Study Guide

2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine
2005 CE Bus
Program 2C:
Unique Repair:
Radiator, Wipers and Engine
Study Guide
BMT-100602

©2006 IC Corporation,
4201 Winfield Road, Warrenville, IL 60555.
All rights reserved. No part of this publication may be
duplicated or stored in an information retrieval system
without the express written permission of
IC Corporation.
BMT-100602
Table of Contents
Introduction....................................................................... 2

Module I: CE Bus Radiator Service............................. 6

Cross Member Removal...................................................................... 9
Surge Tank Removal...........................................................................10
Charge Air Cooler Pipes...................................................................10
Radiator Hose Removal.....................................................................11
Radiator Removal................................................................................11
Radiator Shroud and Frame Removal............................................11
New Radiator Core Installation........................................................12
Radiator Hose Install..........................................................................14

Module II: CE Bus Wiper Service................................ 20

Module III: CE Bus Engine Service............................. 24

 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

CE Bus Program 2C:

Unique Repair:
Radiator, Wipers, Engine
Introduction

“The CE Bus The CE Bus features a modular

features a modular style radiator and air-to-air cooling
style radiator system. When repair is required, this
and air-to-air modular design requires a new service
procedure. This procedure is required
cooling system.”
for any type of radiator or air-to-air
cooler service.

This program will take you through

all the steps needed to successfully
remove, replace and reinstall the cooling
system module.

Before we begin keep in mind

that proper service techniques,
environmental concerns, and safety are
the most important parts of the process.

Perform service inside a well

ventilated dry shop. Make sure the
vehicle is parked on a flat surface, with
the parking brake set and the wheels
blocked.

When working on the cooling system,

keep the work area and tools as clean
as possible. Also, clean all connections
or fittings before disconnecting
 Study Guide 

or removing components. Use a

suitable pan to catch any fluid when
disconnecting components.

All openings should be immediately

plugged during removal and remain so
until reinstallation to prevent the entry of
dirt, and other foreign material.

Wear safety glasses when performing

work of any kind.
 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

NOTES
Study Guide 

NOTES
 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Module I CE Bus Radiator Service

Begin the process by unlatching the
hood straps.

Tilt and disconnect the harness to the

hood. Then disconnect the harness to
the safety gate power unit.

If the vehicle is equipped with heated

cross-view mirrors, the mirror heater
connection harness will need to be
disconnected.

Close the hood.

Remove the bumper and safety gate

power unit as an assembly. Place the
unit out of the way, and in a secure
location.

Remove the grill.

Tilt the hood open.

Remove the hood splash shields.

“The CE Bus hood Support the hood with a floor stand

opens with the to relieve tension on the hood cable
assistance of a stop assemblies.
twin torsion bar The CE Bus hood opens with the
system that must assistance of a twin torsion bar system
be removed for this that must be removed for this service
service procedure.” procedure.
 Study Guide 

Torsion bars are mounted between

the hood and the frame. The driver side
torsion bar is mounted in the passenger
side hood bracket and held in place by
a retainer clip. This torsion bar drops
down and crosses the front of the
chassis above the hood hinge assembly.
The torsion bar is then inserted into
the frame rail retainer bracket and is
locked in place with a retainer clip. The
passenger side torsion bar has a larger
12.5 mm diameter and is generally the
first to be removed and the last to be
replaced.

This torsion bar is mounted in the

hood bracket on the driver side of the
hood assembly. This bar drops down
and crosses the front of the chassis
over the hinge assembly and over the
opposite torsion bar to the passenger
side of the chassis.

Locate the torsion bar hood mounting
bracket on the driver side of the hood
assembly.

Remove the retainer clip.

“Remove the
Remove the torsion bar end from the
retainer clip from
hood mounting bracket.
the torsion bar on
Remove the retainer clip from the the passenger side
torsion bar on the passenger side of the of the frame rail
frame rail mounting bracket. mounting bracket.”
 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Lift the torsion bar out of the frame

rail mounting bracket and alignment
guide.

Remove the passenger side retaining

.
! CAUTION:. clip securing the torsion bar in the hood
mounting bracket.
Note that the diameter
of the passenger side Remove the retainer clip on the driver
torsion bar is larger
than the driver side side frame rail retention bracket.
torsion bar. The bars
must be replaced in Lift and remove the torsion bar from
the proper locations.
the bracket and guide.

Remove both the right and left hood

stop cable retaining pins from the clevis.

Close the hood.

Mark or scribe the position of the

hood hinge on the hood hinge mounting
plate.

Loosen, but do not remove the hood

hinge plate mounting bolts.

With an assistant, remove the hood

assembly from the chassis.

Place the hood assembly on a flat,

secure, padded area to prevent
scratches or paint damage.

Prior to removal of the cooling

module, the cooling system must be
drained. Remove the coolant cap. Place
 Study Guide 

a clean drain pan below the radiator

drain plug and drain the coolant. Keep
in mind that you will need to save the
coolant to refill the system after making
the necessary repairs.

With the coolant draining, continue

with the following steps.

If the vehicle is equipped with an “If the vehicle is

engine block heater, remove the power equipped with
cord from the socket. an engine block
heater, remove the
Cross Member Removal power cord from
the socket.”
Next, locate the cross member
mounting bolts for the front tow hooks.
Remove the bolts and the tow hooks.

Also remove the front bumper

mounting bracket bolts and brackets
located above the tow hook bolt holes.

Using a pry bar, remove the hood

hinge support bracket.

Remove the lower crossover wiring

harness tie straps.

Remove the cross-member.

Next, remove the left and right air

recirculation seals.
“Remove the
Remove the de-aeration hose from de-aeration hose
the radiator. from the radiator.”
10 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Surge Tank Removal

The next procedure involves removal

of the surge tank located on the
driver’s side of the cooling module.

Disconnect the harness to the low

coolant sensor.

Loosen and remove the lower, and

then the upper surge tank mounting
bolts.

Remove the surge tank and secure it

out of the way.

Close the drain valve and move the

drain pan out of the way.

Remove the transmission oil cooler

lines and plug them.

Disconnect the cooling module

ground connector.

Charge Air Cooler Pipes

Next, remove the charge air cooler

pipes and clamps.

Plug all openings immediately.

Remove both lower stay rod bracket
bolts.
 Study Guide 11

Radiator Hose Removal .

! CAUTION:
The CE Bus cooling system is fitted
When running
with Gates Power Grip SB heat shrink the knife over the band
clamps on the inlet and outlet radiator clamp, use care not to
hose connections. A hot knife tool is cut into the hose. Only
cut deep enough to cut
required for removal. the band to break .
it loose.
Remove both the inlet and outlet
band clamps. Then remove the hoses
from the radiator.

Radiator Removal

Attach a sling to the top of the

cooling module and then to a lifting
hoist. Be sure it is secure.

Loosen and remove the module

mounting bolts, insulators, and
bushings.

Using the hoist and sling, carefully “Using the hoist

remove the module assembly from the and sling, carefully
vehicle. remove the module
assembly from the
Radiator Shroud and Frame vehicle.”
Removal

Once the module assembly is

securely positioned on the floor, remove
the fan shroud.
12 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Next remove all the frame bolts

except the lower two on each side. Only
loosen these bolts.

Spread the module frame apart, away

from the core.

Then remove the charge air cooler

assembly.

Next, remove the radiator drain valve.

Then remove the radiator-to-frame

ground wire.

Lift and remove the radiator core.

If the radiator core is being replaced,

switch all needed components.

New Radiator Core

Installation

“Place the frame Place the frame in position to accept

in position to the new radiator core.
accept the new
radiator core.” Install the radiator core assembly.

Next install the air-to-air cooler

assembly.

Position, and align the bolt holes for

the side frame. Install all the mounting
bolts finger tight. When all the frame
bolts have been installed, tighten the
bolts.
 Study Guide 13

Next, install the radiator drain valve.

Then install the fan shroud.

Attach a sling to the top of the

cooling module and then to a lifting
hoist.

Lift and position the cooling module

on the vehicle.

Next install the mounting bolts,

insulators, and bushings, finger tight.

Then install the bottom stay rod

bracket bolts. Tighten all mounting
bolts. Then move the sling and hoist out
of the way.

Install the radiator-to-frame ground wire.

Reconnect the ground wiring

harness.

Next, install the transmission oil

cooler lines.

Install the air-to-air piping.

Next install the surge tank.

Then reconnect the de-aeration line.

14 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Radiator Hose Install

“Inspect the Inspect the radiator hoses to be

radiator hoses to
be sure they
are in good
condition before
reinstallation.”
sure they are in good condition before
reinstallation.
Remove the new clamps from the
cardboard reinforcements by squezzing
the bands to collapse them—and then
by folding them in half to remove them.

“The cardboard The cardboard reinforcements

reinforcements prevent any shrinkage when exposed
prevent any to heat during storage. Be sure that the
shrinkage when clamps are stored with the cardboard
reinforcements.
exposed to heat
during storage.” Next, install the heat shrink band on
the hose.

Then, position the hose over the

radiator fittings.

Avoid letting the clamp cover any

of the hose that’s unsupported by the
fitting.

Next apply heat using a 1000 watt

. heat gun with the setting on high.
! CAUTION:.
Don’t use an open Hold the heat gun about 2 to
flame to apply heat. 3 inches from the clamp while
This will damage the continuously moving the gun. Don’t
clamp and the hose.
apply heat in one spot too long—too
much heat can melt the clamp.
 Study Guide 15

Cover as much of the clamp’s

surface as possible—1/3 of the surface
minimum.

The clamp will shrink and make a

proper seal in 60 seconds or less.

Remove the heat source and check

the connections to be sure there is a
good seal by trying to turn the hose.

Install the right and left air

recirculation seals.

Then install the crossmember and the

hood hinge support bracket.

Install the tow hooks and the bumper

brackets. Install all the bolts finger tight.
When they’re in place, tighten all the
bolts.

Reinstall the engine block heater

power cord.

Reinstall the lower crossover wiring

harness with new tie straps.

Reinstall the hood and tighten the “Reinstall the

hinge bolts aligning the hinge with the hood and tighten
mark made at removal. the hinge bolts
Tilt the hood up and support it with a aligning the hinge
floor stand. with the mark
made at removal.”
Install the hood splash shields.
16 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Reinstall the hood stop cable

assembly clevis pins.

Reinstall the torsion bars and

retaining clips.

Close the hood.

Reinstall the grill.

Install the bumper.

Then tilt the hood and reconnect all

wiring harnesses.

“Replace the Replace the coolant and run the

coolant and run the engine to operating temperature.
engine to operating Inspect the engine and verify that there
are no leaks.
temperature.”
This concludes the cooling module
repair procedure.
Study Guide 17

NOTES
18 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

NOTES
Study Guide 19

NOTES
20 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Module II CE Bus Wiper Service

Although wiper system service is
basic, this section is provided to show
the location of the wiper motor and to
emphasize the importance of properly
re-aligning the wiper arms after service.

CE Bus wiper service is

accomplished by working from the
inside of the cowl panel.

“Before beginning However, it is critical to re-align the

service, mark
the position of
the wipers with
a wax pencil or
tape that’s safe
to use on painted
surfaces.”
wiper arms after wiper motor or wiper
mechanism service to prevent damage
to the bus or the wiper arms.
Before beginning service, mark the
position of the wipers with a wax pencil
or tape that’s safe to use on painted
surfaces.
 Study Guide 21

To access the wiper mechanism

remove the dash panels as shown.

Once the mechanism is accessible

and the motor or mechanism service
is completed, re-assemble the dash
panels.

Then re-align the wiper arms using

the marks made before beginning the
service procedure.

Also, test operation of the wipers

to assure the wipers are positioned
properly.
22 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

NOTES
Study Guide 23

NOTES
24 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

Module III CE Bus Engine Service

Whether servicing the VT 365 or
the I-6 Engine series, comprehensive
training is available from
International Truck and Engine
Corporation.

For I-6 Engines, please refer to the

2004 I-6 Engine DVD Training Series.
Available now are Program I: 2004 I-6
Engines Introduction, and Program II:
2004 I-6 Engines Diagnostics.

For VT 365 Engines, please refer to

the 2004 VT 365 DVD Training Series.

These programs sometimes refer to

truck application. Although virtually all
concepts and service procedures are
virtually the same on the CE Bus—there
is one key difference for CE Bus Engine
service. Be aware that the location
of the engine relays and fuses on the
CE Bus are on the engine side of the
cowl panel rather than at the power
distribution box.

Also available as a reference for

service procedures are the 2004
VT 365 and 2004 I-6 Engine Features,
Descriptions, and Unique Service
Procedures Manuals.
 Study Guide 25

In addition, ISIS® provides key “IC® Corporation

resources for engine diagnostics and remains committed
service. And technical assistance is to training,
available by calling International Truck
support, and
and Engine Corporation Technical
Service.
positive customer
experience
IC® Corporation remains committed throughout the
to training, support, and positive vehicle life cycle.”
customer experience throughout the
vehicle life cycle.
26 2005 CE Bus, Program 2C: Unique Repair: Radiator, Wipers and Engine

NOTES
Study Guide 27

NOTES