NHTSA ID Number: 10172213
Manufacturer Communication Number: P16-40
TSB/Document Date: 2020-03-07
Summary
This Procedure outlines steps to replace the double groove belt and single idler pulley bracket on A/C Compressor with single groove matched belts and double idler pulley bracket respectively.
Subject: Double Idler Pulley Kit Retrofit
Field Change Program:
Procedure
Procedure Number:
16-40
Coach Section:
16- Heating & A/C
P/N:
Revision:
A
08-27-1357
Date:
02/21/2020
Type:
Product Improvement
Application:
Coach Model
Model Year
VIN
J4500
2018 - 2019
68801 - 69366
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. Position 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.
P16-40
Double Idler Pulley Kit Retrofit
1.0
Description
This procedure outlines steps to replace the double groove belt and single idler pulley
bracket on AC compressor with single groove matched belts and double idler pulley
bracket respectively.
2.0
Material requirements
Kit 26-16-0034 contains the following parts:
ITEM
1
2
3
4
PART NO
08-27-1538*
08-01-1790**
08-27-1336
08-27-1383
QTY
1
1
2
10
U/M
EA
EA
EA
EA
5
08-27-1354
2
EA
6
08-27-1395
1
EA
7
19-01-1772
3
EA
8
19-03-0498**
1
9
19-03-0535
3
10
19-1-240**
1
11
19-2-296**
1
*This part is a set of 2 belts
EA
EA
EA
EA
DESCRIPTION
Belt-A/C Compr, 5VX, matched set
Spacer
Bolt-Idler pulley, 43.35mm thread LG
Washer-Idler,SST, .406 ID, .135 THK
Pulley- Idler 74mm Dia X 57mm long w/
cover
Bracket assy-Idler
Bolt-Hex,Flanged, 3/8-16UNC X 1-3/4,
Grade 8, Black PH
Nut-Hex,Flanged, Lock 5/16-18
Locknut-Flanged, 3/8-UNC Gr8
Screw-Cap, Hex, 5/16-18 X 2.25
Washer-5/16 Gr8 STL
**Parts apply only for the coaches equipped with DD13 engine.
3.0
Special Tools
Prybar.
4 X 4 wooden block.
Belt Alignment tool (Vendor: VibrAlign, APN: 100-BH2)
Belt alignment tool
Motor Coach Industries Ltd.
Page 2 of 7
P16-40
Double Idler Pulley Kit Retrofit
4.0
Procedure
4.1
Changing the belt
Open the engine door using the latch behind the curbside service door.
Rotate the lever
counter clockwise
Lift the AC compressor unit from the curbside service door using a prybar. Place a 4 x 4
wooden block on the frame as a support for the prybar. Hold the prybar to remove tension
on the belt.
4X4 wooden block
Remove and discard the double groove belt on the AC compressor.
Double groove belt
Page 3 of 7
P16-40
Double Idler Pulley Kit Retrofit
Install single groove matched belts, MCI P/N: 08-27-1538, as shown below.
Single groove
matched belts
4.2 Replacing the top idler pulley bracket assembly
Remove and discard the three bolts, washers and nuts securing the idler bracket
assembly to the idler bracket stiffener. Discard idler bracket assembly.
Idler bracket assembly
Remove and discard the
bolts, washers and nuts
Idler bracket stiffener
Page 4 of 7
P16-40
Double Idler Pulley Kit Retrofit
Install idler bracket assembly, MCI P/N: 08-27-1395, to the idler bracket stiffener using
bolts, MCI P/N: 19-01-1772, and nuts, MCI P/N: 19-03-0535, as shown below. Torque
the bolt to 44 Ft-Lb.
Idler bracket
assembly, MCI
P/N: 08-27-1395
Bolts, MCI P/N: 1901-1772
Idler bracket stiffener
Nuts, MCI P/N: 1903-0535
Remove the dust cover on the idler pulleys, MCIP/N: 08-27-1354, and install them to the
idler bracket assembly using idler pulley bolts, MCI P/N: 08-27-1336.
Idler pulleys, MCIP/N:
08-27-1354
Idler bracket assembly
Idler pulley bolts, MCI
P/N: 08-27-1336
Page 5 of 7
P16-40
Double Idler Pulley Kit Retrofit
If the pulleys are not observed to be at the center of the belt, add idler washers, MCI P/N:
08-27-1383, as required between the pulley and idler bracket assembly as shown below.
Idler washers, MCI
P/N: 08-27-1383
Torque idler pulley bolt to 30Ft-Lb.
Press dust cover into pulley until the flat surface of the cover is recessed .03” past pulley
surface.
If the coach is equipped with ISX engine proceed to Section 5.0.
If the coach is equipped with DD13 engine continue to Section 4.3 below.
4.3
Retrofitting spacer to the oil dipstick
Remove and discard screw and nut securing the oil dipstick clamp.
Oil dipstick
Clamp
Page 6 of 7
P16-40
Double Idler Pulley Kit Retrofit
Secure the dipstick p-clamp to oil fill bracket assembly using the spacer, MCI P/N: 08-011730, nut, MCI P/N: 19-03-0498, screw, MCI P/N: 19-1-240 and washer, MCI P/N: 19-2296, as shown below.
5.0
Verification
Use the belt alignment tool to verify alignment of AC compressor pulley to the pulley on
the crankshaft following the instructions in the maintenance manual section 16A-2.
Laser line on the tool
End of the procedure
Page 7 of 7
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TSB/Document ID: P16-40
Replacement Service Bulletin Number:
MFR Communication Date: 2020-02-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
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