NAVISTAR

FIELD SERVICE CAMPAIGN - 24103
29 April 2024

SUBJECT:
Liquid Line Shut-off Valve Retrofit

MODELS INVOLVED:
IC Bus® Electric CE Series school bus

DEFECT DESCRIPTION:

Certain IC Bus® Electric CE Series school buses may experience liquid refrigerant
migrating into the compressor, reducing the electrical insulation below the calibrated
threshold, causing no High-Voltage drive mode.

ELIGIBILITY:

This procedure applies ONLY to vehicles marked in the International® Service Portals
with FSC 24103. Also complete any other open campaigns listed on the Service Portal
at this time.

TOOLS REQUIRED:

CAUTION! To prevent damage to property, it is recommended to use a dedicated
machine for POE (polyolester oil) systems. If the machine has been used on PAG
(polyalkylene glycol) systems, ensure to flush the lines to prevent cross
contamination.

Description Tool Number Quantity

Yellow Jacket Refrigerant Management System Source Locally 1
Ear Clamp Pincers Source Locally 1
Programmer Panel GL-P4SGL004 1
Panel Programming Cable 401.00.069 1
Blank USB Drive (1 GB Min) Source Locally 2
Air Conditioning (A/C) Control Module Software | PEHNV001 - Version 1.1

- GL-P6HAP002 1

M1HNV001 - Version

ECU Software- GL-M1HPA002 11 2
Battery Charger 55 amp PSC550CC 1

Table 1 Tool Information

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PARTS REQUIRED:
NOTE: For vehicles equipped with front and rear evaporator only.

Part Number Description Quantity
VALVE, SOLENOID,12V NC A/C SHUTOFF,
4471307C1 ZRVS-B100PBEX-1G-A 2
AIR CONDITIONING (A/C) FITTING, COMMON
4497145C1 SHUTOFF, STRAIGHT #8 CLIP 2
AC FITTING, SHUTOFF OUTLET #8 CLIP,
4497154C1 FRONT EVAP 1
AC FITTING, SHUTOFF OUTLET #8 CLIP,
4497153C1 REAR EVAP 1
4498810C1 SUPPORT, FRONT EVAP. 1
SUPPORT, SOLENOID VALVE, REAR EVAP
4498811C2 TO CAB 1
SUPPORT, SOLENOID VALVE, REAR EVAP
4600244C1__| TO VALVE 1
3607293C1 BOLT, M6 X 25, TMS-4518 TYPE | 4
SCREW, M5 X 12 PAN HEAD RECESS
30940R1 MACHINE 4
30481R1 WASHER, FLAT, M5 ZN 4
SCREW, HEX SOCKET HEAD CAP,
4586615C1 M4X0.7X6MM, ZN-PLTD 4
FRONT EVAPORATOR SOLENOID VALVE
4531909C91 HARNESS 1
REAR EVAPORATOR SOLENOID VALVE
4531910091 | HARNESS (SWB) 1 (If equipped)
REAR EVAPORATOR SOLENOID VALVE
4531911091 HARNESS (LWB) 1 (If equipped)
M6 HEX FLANGE NUT-TMS-4518 FINISH
3544378C1 (Bracket to Bus) 4
HEAVY HEX FLANGE HEAD M6 X 20 (Bracket
31046R1 to Bus) 4

Table 2 Parts Information

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Part Number Description Quantity
6.4MM ID, 12.5MM OD, 2MM THICK, B-ZND

30325R1 (Bracket to Bus) 4
Source Locally _| IN-LINE FUSE HOLDER 2
ATOS 5A FUSE 2
365680C2 3/8 RING TERMINAL (GRND) 2
2206638C1 #10 RING TERMINAL (POS T2 and T52) 2
Source Locally _| HEAT SHRINK 4

Table 2 Parts Information Continued

NOTE: For vehicles equipped with High Performance A/C system dash mounted
evaporator, refer to the table below.

NOTE: Dash mounted solenoid valve assembly is only equipped on 4 vehicles.
Use the VIN to check and verify if the vehicle has feature code 0048ADL in the

International® Service Portal™ under components before proceeding.

Part Description Quantity Feature
Number Code
AIC FITTING,
4497156C1_ | SHUTOFF INLET #8 CLIP, DASH EVAP 1 0048ADL
SUPPORT, SOLENOID VALVE, DASH
4498646C1 | evap 1 0048ADL
3607293C1 | BOLT, M6 X 25, TMS-4518 TYPE | 2 0048ADL
SCREW,
30940R1 | M5 X 12 PAN HEAD RECESS MACHINE 2 0048ADL
30481R1 | WASHER, FLAT, M5 ZN 2 0048ADL
SCREW, HEX SOCKET HEAD CAP,
4586615C1 | \4x0.7X6MM, ZN-PLTD 2 0048ADL
DASH EVAPORATOR SOLENOID VALVE
4531908C91 | HARNESS 1 0048ADL
M6 HEX FLANGE NUT-TMS-4518 FINISH
3544378C1 | (BRACKET TO BUS) 4 0048ADL
HEAVY HEX FLANGE HEAD M6 X 20
31046R1 (BRACKET TO BUS) 4 0048ADL

© 2024 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 3

6.4MM ID, 12.5MM OD, 2MM THICK, B-
30325R1 ZND (BRACKET TO BUS) 4 0048ADL
Obtain 1 (Source
Locally FUSE, 5A MAXI Locally) 0048ADL

Table 3 Parts Information Continued

WORK INSTRUCTIONS

WARNING! To prevent personal injury or death, or damage to property, NEVER
service a high-voltage vehicle without completing High-Voltage Safety training.
Before working on vehicle, read and obey all High-Voltage Safety and Lock-Out
Tag-Out procedures and information.

WARNING! To prevent personal injury or death, or damage to property, read all
information in the Safety Information and High-Voltage Safety sections of the
service manual.

WARNING! To prevent personal injury and / or death, or damage to property, park
vehicle on hard flat surface, turn the engine off, set the parking brake, and install
wheel chocks to prevent the vehicle from moving in both directions.

WARNING! To prevent personal injury and / or death, always wear safe eye
protection when performing vehicle maintenance.

WARNING! To prevent personal injury and / or death, or damage to property, if
the vehicle must be raised, do not work under the vehicle supported only by
jacks. Jacks can slip or fall over.

WARNING! To prevent personal injury and / or death, or damage to property, keep
flames or sparks away from vehicle and do not smoke while servicing the
vehicle’s batteries. Batteries expel explosive gases.

1. Park vehicle on a dry and level surface.
2. Put drive mode selector in Neutral and set parking brake.
3. Turn ignition to Key OFF position.

4. Install wheel chocks.

© 2024 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 4

CAUTION! To prevent damage to property, it is recommended to use a dedicated
machine for POE (polyolester oil) systems. If the machine has been used on PAG
(polyalkylene glycol) systems, ensure to flush the lines to prevent cross
contamination.

NOTE: During the recovery of the rear Air Conditioning (A/C) system, go to Step 6
to remove the front and rear evaporators covers.

5. Recover rear Air Conditioning (A/C) system. Refer to appropriate technician manual
for instructions.

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Figure 1. Front Evaporator Core Cover

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1. Front evaporator core cover
2. Mirror assembly
3. First aid kit

6. Remove fasteners from first aid kit (Figure 1, Item 3) and mirror assembly (Figure 1,
Item 2) and set aside on clean work bench.

7. Remove front evaporator core cover (Figure 1, Item 1) and set aside on clean work
bench.

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000484435

Figure 2. Front Cover

1. Support bracket
2. Passenger-side cover
3. Pillar cover

8. Remove support bracket (Figure 2, Item 1) from passenger-side cover (Figure 2,
Item 2) and set aside on clean workbench.

9. Remove fasteners from passenger-side cover (Figure 2, Item 2) and set cover on
clean workbench.

10. Remove passenger-side dashboard. Refer to appropriate technician manual for
instructions.

11. Route front harness through pillar cover to dash panel.

12. Connect battery charger / maintainer to vehicle battery.

NOTE: The USB flash drive must have a minimum of 1 GB of storage space and
must have no other files on it. It is recommended to have two USB flash drives for

each program.

13. Download P6HNV001 1.1 file from Table 1 Tool Information onto a USB flash drive.

© 2024 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 6

Figure 3. A/C Control Module

14. Remove A/C Control Module (Figure 3). Refer to appropriate technician manual for
instructions.

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Figure 4. A/C Control Module Harness (Front View)

1. A/C Control Module
2. Program module

3. Programming harness
4. Power source

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Figure 5. A/C Control Module Harness (Rear View)

1. A/C Control Module
2. Program module w/ USB drive
3. A/C Control Module port

15. Connect programming harness (Figure 4, Item 3) to A/C Control Module (Figure 5,
Item 1) and program module (Figure 5, Item 2).

16. Connect 12V DC / 24V DC power source (Figure 4, Item 4) to programming
harness (Figure 4, Item 3).

17. Insert USB flash drive into program module (Figure 5, Item 2).

18. Go to UPDATE SW and select PEXXXNNN.

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SRERHRANNT

Sending
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Figure 6. Programming Mode Display
19. A/C Control Module displays App Download Running! (Figure 6).

Figure 7. Software Update Complete

20. Update complete when program module screen displays Update OK (Figure 7).

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Figure 8. Software Version Display

. Software version

2. Maintenance button

NOTE: The Maintenance button is also used as the enter button. The Auto 2
button is used to go back. The blower speed fan adjustment arrows on the right
are used for scrolling up and down.

21.

22.

23.

24.

25.