2017-2020 MCI J4500 Motor Coaches SB486 Coolant Hoses Replacement

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Subject: Coolant Hoses Replacement
Field Change Program:
Field Campaign
FCP Number:
FCP 486
Revision:
Date:
10/27/2020
Coach Section:
06 – Cooling
P/N:
06-08-1006, 16-11-1970
Type:
Safety Recall
Ref. NHTSA Recall No.:
20V-526
Ref. Transport Canada Recall No.:
2020-501
Application:
Coach Model Model Year VIN
J4500 2017-2020 67759 – 68817, 68819 – 68148, 68150 – 68605, 68607 –
68617, 68619 – 68677, 68679 – 68690, 68692 – 68745,
68748 – 68771, 68773 – 68802, 68804 – 68876, 68878 –
68908, 68910 – 68934, 68936 – 68964, 68966 – 69517
This bulletin does not apply to all coaches in the entirety. Please ensure to check the
VIN range applicable for each section.
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 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 2 of 19
Description
Customer complaint:
Motor Coach Industries (MCI) has become aware that on certain J4500 coaches, the coolant hose elbows supplied by Purosil LLC are failing prematurely.
Cause:
The coolant hoses supplied by Purosil LLC have poor build quality.
Corrective action:
MCI recommends owners of the affected coaches have the following procedure performed to replace the coolant hose elbows and clamps supplied by an alternative vendor.
Coach configuration
Material requirements
Refer to Sections 5.1, 6.1, 7.1, and 8.1.
Special tools
No special tools required.
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 3 of 19
HVAC Coolant hose replacement
This section impacts certain coaches equipped with ISX, DD13 engines, and electrical/ mechanical fan cooling systems.
5.1 Material requirements
ITEM
PART NO
QTY
U/M
DESCRIPTION
1
16-11-2768
1
EA
Hose-Formed Hot Water Supply
2
19-4-205
2
EA
Clamp-Stepless Spring, Constant Torque, 1.56-1.77 DIA.
5.2 Replacing the coolant hose
Remove and save the evaporator door in the Baggage Bay #3 compartment.
Remove the coolant from the cooling system to drain the coolant from the main heater core petcock.
Locate the evaporator hot water coolant hose, MCI P/N: 16-11-1970.
Remove and save the evaporator door
Locate the coolant hose 16-11-1970
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 4 of 19
Remove and save the nuts and bolts securing clamp on the coolant hose. Save the clamp.
Remove and discard the clamps securing the hose. Discard the hose.
Install the new coolant hose, MCI P/N: 16-11-2768, using two new clamps, MCI P/N: 19-4-205. Torque the clamps to 18 In-Lb.
Remove and save bolt, nut and clamp
Remove and discard the clamps and hose
Install new hose, 16-11-2768, using clamps, 19-4-205
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 5 of 19
Reinstall the clamp using the existing bolt and nuts.
Reinstall the evaporator door.
Elbow hose rework on coaches equipped with ISX12 engine and electrical/ mechanical fan cooling systems
6.1 Material requirements
ITEM
PART NO
QTY
U/M
DESCRIPTION
1
06-08-2261
1
EA
Hose-Coolant 90 Below
2
19-04-0520
2
EA
Clamp-Hose, 2.48 TO 3.07, SST
6.2 Elbow hose replacement
Locate the coolant hose elbow in the rear of the engine compartment.
Coolant elbow hose
Reinstall the clamp using existing nuts and bolt
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 6 of 19
Remove and discard the two clamps securing the coolant elbow hose. Discard the hose.
Install the new elbow hose, MCI P/N: 06-08-2261, using two new clamps, MCI P/N: 19-04-0520. Torque clamps to 105 In-Lb.
Remove and discard the clamps and hose
Install new hose, 06-08-2261, using clamps, 19-04-0520
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 7 of 19
Elbow hose rework on coaches equipped with DD13 engine and mechanical fan cooling system
7.1 Material requirements
ITEM
PART NO
QTY
U/M
DESCRIPTION
1
06-08-2261
3
EA
Hose-Coolant 90 Below
2
19-4-150
1
EA
Clamp-Stepless Spring, Constant Torque,
Breeze Cl-300 L
3
19-04-0520
5
EA
Clamp-Hose, 2.48 TO 3.07, SST
7.2 Elbow hose replacement
Locate the three coolant elbow hoses in the rear of the engine compartment.
Hose #1
Hose #3
Hose #2
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 8 of 19
Remove and discard the clamps securing the coolant elbow hose #1. Discard the hose.
Install the new elbow hose, MCI P/N: 06-08-2261, using the wider clamp, MCI P/N: 19-4-150, towards the radiator and the thinner clamp, MCI P/N: 19-04-0520, towards the engine. Torque the wider clamp to 115 In-Lb and thinner clamp to 105 In-Lb.
Remove and discard elbow hose and clamps
Thinner clamp, 19-04-0520
Wider clamp, 19-4-150
Install the new elbow hose, 06-08-2261
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 9 of 19
Remove and discard the clamps securing the coolant elbow hose #2. Discard the hose.
Install the new elbow hose, MCI P/N: 06-08-2261, using new clamps, MCI P/N: 19-04-0520.Torque the clamps to 105 In-Lb.
Remove and discard the clamps securing the coolant elbow hose #3. Discard the hose.
Remove and discard clamps and hose
Remove and discard clamps and hose
Install new hose06-08-2261, using clamps, 19-04-0520
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 10 of 19
Install the new elbow hose, MCI P/N: 06-08-2261, using new clamps, MCI P/N: 19-04-0520.Torque the clamps to 105 In-Lb.
Install new hose06-08-2261, using clamps, 19-04-0520
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 11 of 19
Elbow hose rework on coaches equipped with DD13 engine and electric fan cooling system
8.1 Material requirements
ITEM
PART NO
QTY
U/M
DESCRIPTION
1
06-08-2261
2
EA
Hose-Elbow, Coolant
2
19-04-0520
4
EA
Hose Clamp
8.2 Elbow hose replacement
Locate the coolant hose elbow on the right hand side of the engine.
Remove and discard the coolant hose elbow and the two hose clamps.
Remove and discard hose elbow and clamps
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 12 of 19
Install the new elbow hose, MCI P/N: 06-08-2261, using new clamps, MCI P/N: 19-04-0520.Torque the clamps to 105 In-Lb.
Locate the coolant elbow hose connected to the transmission cooler.
Coolant elbow hose,
06-08-2261
Transmission cooler
Install new hose06-08-2261, using clamps, 19-04-0520
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 13 of 19
Remove and save the six screws securing the engine compartment access panel inside the coach.
Loosen the clamp on the top of the coolant hose.
Loosen the clamp
Remove and save the screws
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 14 of 19
Lift the coach at the jacking points following the instruction in Section 3F in the MCI J4500 maintenance manual.
From under the coach, remove the clamp securing the coolant hose. Discard the hose
Install the new elbow hose, MCI P/N: 06-08-2261, using new clamps, MCI P/N: 19-04-0520.Torque the clamps to 105 In-Lb.
Remove and discard elbow hose and clamps
Lift the coach
Install new hose06-08-2261, using clamps, 19-04-0520
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 15 of 19
Appendix
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 16 of 19
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 17 of 19
Field Change Program Conditions:
The parts required for this change will be supplied without charge.
A labor allowance will be granted to the rework according to the values specified in Section 9.0-Appendix.
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.
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
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 18 of 19
10.1 MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION
CONTACT INFORMATION
CUSTOMER NAME:
____________________________________________________
(PLEASE PRINT)
FCP INFORMATION – ONE FORM PER UNIT
FCP#: _________ Coach Model ___________ Model Year _______________
COACH SERIAL #:
(At least the last 5 digits)
DATE COMPLETED __ / __ /____
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:
FCP 486
Coolant Hoses Replacement
Motor Coach Industries Ltd. Page 19 of 19
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.

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Reliability DRIVENIMPORTANT
SAFETY RECALL NOTICE
29 October 2020
Subject: Motor Yebicle satety Recan 2oy.s2s -Pyros;i c001aot Hoses
Dear
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle
Safety Act.
Motor Coach Industries (“MCI”) has decided that a defect which relates to motor vehicle safety exists on
certain MCI coaches originally equipped with coolant hoses manufactured by Purosil LLC. MCI records
indicate that you are the owner or operator of the following vehicle(s) included in this recall:
Make: MCI
Bus Model: J4500
The defect is that the coolant hose may rupture due to the hose liner seam not being fully fused during the
manufacture curing cycle.
A failure of the hose would result in a low coolant warning, followed by an engine shut down
sequence. Engine coolant has the potential to be spilled onto the roadway causing a traction
hazard to other motorists. Additionally, the coach may not be able to be driven from the point of
disablement, which would require the loading and unloading of passengers and baggage at the
breakdown location. The spilled coolant may increase the risk of a crash. Additionally,
transferring passengers from the disabled bus can increase their risk of injury.
MCI urges you to have the recall work performed on your vehicle(s) as quickly as possible.
MCI will remedy the affected coaches at no cost to customers by installing a hose from a different
manufacturer. MCI recommends that owners of the affected coaches make an appointment as soon as
possible by calling the MCI Customer Service Line at 1-800-241-294 7, to have the repairs performed by
trained technicians who have the necessary equipment. MCI estimates that it will take approximately 1.5 to
MOTOR COACH INDUSTRIES
200 East Oakton Street
Des Plaines, IL 60018
JOU FREE 866 624 2622
www.mcicoach.com
MOTOR COACH INDUSTRIES
200 East Oakton Street
Des Plaines, IL 60018
TOLL FREE 866 624 2622
www.mcicoach.com
4 hours based on your specific coolant hose configuration to make the necessary repairs. Please see the
enclosed MCI Service Bulletin FCP 486 for further information.
You may contact the MCI Customer Service Line at 1-800-241-2947 if you have any questions about this
recall campaign or wish to arrange to have your vehicle(s) repaired at an authorized MCI service center.
Submittal of MCI Warranty Claim Forms may be completed on MCI’s website at
https://fleetsupportiw.mcicoach.com/iwarranty/signon (click on Customer Care System), or a photocopy of
the Warranty Claim Form found in the Warranty Manual can be mailed / faxed to the MCI Warranty
Department. Please refer to the enclosed MCI Service Bulletin FCP 486, and your OWNER LIMITED
WARRANTY MANUAL, for more detailed information.
After contacting MCI Customer Service, if you are still unable to have the safety defect remedied without
charge and within a reasonable time, you may submit a written complaint to:
Administrator,
National Highway Traffic Safety Administration,
1200 New Jersey Ave. SE,
Washington, DC, 20590,
or call 1-888-327-4236 (TTY: 1-800-424-9153);
or go to https://www.safercar.gov.
If you are the lessor of the vehicle(s) identified above, Federal law requires that you forward this notice by
first class mail to the most recent lessee(s) known to you, within ten days of your receipt of this notice.
If you have sold or otherwise transferred the vehicle(s) identified above, please contact the MCI Customer
Service Line at 1-800-241-2947 with all of the information you have regarding the current owner/operator
of the vehicle(s).
If you had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you
may be eligible for reimbursement. Please contact the MCI Customer Service Line at 1-800-241-2947 for
further information in that regard.
We regret any inconvenience which this action may cause you. However, we are concerned about the
safety of your passengers and employees.
Thank you for your attention to this important matter.
Sincerely,
MOTOR COACH INDUSTRIES
By: Kerry Legg
Vehicle Safety & Regulatory Compliance Manager
(204) 224-6706
cc: Scott Halbesma – Vice President, Customer Care
Enclosure: MCI Service Bulletin FCP 486

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