SB-10043824-1223

SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. This Service Manual Bulletin supplements existing information in your New Flyer
Service Manual. Refer to details below.

SMB-114
ISSUE DATE: Feb 23 2012

APPLICABILITY
VEHICLE LENGTH

† 30ft.

† 35ft.

† 40ft.

† 60ft.

„ ALL

VEHICLE TYPE

„ High Floor

„ Low Floor

† Invero

„ Xcelsior

† ALL

† Diesel

† Electric

† CNG

† LNG

† Diesel/Electric

† Gas/Electric

† Fuel Cell

FUEL TYPE

„ ALL

SUBJECT

Exhaust Tubes Alignment Procedure

SECTION TITLE

4 - ENGINE SYSTEM

DETAILS

This bulletin provides the alignment procedure for the exhaust tubes
used on your New Flyer vehicle.
The listed tool can be used on any type of vehicle that uses one of the
following flex connectors: 279601, 284878, 382905 & 425432. Refer to
PMB-038 for tool part number.
Make this Service Bulletin available to service personnel to inform them
of changed information and procedures.

SMB-114

Copyright © 2012 New Flyer Industries Canada ULC

Cover

SERVICE MANUAL BULLETIN
SMB-114
1.

EXHAUST TUBES, EXHAUST
FLEX CONNECTOR &
EXHAUST BLANKETS

2. Remove the V-band clamps from the
exhaust tube at the DPF inlet and from one
end of the exhaust flex connector. Remove
exhaust tube. See “Fig. 1: Exhaust System
Removal & Installation” on page 1.

1.1.

Removal

3. Remove V-band clamp from other end of
exhaust flex connector and remove
exhaust felx connector.

1. Cut the stainless steel wire using side cutters and unlace the exhaust blankets.
Remove exhaust blankets.

4. Remove U-clamp from mounting bracket
and V-band clamp from turbo outlet.
Remove the exhaust tube.

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1. Upper DPF Clamp
2. Gasket
3. U-Band Clamp
4. V-Band Clamp
5. Gasket
6. Flex Connector
7. V-Band Clamp

s126858a.svg

Fig. 1: Exhaust System Removal & Installation

SMB-114

Copyright © 2012 New Flyer Industries Canada ULC

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SERVICE MANUAL BULLETIN
SMB-114
1.2.

☞NOTE:

Installation
1. Loosely assemble and install V-clamp on
the exhaust tube at the turbo outlet and
loosely install the U-clamp to the mounting
bracket.
2. Loosely assemble remaining exhaust tube
on DPF inlet.
3. Align the exhaust tubes. Procure special
tool required for procedure. Refer to New
Flyer Parts Manual Bulletin PMB-037 for
tool part number.
4. Collapse alignment tool and position in
between the exhaust tubes.
5. Rotate both ends of the alignment tool until
it locks into the expanded position (locating
pin should be out of the slot and in contact
with edge of the slotted end of the tool).
Make sure that the flanged end of the
exhaust tubes are properly seated to the
tool. See “Fig. 2: Flex Connector Alignment Tool” on page 2.

Adjustment of DPF and/or exhaust
tubes might be necessary to achieve
proper alignment. If the tool does not
align or does not fit between the
exhaust tube ends, loosen the following: upper DPF clamp and 3 lower DPF
base bolts, DPF elbow V-Band clamp,
downpipe V-band, downpipe U-Bolt
and turbo charge connection V-Band
See “Fig. 1: Exhaust System Removal &
Installation. Install the tool to exhaust
tubes.
6. After verifying that the tubes and tool are
all aligned, tighten the V-band clamp on
the turbo charger connection to 75 in-lb
(8.5 Nm). Tighten U-clamp.Tighten V-band
clamp on the DPF connection to 75 in-lb
(8.5 Nm). Tighten bolts on the DPF base if
these were loosened.
7. Loosen V-band clamps on the tool and
slide them out of the way. Collapse the tool
by rotating both ends and slipping the pin
to the slot. Remove the tool.

1. Tool, Flex Connector Alignment
2. Locating pin
3. V-Band Clamp

s121007a.svg

Fig. 2: Flex Connector Alignment Tool

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Copyright © 2012 New Flyer Industries Canada ULC

SMB-114

SERVICE MANUAL BULLETIN
SMB-114
The exhaust tubes on either side of the
exhaust flex connector must be aligned
parallel with each other and display no
offset.

8. Install exhaust flex connector and attach
loosely to exhaust tube with V-clamp.
9. The following criteria must be met while
aligning exhaust tubes and exhaust flex
connector:

10.When installation is correct, torque the
V-band clamps to 75 in-lb. (8.5 Nm). See
“Fig. 3: Exhaust Flex Connector Installation” on page 3.

a. Adequate clearance must be maintained between exhaust components
and vehicle structure.

11.Install each section of exhaust blanket by
wrapping the blanket around the tube so
that the seam is at the bottom. Compress
the blanket sufficiently so that the seam is
closed with ends of the insulation butting
together. Ensure seam is overlapped with
the blanket flap.

b. Ensure the exhaust flex connector is
installed without any twisting applied to it
so that its convolutions are straight and
equally spaced from one end to the other.
c. Directional flow arrow on the exhaust
flex connector outlet flange must point
towards the DPF side of the installation.

☞NOTE:

d. The exhaust flex connector length shall
be 4.92 ± 0.18" when measured
between the crimping rings on either
end. Adjust DPF exhaust tube as
required to achieve this dimension.

Plastic tie-wraps may be used to temporarily hold the blanket in place while lacing
the blanket together.
12.Lace the blanket together using stainless
steel wire. Form a loop in the wire and
hook it around the first rivet/hook. Lace the
wire across the blanket to close the seam.

e. Examine the tubes and flex connector
from above and below, with a 90° angle
between the viewing points.
TO
MUFFLER

INSTALLED
LENGTH

DIRECTIONAL FLOW
ARROW

V-BAND
CLAMP

CRIMPING RING

4.92

0.18

V-BAND
CLAMP

FROM
TURBO

4.92

0.18

EXHAUST TUBE
ALIGNED

s121004a.wmf

Fig. 3: Exhaust Flex Connector Installation

SMB-114

Copyright © 2012 New Flyer Industries Canada ULC

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