INFORMATION LETTER

LI4263E

1.30.

Adjust the DEF hose length to fit the 90° quick connector at the dosing module.

1.31.

Insert 90° quick connector N90005 in DEF hose and install stepless crimp as shown (see Figure 18).

1.32.

Fix the 90° quick connector on the dosing module (see Figure 18).

DEF Hose
DEF Hose

Dosing Module

Stepless
Crimp
90 ° Quick Connector:
N90005

Figure 18 - Typical View of Quick Connector on Dosing Module

1.33.

Install the reflective sleeve to cover the cut portion and 90° quick connector.

1.34.

Secure the DEF hose with the mount fire tree fixed on the new brackets (see Figure 19).

Mount Fire Tree: N57807

Reflective Sleeve to be
installed

Figure 19 - Installation of Reflective Sleeve

PAGE 17 OF 18

INFORMATION LETTER
1.35.

SAV.1F.2012MA

LI4263E

Fill the coolant circuit.
WARNING

Connect the batteries after the repair is completed. See manual section 16: BATTERIES for the procedure.
1.36.

Return the rear run switch to the normal operating position.

1.37.

Run the bus for 15 minutes and check for any possible leaks.

1.38.

Return the vehicle to service.

PAGE 18 OF 18