NHTSA ID Number: 10164611
Manufacturer Communication Number: P03-267
TSB/Document Date: 2019-09-09
Summary
This Procedure outlines the rework to address engine compartment door de-bonding on model year 2018-2019 J4500 model coaches that have part number 03-31-4155 engine door.
Procedure 03-267
Date: 02/28/2019
J Coach Engine Door Rework
Description:
This procedure outlines the rework to address Engine compartment door de-bonding
The procedure applies to J4500 coaches with 03-31-4155 engine door.
Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses
and protective gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Positioning the ENGINE RUN and ENGINE START switches on the engine
compartment remote control box to the OFF position.
e. Allow enough time for components to cool down prior to working in the
engine compartment.
Ltd.Page 1 of 7
Procedure 03-267
1.0 Material Requirements:
Service kit T03-3015 contains following parts:
ITEM PART NO.
QTY
U/M
DESCRIPTION
1
23-02-0005
5
OZ
Adhesive - Methacrylate
2
23-02-0012
5
OZ
Adhesive Promoter-Methacrylate
2.0 Special Tools:
3M Scotch Brite 7447
3.0 Surface preparation
3.1 Detach the engine door from the coach
Open the engine door using the latch behind the curb side service door.
Rotate the lever
counter clockwise
Page 2 of 7
Procedure 03-267
Disconnect the license plate harness from the engine compartment harness.
Disconnect
the harness
On the driver side, remove the shoulder screw, lock nut attaching the long link
assembly to the bracket of coach frame. Save the lock nut and screw for later
use. Repeat the process for the curb side.
Remove and save
the shoulder
screw, lock nut
Page 3 of 7
Procedure 03-267
On the driver side, remove the shoulder screw, lock nut bonding short link
assembly to the frame tube. Save the lock nut and screw for later use. Repeat
the process for the curb side.
Remove and save
the shoulder screw,
lock nut
Detach the mating end of helping gas spring to driver’s side ball stud located in
the middle left area of the coach. Repeat the process on curb side.
Detach the
mating end
Page 4 of 7
Procedure 03-267
3.2 Scrape off existing adhesive
The following steps should be repeated for entire area where de-bonding is
observed.
Scrape the existing adhesive from the fiberglass door, metal frame surface and
holes in the metal frame at the detached location.
Using scotch brite abrade the metal bracket where the detachment is observed.
Scuff the metal
bracket
Clean the scuffed metal frame and the fiberglass door with 23-02-0012, adhesive
promoter.
4.0 Re-bonding
4.1 Adhesive application
The following steps should be repeated for entire area where de-bonding is
observed.
Apply the adhesive, 23-02-0005, on the fiberglass door and attach the metal
frame. Apply adhesive to fill the holes in the metal frame.
Adhesive
in the hole
Metal frame
Fiberglass
door
Use clamps to hold the fiberglass and metal frame. Make sure to bond the parts
within 12 minutes from applying adhesive and after a minimum of 20 minutes
from applying adhesive, remove the clamps.
Page 5 of 7
Procedure 03-267
4.2 Attach the door to the coach
On the driver’s side, position the short link assembly parallel to the frame tube
where the shoulder will be installed. Mount the previously detached shoulder bolt
of the short link assembly to the tube frame and secure it with the lock nut.
Repeat the process on curb side.
Shoulder screw
On the driver’s side, mount the shoulder bolt of the long link assembly to the
welded bracket on the coach frame and secure with previously detached lock
nut. Repeat the process on curb side.
Shoulder screw
Torque all four shoulder screws to 19-23 FT-LBS.
Page 6 of 7
Procedure 03-267
Attach the mating end of the helping gas spring to the driver’s side ball stud
located in the middle left area of the coach. Repeat the process for the curb side.
Attach the
mating end
Connect the license plate harness to the engine compartment harness.
Connect the
harness
Make sure to not use the door for again for the next 24 hours to allow the
adhesive cure completely.
End of procedure
Page 7 of 7
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TSB/Document ID: P03-267
Replacement Service Bulletin Number:
MFR Communication Date: 2019-02-28
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
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