NHTSA ID Number: 10154134
Manufacturer Communication Number: IK1500097
TSB/Document Date: 2019-03-04
Summary
Gasoline Engine Bus Fuel System Issues; only models built with PSI 8.8 Gasoline Engine
IK1500097 - Gasoline Engine Bus Fuel System Issues
Page 1 of 10
Countries:
CANADA, UNITED STATES Document ID: IK1500097
Availability:
ISIS, Bus ISIS, IsSIR
Revision:
14
Major System:
FUEL SYSTEMS
Created:
8/1/2018
Current Language: English
Last Modified: 1/18/2019
Other Languages: NONE
Author:
Viewed:
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Title : Gasoline Engine Bus Fuel System Issues
Applies To : PSI Gasoline Bus
Change Log
Please refer to the change log text box below for recent changes to this article:
01/18/2019 ‐ Added a note for updated hose and bracket in steps 5 and 7
12/06/2018 ‐ Added updated Part Numbers
11/09/2018 ‐ Revised diagnositc steps and added additional repair steps
10/19/2018 ‐ Revised Evaporative System Test PDF file
10/17/2018 ‐ Added Evaporative System Test step, added note for over stretching fuel fill line in Repair Steps, added note for clocking fuel receiver tie
strap in the PDF document
Description
This article identifies known fueling issues on the PSI 8.8 Gasoline Engine for Bus.
Symptoms
Diagnostic Trouble Codes & Dashboard Indicator Lights:
DTC/Light
Description
No Faults or Warning Lights
Customer Observations or Concerns:
• Hard to fuel/Does not take fuel in
• Incorrect fuel level reading
Special Tools / Software
Tool Description
Tool Number
Comments
Instructions
Not Applicable
Service Parts Information
Kit Description
Part Number
Quantity Required
Valve, Check, Fuel Fill Inlet (flapper/spit
back valve)
4109247C1
1
Tie Strap
306132C1
1
Fuel Fill Receiver Bracket (30degree
angle)
4109896C3
1
Notes
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 2/1/2019
IK1500097 - Gasoline Engine Bus Fuel System Issues
Filler Assembly Kit, Fuel Fill Receiver and 4107649C93
Hose Kit (no bracket)
1
Formed Fuel Hose
2520493C1
1
Formed Hose (not cut to size, cut 50mm
from formed end)
2520482C1
1
Page 2 of 10
Diagnostic Steps
Fueling issues diagnostic steps
***If a unit after a built date of 1/7/2019 has a complaint of not taking fuel in, please take pictures of any issues found before repairs are
made and submit it to technical support case file***
Step Action
DIAGNOSTIC:
1
Decision
Yes: Go to Step 2
Difficulties fueling the Bus
YES/NO QUESTION?
No: End of Diagnostics
Is the bus hard to fuel/not taking fuel in?
Step Action
DIAGNOSTIC:
2
Verify the fuel fill tube Mat/Diaper is installed
properly
Decision
Yes: Go to Repair Steps for Fuel Fill Tube
Mat/Diaper Installation
YES/NO QUESTION?
No: Go to step 3
Is the rubber Mat/Diaper NOT installed properly
or touching the filler tube?
Step Action
DIAGNOSTIC:
Decision
Yes: Go to Step 4
Verify fuel fill receiver is properly secured
with the tie strap as per Figure 3
3
YES/NO QUESTION?
No: Go to Repair steps for Filler Neck Alignment
Is the fuel fill receiver properly secured and NOT
able to be moved by hand just holding on to the
fuel cap?
Step Action
DIAGNOSTIC:
4
Verify fuel fill receiver is installed properly
with vent orientation at 10‐11o'clock position as
per Figure 1
YES/NO QUESTION?
Decision
Yes: Go to Step 5
No: Verify the updated Part Number for Fuel Fill
Receiver is installed as per Repair steps for Filler
Neck Alignment
Is the filler receiver and vent line in the correct
orientation?
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Step Action
DIAGNOSTIC:
Page 3 of 10
Decision
Yes: Go to Step 6
Inspect the fuel fill hose for excessive droop.
Acceptable droop Figure 4
Unacceptable droop Figure 5
5
YES/NO QUESTION?
Is the fuel fill hose within acceptable droop
range?
No: Go to Repair steps for Fuel Fill Hose Excessive
Droop
NOTE busses built after 1/7/2019 will
have updated formed hose and a 30 degree
bracket
Step Action
DIAGNOSTIC:
6
Decision
Yes: Go to Step 7
Verify vent line routing through the frame (at
3o'clock position) and over the fill hose as per
Figure 1
No: Route the vent line as Figure 1
YES/NO QUESTION?
Is the vent line routed and secured properly?
Step Action
Decision
DIAGNOSTIC:
Check the gap between the fuel fill receiver
bracket and the sill
7
Yes: Go to Repair Steps for Fill Receiver Bracket
Repair
Acceptable ‐ Figure 6
Unacceptable ‐ Figure 7
YES/NO QUESTION?
Is there excessive gap noticed?
No: Go to Step 8
NOTE busses built after 1/7/2019 will have
updated formed hose and a 30 degree bracket
Step Action
DIAGNOSTIC:
Decision
Yes: Go to Repair Steps for Valve replacement
Check for sticking flapper valve/spit back valve.
Check for any residue on the valve as per Figure 2
8
YES/NO QUESTION?
Is the valve sticking, or any residue seen on the
valve?
or
Is valve orientated incorrectly with hinge (flat
edge) side on the bottom?
No: Go to Step 9
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Step Action
DIAGNOSTIC:
9
Page 4 of 10
Decision
Yes: End of Diagnostics
In Repair Steps, follow the procedure under
Evaporative System Test to check for restrictions
within Evap lines and canisters
YES/NO QUESTION?
No: Repair as Needed. Verify the Repair Resolved
the Complaint
Are the Evap lines and canisters free of any
blockage and restrictions?
Figure 1
Figure 2
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Page 5 of 10
Figure 3
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Page 6 of 10
Figure 4 ‐ Acceptable Fuel Fill Hose Droop
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Page 7 of 10
Figure 5 ‐ Unacceptable Fuel Fill Hose Droop
Figure 6 ‐ Acceptable Fill Receiver Bracket Gap
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Page 8 of 10
Figure 7 ‐ Unacceptable Fill Receiver Bracket Gap
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Page 9 of 10
Repair Step(s)
Fuel Neck Alignment (Plant clean date 6/15/2018)
1. Step 1: Follow the procedure in the link on Step 2
2. Step 2: Fuel Neck Alignment Repair
3. Step 3: Verify that the fuel receiver tie strap is clocked in the correct position as per drawing in the procedure above
Flapper/Spit Back Valve Replacement (Clean date 7/2018)
1.
2.
3.
4.
Step 1: Remove the filler hose/line
Step 2: Pry off the old valve, clean surface of any debris on the fill neck
Step 3: On a new valve apply one drop of Loctite on the bottom of the valve to secure the valve to the fill neck
Step 4: Install the valve in the same orientation as it was removed, flapper part facing down and hinge (flat edge) on top (or as shown in
Figure 2)
5. Step 5: Reinstall the filler hose/line, torque fill neck clamp to 38‐42 in‐lb
Fuel Tank Replacement (Clean date 6/11/2018)
1. Step 1: Follow the procedure in the link on Step 2
2. Step 2: Fuel Tank Removal and Installation Procedure
Fuel Fill Hose Excessive Droop (Clean date 9/10/2018)
1.
2.
3.
4.
Step 1: Disconnect the fuel fill hose from the filler neck
Step 2: Trim the fuel fill hose as needed
Step 3: Reattach the hose as per "Fuel Neck Alignment" steps above
Step 4: Make sure to torque fill neck clamp to 38‐42 in‐lb
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IK1500097 - Gasoline Engine Bus Fuel System Issues
Page 10 of 10
5. Step 5: Verify the fuel fill hose is within an acceptable droop range
6. ***Note*** Do not over stretch the fuel fill line to the point it is effecting the angle of the fuel fill receiver
Fill Receiver Bracket Repair (Clean date 9/25/2018)
1.
2.
3.
4.
5.
6.
Step 1: Remove the fill hose protecting diaper
Step 2: Remove the fill receiver from the support bracket by cutting the zip ties
Step 3: Drill out the improperly installed rivets
Step 4: Mount the bracket flush to the sill with new rivets
Step 5: Reinstall the fuel fill receiver as per "Fuel Neck Alignment Repair" above
Step 6: Verify the gap is no longer visible
Evaporative System Test
1. Step 1: Follow the procedure in the link on Step 2
2. Step 2: Evaporative System Test
Fuel Fill Tube Mat/Diaper Installation
1. Step 1: Refer to installation diagrams in Step 2
2. Step 2: Fuel Fill Tube Mat/Diaper Diagrams
Warranty Information
Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.
Standard Repair Time(s):
Refer to the SRT Manual for Repair Times
Other Resources
Master Service Information Site
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Copyright © 2019 Navistar
, Inc.
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TSB/Document ID: IK1500097
Replacement Service Bulletin Number:
MFR Communication Date: 2019-01-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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