IS-19040A

Instruction Sheet

POWER STEERING PUMP DISCHARGE HOSE (PRESSURE)
REPLACEMENT

Revision: A
09-19-2019

Addition of kit #160122 in MATERIAL

Use this instruction sheet for the replacement of the following hoses: #161335P, #160039
Applicable to the following models:

XLII Entertainer
X3-45 coaches & X3-45 Commuter
X3-45 VIP motorhomes
X3-45 VIP commercial use

Kit #160127 or #160122 are necessary at time of first installation as the new hose #160006 has
a greater diameter than the former hose model installed , thus it is necessary to use new split
block #504189.

MATERIAL
Kit #160127 (X3 Series, starting from vehicle D-5388) includes the following parts:
Part No.

Description

Qty

160006

HOSE, PRESSURE 11690 mm (460 inches), dia. 22 mm

1

500107

SCREW, TC HEX Z050 1/4-20x2

3

501031

SEAL, JIC 37° #8

1

504189

CLAMP, SPLIT BLOCK 22 mm/19 mm PA GROUP 3,

13

504728

RETAINER PLATE T3

3

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FEUILLE D’INSTRUCTION

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INSTRUCTION SHEET

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Kit #160122 (X3 Series, up to vehicle D-5387 included) includes the following parts:

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Part No.

Description

Qty

160006

HOSE, PRESSURE 11690 mm (460 inches), dia. 22 mm

1

1600100

FLANGE, POWER STEERING HOSE (wall mount split block half)

2

500107

SCREW, TC HEX Z050 1/4-20x2

3

501031

SEAL, JIC 37° #8

1

504189

CLAMP, SPLIT BLOCK 22 mm/19 mm PA GROUP 3,

13

504728

RETAINER PLATE T3

3

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FEUILLE D’INSTRUCTION

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IS-19040

INSTRUCTION SHEET

1

NOTE
Material can be obtained through regular channels.

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop the engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to
your local procedure for detailed information regarding the control of hazardous energy.

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FIGURE 1 : POWER STEERING PUMP DISCHARGE HOSE (PRESSURE)

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Wall mount split block - 2x p/n #1600100
X3 Series, up to vehicle D-5387 included.
One (1) split block designed to be mounted on a wall might be installed on your vehicle, depending on the model and year-model.
Take note that the new wall mount split block has two (2) 22 mm
(7/8″) passage holes. The power steering pump return hose has a
diameter of 19 mm. You need to add a couple of tape layers around
the return hose to make sure it is properly clamped in this split
block.

1. Turn off the engine and ensure that steering fluid has sufficiently cooled before starting the following
procedure
2. Have a suitable container to collect the steering fluid under the steering gear.
3. Locate the discharge hose (pressure).
•

In the spare wheel compartment, it is
wrapped in a yellow sheath and is
connected to the top of the steering
box (fig.2).

•

In the rear wheel well, it is located on
the curb side. It is connected to a
hard section (metal pipe) from the
steering pump (fig. 3). Search above
the rear R.H. side air spring of the
drive axle

FIGURE 2

FIGURE 3

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4. In the spare wheel compartment, separate
the hose from the five (5) securing elements
identified and remove the split block.

FIGURE 4 : TWO (2) P-CLAMPS, THREE (3) HOSE GUIDES,
ONE (1) SPLIT BLOCK

5. In the front service compartment, place a
container under the steering gear to collect
the steering fluid that may drip.
6. Locate the straight fitting of the discharge
hose (pressure) at the top of the steering
gear.
7. Loosen the discharge hose (pressure)
straight fitting while holding the elbow fitting
with a wrench.

FIGURE 5

8. Drain the fluid from the hose in the container.

FIGURE 6

9. If a JIC 37 ° #8JIC-F plug is available, use it
to plug the steering gear elbow fitting in order
to avoid intrusion of dirt.

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10. Locate the discharge hose (pressure) on the
curb side of the rear wheel well. It is
connected to a hard section (metal pipe)
which is from the steering pump (fig.7).
Unscrew the fitting while holding the hard section
(metal pipe) with a wrench.

If a JIC 37 ° #8JIC-F plug is available, use it to
plug the hard section.
11. To avoid splashing, place the end of the hose
that is located in the front service
compartment in the container and drain the
hose by injecting compressed air from the
other end.

FIGURE 7

12. Remove thirteen (13) split blocks identified in
figure 1. Note that split blocks 11, 12 & 13 are
located at the top of the rear wheel well.

FIGURE 8 : SPLIT BLOCK #1 IN THE SPARE WHEEL
COMPARTMENT

FIGURE 9 : OTHER TYPICAL SPLIT BLOCKS AT THE CEILING
OF THE BAGGAGE COMPARTMENTS (9 LOCATIONS)

13. In the spare wheel compartment, join the old
and new hose together with a male-male JIC
37 ° #8 union fitting. This will help guide the
new hose in place while removing the old
hose.
FIGURE 10

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14. Begin to remove the old hose by pulling from
the wheel well while a colleague helps feed
the new hose from the spare wheel
compartment.

15. Help the colleague in guiding the new hose in
the baggage compartments, while he
continues to remove the existing pipe.

FIGURE 11

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CONNECTION TO THE HARD SECTION

16. Inspect the sealing surfaces. Clean and dry
the fitting.
17. Place seal #501031 on the fitting of the rigid
section.

FIGURE 12

18. Apply red Loctite on the JIC fitting threads
only. Take care not to put Loctite on the
conical part (flare) of the fitting or inside the
hose.
19. Tighten the fitting by hand, then with a 7/8
open wrench, tighten the fitting by turning it
90° further while holding the other hexagonal
section with a wrench.
FIGURE 13

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CONNECTION TO THE STEERING
GEAR

20. Inspect the sealing surfaces. Clean and dry
the fitting.
21. Apply red Loctite on the JIC fitting threads
only. Take care not to put Loctite on the
conical part (flare) of the fitting or inside the
hose.
FIGURE 14

22. Tighten the fitting by hand, then with a 7/8
open wrench, tighten the fitting by turning it
90° further while holding the other hexagonal
section with a wrench.

23. From the spare wheel compartment, pull on the hose to stretch and move 'slack' in this compartment.
24. Install the new thirteen (13) split blocks
#504189 (figure 1 & 15). Reuse the retainer
plates and existing screws except for the split
blocks #11, #12 & #13 located in the rear
wheel well where the existing hardware is
more likely to be corroded.
Note: make sure that the new hose is placed
in the 22 mm (7/8″) diameter housing.
FIGURE 15

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25. In the compartment spare wheel, secure the
discharge hose (pressure) as previously
arranged.

FIGURE 16 : TWO (2) P-CLAMPS, THREE (3) HOSE GUIDES

FLUID FILLING AND BLEEDING
26. Remove the tank cover and place the nut on
the spring to maintain normal pressure on the
filter in the tank.
27. Fill the tank with fluid up to 2 inches from the
top of the tank (only to prevent spills).
28. Start the engine and have it run at idling
speed to fill the steering system with fluid.
During this operation, the fluid level in the
tank will quickly drop. Therefore, to avoid any
suction of air, the fluid tank has to be topped
up constantly.

FIGURE 17

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BLEEDING

29. FOR STEERING GEAR VERSIONS WITH AUTOMATIC BLEEDING …
Steering gear versions with automatic bleeding do not have any bleed screws. These steering gears
automatically bleed any air remaining within the steering system. Proceed as follows :
a) Lift the front of the vehicle so that the wheels are not on the ground.
b) Start the engine and have it run at idling speed for 2-3 minutes. Ask a colleague to turn the wheel
from one knuckle stop to the other until the effort needed is constant, so the air will be evacuated
by the steering fluid reservoir. Monitor the fluid level in the tank.
c) After bleeding, fill the tank up to 1" from the top of the tank. Check the fluid level with the dipstick.

30. STEERING
GEAR
BLEEDER/BLEEDER SCREW

WITH

Refer to paragraph 5.4.3 Bleeding of RB Robert
Bosch Servocom Service Manual (8090)
available on the Technical Publications site.
https://techpub.prevostcar.com/en/download?id=
352&type=publications

FIGURE 18 : BLEEDER (item 57) & BLEED SCREWS

31. Inspect the connections to make sure that there are no leaks at the fittings.
32. Check the good operation of the system by performing a test drive.

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

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