BS4409E

SERVICE BULLETIN
1.21.

Remove the fan cable supply. Keep the p-clamps N84090-05 for later reinstallation. Discard bracket N34498,
screw N44881-03, screw N80661 (2x),locknut N44887 and spacer N92297.

1.22.

Remove and discard the bracket N82200 under the engine box. Keep for later reinstallation the fuse assembly
N47760 and discard brackets N10322 (2x) screw N40492 (2x) and locknut N44887 (5x).

Discard Cable
N73364

Discard:
Bracket N34498
Screw N4481-03
Screw N80661 (x2)
Locknut N44887
Spacer N92297

Discard Bracket
N82200

Keep Fuse
assembly N47760
for later

Discard:
Bracket N10322 (2x)
Screw N40492 (2x)
Locknut N44887 (5x)

Figure 13 - Fan Cable Removal

PAGE 14 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

GENERATOR REPLACEMENT
WARNING

Before unbolting the generator from its bracket, make sure it is held in place by a safety clip.
1.23.

Lift up the retractor arm and pulley to remove the drive belt from the generator. Keep the belt for later
reinstallation.

1.24.

Remove and discard the belt tensioner bracket.

1.25.

Remove the bolts attaching the generator to the engine mounting bracket. It might be easier to disconnect
the coil #1 for a better access to one of the bolts.

1.26.

Remove the four nuts and lock washers and lift the generator from its assembly rack.

1.27.

Install the new generator N90068. Due to his size, it might be easier to install the new generator from the
inside of the bus. Use the inside engine acess door from the seats located in the interior rear of the vehicle.
Torque screws N81850 with washers N56816 to 69 ±4 lb-ft (94 ±6 N•m). Apply torque seal and reconnect
the coil #1 if previously disconnected.

1.28.

Install the new bracket n93213 for the tensioner with bolts N33228. Torque to 33 ±4 lb-ft (45 ±6 N•m). Apply
torque seal.

1.29.

Install the tensioner. Torque to 197 ±16 lb-ft (267 ±22 N•m).

69 ±4 lb-ft (94 ±6 N•m) (4x)

33 ±4 lb-ft (45 ±6 N•m) (4x)

Figure 14 - Torque Generator and Tensioner

PAGE 15 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

INSTALL THE NEW GENERATOR CABLES
NOTE

Use a product like Maxi-coat (N35450) to inhibit the corrosion on electrical connections. Whenever torque seal
is applied, it must be done after the torque is applied AND after the application of the anticorrosion product.

1.30.

Before installing the new bracket N93087, make sure that the bolt head for the clamp beside will be accessible
(reposition it if required). Then install new bracket N93087 with screw N36608 (2x) and washer N31593 (2x).
Torque to 33 lb-ft (45 N•m). Apply torque seal.

Reposition clamp if required

Install bracket N93087

Figure 15 - Install Bracket N93087

PAGE 16 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

1.31.

Install new cables N92987 and N92986. Use the white tapes for the proper position. Install original p-clamps
and new dual clamp ties N37749. Torque the cables on their junction block to 31 N•m.

1.32.

Install transmission dipstick on the bracket.

Dual clamp tie

Cable N92987
Cable N92986

Dipstick

Dual clamp ties

Figure 16 - Install Cables N92987, N92986 and Dipstick

PAGE 17 OF 30
NQF772001 VERSION 3

BS4409E

SERVICE BULLETIN
1.33.

Install the bracket N93088 on the generator with bolt N16755 (2x), washer N20779 (2x) and lock washer
N17904 (2x). Torque to 6.5 ±0.5 lb-ft (9 ±1 N•m).

Figure 17 - Install Bracket N93088
1.34.

Install tie mount N57040 (2x) with screw N44881-02 (2x) and locknut N44887 (2x). Fix the connectors (2x)
to the tie mounts with cable ties G5007996 (2x).

1.35.

Install cable N82294 to the negative post of the generator and cable N92987 to the positive. Do not tighten
yet. Attach them with a p-clamp N84090-05 and a locknut N44887.
P-clamps
N84090-05
Tie mount

Capacitor

Tie mount

Figure 18 - Install Tie Mounts on Generator Bracket
PAGE 18 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

1.36.

Install the original capacitor N92656-01 by fixing the capacitor on the positive cable N92987 with a dual clamp
tie N37749. Attach the wires with three wire clamping cable ties N71311.

1.37.

Install a new terminal ring N81433-01 on the black wire of the capacitor and install it on the negative post.
Torque the nut to 32 ±2 lb-ft (44 ±3 N•m).

1.38.

Install the cable N92987, the fan cable N92988 and the red wire of the capacitor on the positive post. Torque
the nut on the positive post to 32 ±2 lb-ft (44 ±3 N•m). See the next two Figures.

Attach capacitor wire with N71311
Attach capacitor
with dual clamp
N37749

Torque to 32 ±2 lb-ft
(44 ±3 N•m)
Install a swivel
N56836 between
hose and cable

Figure 19 - Connect Cables and Capacitor

Fan cable N92988
with p-clamp
N84090-05 and
locknut N38593

Figure 20 - Install Fan Cable
PAGE 19 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

NEW FAN CABLE INSTALLATION
1.39.

Install bracket N93001 under the engine box.

1.40.

Install the original fuse assembly N47760 with two new locknuts N44887.

1.41.

Install cable N92988 with original p-clamps and new locknuts N44887.

1.42.

Install the original cable on the new bracket and to the fuse holder.

New bracket
N93001

New cable N92988
with original
p-clamps

Original fuse
holder N47760

Attach the original
cable to the
bracket.

Figure 21 - Install Fan Cable and Fuse Holder Bracket

PAGE 20 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

MODIFICATIONS ON GENERATOR CONNECTORS
1.43.

Cut the ring terminals on the wires going to the generator.

1.44.

Install splice N152758 and wire N25831-25 on the 64-2096 circuit.

1.45.

Install the terminals, seals and connectors as per the Figure below.

WIREMARKER
MARKERAWGAWG
WIRE
COLOR
64-1546
64-1546
14 14
RD
64-2096
16 WH

COLOR
TERMINAL CONNECTOR
SEAL
TERMINAL SEAL

RD
12124582 12010996
15324981
12124582
15324981
12124580 15324981 12015791

WIRE MARKER

64-2096

AWG
COLOR
WIRE MARKER

1664-2096WH

CONNECTOR

12010996

TERMINAL
SEALSEAL
CONNECTOR
AWG
COLOR TERMINAL
CONNECTOR
12124580
15324981
1201591
16 WH
12124580 15324981 12015791

Figure 22 - Install New Connectors

PAGE 21 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

HARNESS 64 ROUTING
1.46.

Route and secure harness 64 as shown below with cable ties G5007996, spacer N56836 and p-clamp
N84090-02.

Secure connector
Secure harness

Install a spacer
N56836 with
two cable ties
and fix it to
cable N92988

Secure connector

Install p-clamp
N84090-02 and
locknut N44887

Figure 23 - Secure Harness

PAGE 22 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

FUEL FILTER REPOSITIONING
1.47.

Remove and discard fuel filter hoses.

1.48.

Remove the three bolts holding the fuel filter to the bracket.

Discard hoses
Figure 24 - Unbolt the Fuel Filter (Some Parts Removed For Clarity)

CAUTION

The qualified personnel should take the necessary precautions to avoid any risk of personal injury or damage
to the equipment. Adjacent surfaces should be suitably protected (by using proper fire blocker blankets,
etc.) to prevent damage.
1.49.

Cut and remove the fuel filter bracket completely from the square tube. Grind and clean the surfaces as needed.

Front

Rear

Figure 25 - Cut the Fuel Filter Bracket
PAGE 23 OF 30
NQF772001 VERSION 3

BS4409E

SERVICE BULLETIN
1.50.

Using the bracket N93157 as a jig, mark the holes required to install the bracket.

1.51.

Drill the two holes (3/8 in.) and install the fuel filter bracket N93157 and the pipe bracket N93158 with bolts
N44885-6 and nuts N43233.

N93157

N93158

Front

Rear

Figure 26 - New Fuel Filter Configuration

1.52.

Install the fuel filter on the new bracket.

1.53.

Install the new fuel filter hoses N95839-02 then N95839-03 then reorient the fittings as required.

PAGE 24 OF 30
NQF772001 VERSION 3

BS4409E

SERVICE BULLETIN
INSTALLATION OF THE AIR COOLING PIPE

Elbow (90°) N91342
with
clamp N12883

Clamp N22781-07
Union N75806

Hose N75803
with clamps
N12883

Elbow (55°)
N93143
Air intake
box N93763

Air intake box bracket
N93144

Figure 27 - EMP Air Cooling Installation

PAGE 25 OF 30
NQF772001 VERSION 3

BS4409E

SERVICE BULLETIN
1.54.

Using the bracket as a jig and the distance shown below to mark the first hole, drill the two 3/8 in. holes in
the structure. Install the air intake box bracket N93144 with bolts N43775 and nuts N43233. Torque to 24.4
±1.5 ft-lb (33 ±2 N•m).

Air intake box gasket
N18813

3 1/8

in.

Air intake box bracket
N93144

Figure 28 - Drill the Two Holes for the Air Intake Bracket

1.55.

Install the air intake box N93763 onto the bracket N93144 with two bolts N40492 and nuts N44890. Torque
to 8 ±0.7 lb-ft (11 ±1 N•m).

1.56.

Cut and install gasket N18813 on the air intake box.

PAGE 26 OF 30
NQF772001 VERSION 3

BS4409E

SERVICE BULLETIN
1.57.

Install elbow N93143 on the bracket N93158 with bolts N40492 and nuts N38593. Torque to 8 ±0.7 lb-ft
(11 ±1 N•m).

P-clamp N84090-11,
bolts N40492 and
nuts N38593

Bracket N93158,
bolts N40492 and
nuts N38593
Elbow N93143

Figure 29 - Install Elbow N93143 (Some Parts Removed for Clarity)

1.58.

Install the elbow N91342, the union N75806, the hoses N93763 and the p-clamps as per Figure 24. Torque
the p-clamp to (6 ±1 N•m).

PAGE 27 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

DRAIN HOSE INSTALLATION
1.59.
1.60.

Drill two 3/8 in. holes to fix the p-clamps N84090-03 for the drain tube 8860102. See the Figure below.
Install the fitting 0696471 on the elbow N93143, then install the drain hose to the fitting and the p-clamps.

3.5 in.

P-clamps
N84090-03

3 3/8 in.

6 5/8 in.

Drain tube
8860102

1.5 in.

Figure 30 - Drain Hose Installation
PAGE 28 OF 30
NQF772001 VERSION 3

BS4409E

SERVICE BULLETIN
FINALIZATION OF THE INSTALLATION
1.61.
1.62.

Install the engine belt as per your manual section 09: Alternator and voltage regulator.
Route the hoses for the air dryer as per Figure below. Replace the shortest one with a new tubing 8861140
and adjust the length accordingly. Secure with cable ties.

Before

After
Figure 31 - Route the Air Dryer Hoses

1.63.

Route and secure the hoses out of the way of the air cooling pipe.

Figure 32 - Route and Secure Hoses

PAGE 29 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN
1.64.
1.65.

Fill with engine coolant as per the manual section 09: Engine
the air in the system.
The vehicle can be put back into service.

cooling system

BS4409E
and make sure to remove



PAGE 30 OF 30
NQF772001 VERSION 3