NHTSA ID Number: 10189591
Manufacturer Communication Number: FCP 493
TSB/Document Date: 2021-03-31
Summary
Technical instruction describing how to replace the plastic fuel tank filler neck gasket.
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TSB/Document ID: FCP 493
Replacement Service Bulletin Number:
MFR Communication Date: 2021-03-24
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL
MFR Component System:
MFR Component Subsystem:
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Subject: Plastic Fuel Tank Neck Fill Gasket Replacement
Field Change Program:
Field Campaign
Coach Section:
09-Fuel system
FCP Number:
Revision:
493
A
P/N:
09-06-2447
Date:
03/24/2021
Type:
Product Integrity
Application:
Coach Model
Model Year
VIN
J4500
2020
69783 - 69909, 69911 - 69929, 69934 - 69938, 69953 69954
D45CRT-LE
2020
81081 - 81083, 81090 - 81093
D4520
2020
81084, 81085
This field campaign does not necessarily apply to all the above-mentioned coaches.
The owners of the coaches affected by this field campaign will be advised by a letter
indicating the Vehicle Identification Number (VIN) of each applicable coach.
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.
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
1.0 Description
Customer complaint:
Motor Coach Industries
(MCI) has become aware that curbside neck fill gasket on certain
J4500 and D45CRT-Le coaches equipped with plastic fuel tank are failing prematurely
and may lead to a fuel leak.
Cause:
Gaskets provided by American Custom Rotomolding (ACR) do not meet MCI
specifications.
Corrective action:
MCI recommends owners of the affected coaches have the following procedure
performed to replace the neck fill gasket.
2.0 Material requirements
ITEM
1
2
PART NO
09-06-1759
19-11-258
QTY U/M
1
EA
1
EA
DESCRIPTION
Gasket- Fill neck assy, Fuel
Tyrap- 7.31” Long
3.0 Special tools
Long handle mesh strainer.
Page 2 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
4.0 Procedure
4.1
Removing fuel door
Open the fuel tank access door and remove the two bolts securing the fuel door. Save
the bolts for later use.
Remove and save the
two bolts
Page 3 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Open the DEF access door and remove the two bolts securing the fuel door. Save the
bolts for later use.
Remove and save the
two bolts
Remove and set the fuel door aside.
4.2
Removing DEF tank
Remove and save two bolts, lock washers, and washers securing the front channel.
Remove and save two bolts,
lock washers and channel
Page 4 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Disconnect the DEF hoses and coolant hoses.
Disconnect the DEF
and coolant hoses
CAUTION
Coolant either needs to be drained or the lines immediately capped when removed.
Disconnect DEF tank sensor harness.
Disconnect DEF tank
sensor harness
Slide DEF tank out of the fuel compartment.
Page 5 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
4.3
Removing the fuel tank
Open the condenser compartment door.
Open the condenser
compartment door
Remove and save the four bolts and lock washers securing the street side funnel
assembly.
Remove and save four
bolts and lock washers
On the curbside, remove and save the bolts securing the fuel sensors.
remove and
save the bolts
Page 6 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Remove and save the hose and clamp secured to the safety valve of the fuel tank.
Remove and save the
fuel hose and clamp
Remove and save the hose and clamp secured to the relief valve of the fuel tank.
Remove and save the
fuel hose and clamp
Page 7 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Disconnect the fuel supply and return lines to fuel tank.
Disconnect fuel return
and supply lines
Disconnect the hoses installed to electric fuel pump.
Disconnect electric
fuel pump lines
Remove and save the four bolts and washers securing the top bracket. Save the bracket
Remove and save bolts, washers and bracket
Page 8 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Remove and save the four bolts securing the base assembly to the coach frame at the
top.
Remove and save bolts
Remove and save the three bolts securing the base assembly to the coach frame at the
bottom.
Remove and save bolts
Disconnect the DEF coolant hose to the control valve.
Page 9 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Slide-out the DEF base assembly.
Slide out the DEF base assembly
Slide-out the fuel tank.
Slide out the fuel tank
Page 10 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
4.4
Replacing the gasket
Remove and save the twenty bolts, washers, and lock washers securing the fill neck
assembly.
Remove and save
the hardware
Remove and save the neck fill assembly. Discard the neck fill gasket.
Discard the gasket
If pieces of the gasket are observed inside the fuel tank, remove them using a strainer.
Remove the pieces of
gasket using strainer
Page 11 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Place the new neck fill gasket on the fuel tank, MCI P/N: 09-06-1759, and re-install neck
fill assembly using existing bolts, washers, and lock washers.
Place new gasket, 09-06-1759
and re-install neck fill assembly
using existing hardware
Torque the bolts to 47 Ft-Lb three times in cross sequence procedure as shown below.
Torque the bolts to 47
Ft-Lb in cross sequence
11
20
8
18
3
15
12
2
5
6
10
13
17
16
4
9
19
14
7
1
Torque sequence
Page 12 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
4.5
Re-installing fuel lines
Slide in the fuel tank.
Re-install the DEF base assembly to coach frame on the top using the existing four bolts.
Re-install the DEF base
assembly to coach frame
Secure the DEF base assembly to coach frame at the bottom using the existing three
bolts.
Secure the DEF base
assembly to coach frame
Secure the DEF coolant hose to control valve using the existing clamp. Torque the clamp
to 13 In-Lb.
Secure the DEF
hose to control valve
Page 13 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
If the DEF and coolant lines were capped, remove the caps and re-install hoses. Torque
the clamp to 13 In-Lb.
Re-install DEF
and coolant hoses
Re-connect DEF tank sensor harness.
Re-connect DEF
tank sensor harness
Re-install the fuel supply and return lines to fuel tank. Torque the fittings to 83 Ft-Lb.
Re-install fuel return
and supply lines
Page 14 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Re-install the hoses installed to electric fuel pump. Torque the fittings to 14 Ft-Lb
Re-install electric fuel
pump lines
Re-install the top bracket using existing bolts and washers. Torque the bolts to 33 Ft-Lb.
Re-install the top bracket
Re-install safety valve hose using the existing clamp.
Re-install safety
valve hose
Page 15 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Re-install relief valve hose using the existing clamp.
Re-install relief
valve hose
Using a zip tie, MCI P/N: 19-11-258, secure the two hoses at the location shown below.
Zip tie, MCI P/N: 19-11-258
Re-install ground PFT cable using existing bolt. Torque the bolt to 47 In-Lb.
Re-install ground
PFT cable
Page 16 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Re-install fuel sensors using existing bolts, as shown below. Torque the bolt to 37 In-Lb.
FC-T490:3
Re-install fuel sensors
FC-T491:1
Re-install the front channel using existing washers and bolts. Torque the bolts to 54 FtLb.
Re-install front
channel
Page 17 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
Re-install the fuel door to the coach frame by installing the two existing bolts from the fuel
tank access door.
Install the two bolts to
re-install the door
Secure the fuel door by installing the two existing bolts from the DEF access door.
Install the two bolts
Page 18 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
In the condenser compartment, re-install the funnel assembly using existing washers and
bolts. Torque the bolts to 90 In-Lb
Re-install funnel
assembly
Check the coolant level in the surge tank and top-off, if needed.
Page 19 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
5.0 Priming fuel delivery
Turn on coach ignition.
Push and hold the fuel pump switch in the RH service compartment for at least one minute
to ensure no air bubbles in the fuel filter
Hold the switch for
at least one minute
6.0 Torque application
Re-torque the bolts on fuel tank neck fill, ground PFT wire, fuel tank sensors, and streetside funnel assembly to their respective torque values after 24 hours from initial torque
application.
Page 20 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
7.0 Field Change Program Conditions:
The parts required for this change will be supplied without charge.
A labor allowance of 3 hours will be granted for the rework.
This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt
of the attached “MCI Field Change Program Verification Form” and a “Warranty Claim
Form” as detailed in your Owner Warranty manual to MCI’s Warranty department. A “MCI
Field Change Program Verification Form” needs to be submitted for each VIN affected.
Photocopy the attached “MCI Field Change Program Verification Form” as required for
the number of affected coaches in your fleet.
This program will end on Month DD, YYYY.
Motor Coach apologizes for any inconvenience resulting from this campaign but urges
you to implement this change as soon as possible.
Sincerely,
Motor Coach Industries
Page 21 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
7.1 MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION
CONTACT INFORMATION
CUSTOMER NAME:
____________________________________________________
(PLEASE PRINT)
FCP INFORMATION – ONE FORM PER UNIT
FCP#: _________
Coach Model ___________
COACH SERIAL #:
Model Year _______________
DATE COMPLETED __ / __ /____
(At least the last 5 digits)
MILEAGE:
IMPORTANT: TO RECEIVE CREDIT FOR ANY ALLOWABLE LABOR CHARGES, THIS
VERIFICATION FORM MUST BE RETURNED TO MCI UPON COMPLETION OF THE
FCP.
SUBMITTED BY: (Please Print)
______________________________________________________
DATE
__ / __ /____
TITLE: (Please Print) _____________________________________________
SIGNATURE:
________________________________________________________________
COMMENTS:
Page 22 of 23
FCP 493
Plastic Fuel Tank Neck Fill Gasket Replacement
FAX TO: 800-360-8886
Mail or fax the completed limited warranty claim form and verification form to MCI’s
warranty department, or photocopy and mail to:
MCI Fleet Support
Attn: Warranty Department
7001 Universal Coach Drive Louisville, KY 40258
Fax Number 1-800-360-8886
To receive credit for the hours used to complete this task. Contact the MCI Fleet Support
Technical Center at 1-800-241-2947 for any further information.
Page 23 of 23
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