Instruction Sheet

IS-14152

Road Side and Workshop Instructions
for Replacing 040949 6mm DEF Hose to a 4mm ID Hose.
X Series from B-5002 up to G-5924

MATERIAL
Kit #IS14152 includes the following parts:
Part No.

Image

Description

Qty

041123

HEATED UREA HOSE, 4MM

1

502638

WASHER FL .312X.734X.065

5

504534

GROMMET .875 ID X 1.250 GROOVE DIA X.187 GROOVE
WIDTH X.562 THK X 1.625 OD

2

504610

RIVET, MAGNA-LOK 1/4” DIA X 5/8” LG SS

5

504637

CABLE TIE 3/16" X 13"

10

506205

SPLIT INSULATION TUBE 5/8” X 1/2” X 72”

2

507383

TIE MOUNT, ANGLE 0.375” HOLE

5

507664

CABLE TIE 3/16" 11" / DOUBLE LOOP HEAD

10

5001113

NUT, HEX JAM NYRT 5/16-18

5

N32553

SCREW, CAP HEX 5/16-18X3/4 FT SS

5

IS-14152

Instruction Sheet

1

FI-14152

Feuille d'instructions

1

IS-14152
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Other parts that may be required:
Part No.
680532

Description
SEALANT SIKA #221 / GREY / 310ml CARTRIDGE

Qty
1

NOTE
Material can be obtained through regular channels.

SPECIAL TOOLS

“UNIBIT” STEP DRILL, DOUBLE FLUTE w/ 1.25” DIMENSION.
MILWAUKEE: 48-89-9205 OR EQUIVALENT

DANGER
Park vehicle safely, apply parking brake, stop engine and set battery master switch(es) to the OFF
position prior to working on the vehicle.

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OVERVIEW
This instruction sheet proposes two methods:

Method A WORKSHOP REPLACEMENT:
This is the prefered method. Use it where safe lifting equipment is available. Hose is routed inside the
vehicle frame. This method requires less parts.

Method B ROAD-SIDE REPLACEMENT:
To be used in situations where vehicle is repaired with limited facilities. Use it where safe lifting
equipement is not available. Hose is routed above drive and tag axle wheels.
A) WORKSHOP REPLACEMENT METHOD
New hose #041123 will be routed from the DEF dosing valve above the DPF then down and forward to
the DEF pump in the condenser compartment.
(Refer to figure 1) Routing above the rear axles will follow the PVC tubes (A), up to the primary tank (B),
then under the frame rail between the wheel mud guard and wall (C), through the condenser compartment
wall (D), and finally to the DEF pump (E).
Images in this procedure show recent frame configurations. Your vehicle may present some variations.

Figure 1 :Hose routing Side view

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A1.

(Refer to figure 2) From the dozing valve on the DPF, follow path downwards A as shown on fig.2
then proceed to the front of the bus, loosely securing to the existing hoses, B progressing towards
the cable and hose management passage C.

A2.

Re-use insulation. If required install new insulation #506205

FIGURE 2

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A3.
Open both service hatches inside the coach floor. You may have to remove the rear cross seat to
access the “engine” service hatch depending on vehicle configuration.
From the cable management passage C, loosely attach hose below the PVC tubes D with cable ties
#507664, progressing forward towards the primary tank.

FIGURE 3

A4.
Above Primary tank, let the hose slip
down the front right side of the tank. (Fig 4)
Then pull down and under the frame. (Fig. 5)

FIGURE 4

FIGURE 5

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A5.

Drill a 1/8” pilot hole at the indicated
location on the aft wall of the condenser
compartment ( Fig. 6)

A6.
Using the step drill, drill a 1.25” diameter hole
at the same location.
Remove any sharp edges and burrs.
Slip grommet #504534 on hose and install in
hole.
Secure hose and grommet with # 680532 Sika
Grey sealant.
Connect to DEF pump.
A7.

Confirm proper operation of all affected
systems.

A8.

Finalize cable tie
tightening each one.

A9.

Clear all active and inactive DTC’s

installation

by
FIGURE 6 : DRILL 1.25 “ HOLE

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B) ROADSIDE REPLACEMENT METHOD
Images in this procedure show recent frame configurations. Your vehicle may present some variations.

FIGURE 7 : OVERVIEW

B1.
On the aft wall
compartment, (A, Fig. 7)

of

the

condenser

Drill a pilot hole of proper dimension at the
indicated location. (Fig. 8)
Drill a 1 1/4in. hole with the step drill. (Fig. 8)
Remove sharp edges and burrs.
Install grommet # 504534 over hose and install.
Seal with grey Sika #680532.

FIGURE 8 : WALL DRILLING LOCATION

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B2.
Drill a pilot hole in the drive axle housing
skirt support (Fig. 10)
From the wheel side, using the step drill, drill a
1-1/4“ hole in the plastic skirt and support. (Fig.10)
Remove sharp edges and burrs.
Pull hose from condenser compartment.
Install a grommet #504534 on the hole.

FIGURE 9

FIGURE 10 SKIRT SCREW LOCATION

FIGURE 11 507383 CABLE TIE SUPPORTS MAY BE INSTALLED WITH RIVETS OR SCREWS.

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B3. Install the cable tie supports #507383 inside
the longitudinal channel closest to the vehicle
frame. (Fig. 12)
Clean bearing surface before installation.
B4. Installing the cable tie supports.
Riveting is the preferred method.
However, if you do not have access to a air
powered riveter, proceed to B6, SCREWING.
FIGURE 12 507383 CABLE TIE SUPPORT LOCATION

B5. RIVETING: Drill a 1/4” hole and install the
supports at 1/2” from the channel bottom edge
with #504610 rivets at locations shown on
Figures 7 & 11. (Fig. 12, 13)
Be careful not to pierce the plastic insulation
behind the channel.
Do not tighten the hose cable ties yet!

FIGURE 13 RIVETED SUPPORT

B6. SCREWING: If riveting is not possible, the
supports may be installed with #N32553
screws, #502638 washers and #5001113 nylon
jam nuts. (Fig. 14)
Drill a 5/16” diameter hole at 1/2” from the
channel bottom edge (Figure 12).
Be careful not to pierce the plastic insulation
behind the channel.
Place the holes at locations shown on Figures
7 & 11

FIGURE 14 SCREW JOINT

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B7.
Attach to the hose management support
(If present) along with tag axle lift chamber hose.
(Fig 15)

FIGURE 15

B8. Use a slit silicone hose to pass through the
shock support. (Fig 16 & 17)
Attach to the shock support with cable ties.

FIGURE 16

FIGURE 17

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B9.
Open the floor hatch and if you have the opportunity you may open also the “engine “service
hatch.
You may have to remove the rear cross seat to access the “engine” service hatch depending on vehicle
configuration.
Route hose under the frame rail E, then in the cable and hose tunnel leading to the engine compartment F
and towards the curb side of the engine compartment G.

FIGURE 18

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B10.

Route up to urea dosing valve and connect. (Fig.19)

B11.

Confirm proper operation

B12.

Finalize cable tie installation by tightening each one.

B13.

Clear all active & inactive DTC’s.

Re-use insulation. If required install new insulation #506205

FIGURE 19

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PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)