SB-10054515-4244

INSTRUCTION TO SERVICE
ITS: 5613
SECTION:

219

WRITTEN BY:

Jermie Marasigan

SUBJECT:

Remove and replace front circular engine mounts.

Engine and Transmission

ITS5613

THIS DOCUMENT AND THE CONTENTS DISCUSSED HEREIN ARE THE CONFIDENTIAL AND
PROPRIETARY INFORMATION OF NEW FLYER INDUSTRIES CANADA ULC AND NEW FLYER OF
AMERICA INC. AND ARE DISCLOSED BY NEW FLYER IN CONFIDENCE. THIS DOCUMENT AND THE
CONTENTS HEREIN ARE NOT TO BE DISCLOSED BY THE INTENDED RECIPIENT WITHOUT THE PRIOR
WRITTEN AUTHORIZATION OF NEW FLYER. ANY UNAUTHOIZED DISCLOSURE, REPRODUCTION OR
OTHER DISTRIBUTION OF THIS DOCUMENT OR INFORMATION IS STRICTLY PROHIBITED AND MAY
RESULT IN ACTION BEING TAKEN AGAINST THE PARTY MAKING THE UNAUTHORIZED DISCLOSURE.
THIS DOCUMENT AND ALL COPIES HEREOF MUST BE RETURNED TO NEW FLYER UPON REQUEST.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
NOTE:

Work with bus on the ground on a level surface.

2. Open the rear engine access door and swing open the belt guard.
3. Visually inspect the front circular engine mount. If the engine mount is not damaged there is no need to
perform this retrofit. If the engine mount is damaged or the rubber is splitting, replace the engine mount
following steps 4 to 10. See Figure 1.
4. Without lifting, support the weight of the engine horizontally along the sides of the oil pan using a transmission
jack/component lift or heavy duty bottle jacks.
NOTE:

Use a piece of 2” X 4” square wood about 14 inches long as an adapter to support the
engine.

5. Remove the four (4) ½ X 1 ¾” bolts (NF P/N: 10B08028) and lock nuts (NF P/N: 40N08000), two (2) 5/8 X 4
½” engine mount bolts (NF P/N: 10B10072) and lock nuts (NF P/N: 40N10000) and washers to disconnect the
engine from the front circular engine mounts while still supporting the weight of the engine. Discard all
fasteners. See Figure 1.

Figure 1: FRONT ENGINE MOUNT INSTALLATION
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6. Once the fasteners were removed, slightly raise the engine using the transmission jack/component lift or
heavy duty bottle jacks just enough to remove the damaged engine mounts (NF P/N: 109982). Discard
damaged engine circular mount pads.
7. Position the new front circular engine mounts pads (NF P/N: 499546) to the cross member using new four (4)
½ X 1 ¾” bolts (NF P/N: 10B08028) and washers (NF P/N: 20W08000). Use new ½ lock nuts (NF P/N:
40N08000). Hand tight nuts only to ease the installation of the two (2) engine mount bolts later.
8. Install two (2) 5/8 X 4 ½ new engine mount bolts (NF P/N: 10B10072) through the cross member and
assemble the bushing (spacer tube), bushing (snubbing) washer (indented surface installed towards the
bushing). Use new lock nuts (NF P/N: 40N10000) on the underside of the cross member leaving the nuts only
hand tight on the bolts.
9. Slowly release the pressure on the jack or lift supporting the weight of the engine allowing the engine to settle
onto the new engine circular mount pads. Remove and set aside the jack or lift and the 2” X 4” square wood.
10. Tighten and torque all engine circular mount pads mounting hardware as shown in Figure 2.
NOTE:

Ensure that there is small amount of space/gap between the cross member frame and
snubbing washer. See Figure 3.

Figure 2: FRONT ENGINE MOUNT INSTALLATION

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Figure 3: FRONT ENGINE MOUNT INSTALLATION

11. Check for proper belt tension and A/C compressor alignment and adjust as required.
12. Close and secure the belt guard and close the rear engine access door.
13. Turn the main battery disconnect switch to the “ON” position.

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LABOUR ESTIMATE
Operation
1

Remove and replace front circular engine mounts

Men

Hours

1

1.0

Labour Time
M X HR
1.0

PARTS REQUIRED
Description

Qty.
per
Coach
2

Units

Item

Part Number

1

499546

2

40N08000

NUT-HEX LOCK ½ NC

4

EA

3

10B08028

BOLT HEX 1/2” 13 UNC X 1 ¾” LG

4

EA

4

20W08000

WASHER FLAT HARDENED ½”

8

EA

5

40N10000

NUT LOCK NYLON 5/8” 11 UNC

2

EA

6

10B10072

BOLT HEX 5/8” 11 UNC X 4 9/16” LG

2

EA

7

20W10000

WASHER FLAT HARDENED 5/8”

2

EA

MOUNT-ENG CIRC 45 HIGH TEMP

Notes

EA

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